Tigercat 6050 CARBONATOR OPERATOR'S MANUAL - PDF DOWNLOAD

6050 CARBONATOR

OPERATOR'S MANUAL

SERIAL NUMBER 60500001 – 60500500

ISSUE 2.0, OCTOBER 2020 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

ii

Tigercat 6050 Carbonator TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v MACHINE IDENTIFICATION AND SERIAL NUMBERS..................................................................................... vi NON-APPROVED FIELD PRODUCT CHANGES..............................................................................................vii SAFETY...............................................................................................................................................................1 CONTROLS AND OPERATION...........................................................................................................................2 LUBRICATION AND MAINTENANCE.................................................................................................................3

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

6050 AVAILABLE LITERATURE Operator's Manual (this manual).....................................................................................................Part No. 60498AENG Service Manual................................................................................................................................Part No. 60499AENG Parts Catalogue...............................................................................................................................Part No. 60500A Machine Moving and Transporting Instructions...............................................................................Part No. 62035AMUL Engine Operation and Maintenance Manual...................................................................................SEBU8735-03 (en-us) iii

iv

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

Tigercat 6050 Carbonator INTRODUCTION An Operator's manual, Service manual and a Parts catalogue are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 6050 Carbonator.

SERIAL NUMBERS: 6050

60500001 – 60500500

The 6050 Carbonator is designed for high-volume conversion of wood and vegetative debris to high-quality, endproduct biochar.

The Operator's manual will assist the operator with the techniques of proper and safe operation of the 6050 Carbonator. There is also important information regarding the safe operation of accessories (if equipped). The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance.

Section 1 in both the Operator's manual and the service manual contains safety information that must be followed.

As well, throughout the rest of the manuals, DANGER, WARNING, and CAUTION notices are displayed where necessary, drawing attention to possible hazards when performing certain procedures.

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

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

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

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

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

Tigercat Industries Inc.

v

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

Introduction

Tigercat 6050 Carbonator

MACHINE IDENTIFICATION AND SERIAL NUMBERS

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine serial number plate location.

Please record all serial numbers related to this machine below and have ready before calling for assistance.

Engine Serial Number:___________________________

6000016

Machine Serial Number Plate Location

The machine serial number plate is located at the frontright corner of the machine.

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

vi

NON-APPROVED FIELD PRODUCT CHANGES..............................................................................................vii

Tigercat 6050 Carbonator

Introduction

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

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes or install options is only to be undertaken as follows: • The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat.

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

Authorization by any other person is unacceptable.

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

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

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

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

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

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

Tigercat Industries Inc.

vii

Introduction

Tigercat 6050 Carbonator

viii

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

Tigercat 6050 Carbonator SECTION 1– SAFETY Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 1

ISSUE 2.0, OCTOBER 2020

B

BACKOVER ACCIDENTS – AVOIDING...................................................................................................................... 1.9 BATTERY DISCONNECT KEY SWITCH................................................................................................................. 1.13 BATTERY SAFETY...................................................................................................................................................... 1.8

C

CARBONIZING PROCESS SAFETY PRECAUTIONS WIND SPEED CHART........................................................................................................................................... 1.12 COOLING SYSTEM.................................................................................................................................................. 1.14

D

DIESEL EXHAUST FLUID (DEF)............................................................................................................................. 1.10

E

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

F

FIRE PREVENTION.................................................................................................................................................. 1.22 AFTER A MACHINE FIRE...................................................................................................................................... 1.24 DRY CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.25 HOW TO PREPARE FOR A MACHINE FIRE....................................................................................................... 1.23 IN CASE OF A MACHINE FIRE............................................................................................................................. 1.23 WET CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.25 FLUID INJECTION INJURY...................................................................................................................................... 1.17

G

GENERAL SAFETY PRECAUTIONS........................................................................................................................ 1.4 GREASE INJECTION INJURY................................................................................................................................. 1.18

H

HAZARD ZONE........................................................................................................................................................... 1.5

L

LIGHTNING SAFETY AWARENESS....................................................................................................................... 1.19 LIGHTNING SAFETY............................................................................................................................................. 1.19 WHAT IS A LIGHTNING STRIKE?........................................................................................................................ 1.19 LOOSE CLOTHING HAZARD.................................................................................................................................. 1.15

M

MACHINE STABILITY AND TRACTION.................................................................................................................. 1.16

N

NOTICE LABELS....................................................................................................................................................... 1.32

O

OPERATING SAFETY PRECAUTIONS.................................................................................................................. 1.10

P

PARKING THE MACHINE......................................................................................................................................... 1.11 PNEUMATIC GREASE GUNS, USING.................................................................................................................... 1.18 PROTECTIVE CLOTHING.......................................................................................................................................... 1.4

S

SAFETY HAZARDS OPERATING............................................................................................................................................................. 1.8 VITON SEALS.......................................................................................................................................................... 1.7 SAFETY LABELS...................................................................................................................................................... 1.26 SAFETY PRECAUTIONS GENERAL................................................................................................................................................................. 1.4 OPERATING........................................................................................................................................................... 1.10 SERVICING............................................................................................................................................................ 1.13

Safety

Tigercat 6050 Carbonator

SAFETY SIGNAL WORDS.......................................................................................................................................... 1.3 SAFETY SYMBOLS..................................................................................................................................................... 1.3 SERVICING SAFETY PRECAUTIONS.................................................................................................................... 1.13 T

TRANSPORTING THE MACHINE........................................................................................................................... 1.11

W

WELDING, PRIOR TO............................................................................................................................................... 1.15 WORKING WITH OIL.................................................................................................................................................. 1.7

1.2

Tigercat 6050 Carbonator

Safety

SAFETY SYMBOLS

The safety alert symbol demands immediate attention to a personal safety issue! It identifies important safety messages on machines, on safety signs, in manuals, or elsewhere. Be alert to the possibility of personal injury or death where this symbol appears. Follow the instructions in the safety message that accompanies the symbol.

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

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

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

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

1.3

Safety

Tigercat 6050 Carbonator

GENERAL SAFETY PRECAUTIONS

WARNING

WARNING Engine components are powered by a 12 V electrical system.

Machine controls are powered by a 24 V electrical system.

Safety is a prime responsibility of all.

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

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.

These safety rules highlight both general and specific measures the operator must be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message.

Keep safety labels in good condition. Repair or replace damaged labels.

DANGER The machine operator is responsible for the safety of persons around the machine. Verify that all personnel remain outside the hazard zone to prevent serious injury or death.

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

• Follow all instructions from safety inspector and supervisors.

• You must be fully trained to operate this piece of equipment. Know the capabilities and the limitations of the equipment. Learn the most efficient operating techniques. Do not let untrained persons operate the machine.

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

1.4

Tigercat 6050 Carbonator

Safety

The following diagram illustrates the HAZARD ZONE. Keep all personnel clear of this zone while the machine is operating.

WARNING

45 M (150 FT)

45 M (150 FT)

45 M (150 FT)

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

45 M (150 FT)

WARNING

6000097

Hazard Zone

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

The HAZARD ZONE is off limits to all individuals with the exception of operators and spotters.

Do not walk on angled steel or irregular shaped surfaces.

• When approaching an active machine on foot, stay at least 45 m (150 ft) away until the operator recognizes your presence. All equipment must be shut down before advancing to the machine.

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

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

• Do not jump off the machine at any time.

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

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

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

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

1.5

Safety

Tigercat 6050 Carbonator

• To reduce risk of fire, completely clean machine of debris daily, particularly all flat surfaces where debris gather and around the engine exhaust components.

Eliminate hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) immediately.

Turn OFF the engine and remove the ignition key before cleaning the machine.

• Maintain a engine compartment, clear away trash or debris.

• Wash machine completely at every major service.

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

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

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

• Check all fluid levels.

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

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

1.6

Tigercat 6050 Carbonator

Safety

WORKING WITH OIL

SAFETY HAZARDS – VITON SEALS

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

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

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

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

• Avoid contact with oil, particularly heated oil.

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

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

• Don't put oily rags in your pockets.

• Change oil soiled clothing as soon as possible.

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

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

• Avoid breathing in oil fumes.

The following procedures are recommended when inspecting equipment subjected to high temperatures such as fire: • Visually inspect any seals or gaskets which have suffered from heat damage. They will appear black and sticky. If these are found, DO NOT TOUCH! • Determine the material composition of any seals or gaskets, If fluoroelastomer seals (Viton, Fluorel, or Tecmoflon) have been used, the affected area must be decontaminated before undertaking further work. Natural rubber and nitrile materials are not hazardous.

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

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

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

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

1.7

Safety

Tigercat 6050 Carbonator

SAFETY HAZARDS – OPERATING • Maintain a charged fire extinguisher near the vehicle at all times and know how to use it.

• Do not carry passengers anywhere on the machine.

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

• Be aware, when performing service and maintenance tasks, surfaces and grab handles in and around the engine and cooling system may become very hot when the engine has been running.

Contact with hot surfaces may cause injury.

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

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

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

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

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

• Maintain a distance of 3 m (10 ft) between the machine and any power line carrying up to 50,000 volts or less plus 10 mm (0.4 in) for each additional 1000 volts above the 50,000 volt level.

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

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

Wash hands after handling.

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

• Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components. Reduce engine speed to LOW and let run for approximately five minutes to allow gradual dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

1.8

Tigercat 6050 Carbonator

Safety AVOID INJURY FROM BACKOVER ACCIDENTS

CAUTION

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

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

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

• Be alert for bystanders moving into the work area.

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

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

• To avoid backover accidents: • Look around the entire machine area before backing up the machine.

• Keep the motion alarm in proper working order.

The motion alarm must sound when the machine travels in forward or reverse.

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

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

• Do not attempt to charge a frozen battery. It can explode.

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

• Keep lights, and cameras in proper working order.

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

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

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

Serious burns or an explosion can result.

1.9

Safety

Tigercat 6050 Carbonator

OPERATING SAFETY PRECAUTIONS

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

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

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

FOR TIER 4F MACHINES ONLY

41581AUNI R0

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

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

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

• Sound the machine horn before starting the machine.

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

WARNING Do not use a liquid starting aid to start an engine.

This machine is equipped with a computer controlled heating element in the engine intake system. Starting fluids will explode on contact with the heating element.

• Before moving the machine to the work site, all doors, panels, and access covers must be installed properly and secured.

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

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

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

1.10

Tigercat 6050 Carbonator

Safety

PARKING THE MACHINE Park the machine with the engine end facing up-wind in a cleared area at least 15 m (50 ft) away from other equipment. In the event of a fire, this distance will minimize the chance of the fire spreading to other equipment.

WARNING

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

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

Perform the following steps when parking the machine: 1. Park the machine on level ground. Do not park on a slope or hillside.

2. Turn OFF the engine.

• Do not travel near co-workers or other pieces of equipment with the machine running.

3. Remove the ignition key.

• Do not allow people or other pieces of equipment near the processing operation.

5. Turn OFF the battery disconnect key switch, remove the key, lock out/tag out.

4. Wait for the 'wait to disconnect' light to go out.

NOTE: If the battery disconnect key switch is used to turn OFF the engine, the engine electronic control unit logs a fault code to record improper shutting/powering down.

This switch completely disconnects all electrical circuits on the machine from the batteries and is located at the front of the machine under the control panel. It is good practice to turn this switch OFF when the machine is left idle for an extended period of time, such as overnight.

WARNING • Use only prearranged and approved signalling practices.

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

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

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

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

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

Refer to AFTERTREATMENT SYSTEM in ENGINE OPERATION AND MAINTENANCE MANUAL for more information.

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

TRANSPORTING THE MACHINE When transporting the machine, enough clearance must be available on both sides and above the machine or any of its attachments to avoid contact with power or telephone lines, bridge structures, etc.

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

Refer to MACHINE MOVING AND TRANSPORTING INSTRUCTIONS literature supplied with the machine.

1.11

Safety

Tigercat 6050 Carbonator

CARBONIZING PROCESS SAFETY PRECAUTIONS WARNING Maintain a safe operating distance of 45 m (150 ft) between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use. Temperatures of the outside surfaces of the carbonizing chamber can exceed 175°C (350°F).

• Maintain a 15 m (50 ft) distance between the machine and combustible materials. This distance does not include wood and vegetative wast piles for disposal during operation, or healthy foliage. Healthy plant life is of minimal threat to operations.

• If carbonizing appears out of control, immediately stop loading the carbonizing chamber. Using the remote, stop the over air fan and under air fan.

Maintain the auger water if operating.

• If the fire in the carbonizing chamber requires extinguishing, smother by dumping dirt into the chamber. Refer to OPERATING THE MACHINE – PERMANENT SUPPRESSION in SECTION 2.

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

DANGER Do not use highly volatile accelerants such as gasoline or kerosene to light the fire in the carbonizing chamber.

These fluids ignite almost explosively and may cause injury or death.

• If an accelerant is to be used to light the material in the carbonizing chamber, only diesel fuel is recommended.

• Operators and spotters on the ground will be required to work within the 45 m (150 ft) hazard zone to load and tend the machine during operation. Use the remote to control the machine functions.

• Wear protective clothing such as fire-resistant Nomex® coveralls when operating the machine or feeding the carbonizing chamber.

• Do not open the rear door or side access doors during the carbonizing process.

• Do not climb on the machine during the carbonizing process.

WARNING The machine does not prevent all hot embers from escaping. Emissions are reduced through efficient carbonizing. Operator must be aware of the surroundings.

• Monitor the work area for hot embers escaping from the carbonizing chamber that could ignite the working pile.

WARNING Only use water to extinguish a fire in the carbonizing chamber as a last resort or possible damage to the refractory panels will occur.

• Use a hand-held anemometer to determine accurate wind speed before beginning the carbonation process.

• Do not operate the machine during sustained winds exceeding 45 km/h (28 mph) without providing a natural or constructed wind barrier. The potential to carry hot embers is increased without this barrier.

• Substantial wind speed may affect the integrity of the over air on the top of the carbonizing chamber, causing hot embers to travel farther distances.

WIND SPEED CHART Sustained Wind Speed vs Suggested Safe Distance Combustible Material Piles

Working Material Pile

Wind Speed

Occupied Structures

Woods/ Trees

km/h

mph

m

ft

m

ft

m

ft

m

ft

24

15

91

300

15

50

15

50

6

20

27

17

91

300

15

50

15

50

6

20

31

19

91

300

23

75

23

75

6

20

34

21

91

300

23

75

23

75

6

20

37

23

91

300

30

100

30

100

6

20

40

25

91

300

30

100

30

100

6

20

43

27

DO NOT CARBONIZE

NOTE: The above chart is provided as a guideline only. Continually observe the entire work area during operation. Observe and comply with all jurisdictional fire and forestry ordinances.

• Do not locate the machine atop combustible materials while in operation or when parked after operations have been completed.

• Keep the area around the machine clear of all debris.

1.12

Tigercat 6050 Carbonator

Safety

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

6000122

6000123

• Before performing any service, lockout and tagout the machine to ensure the machine cannot be started by personnel other than those servicing the machine. Follow all lockout tagout rules in accordance with local regulations.

• Close the lock out hasp (when equipped) and place a padlock through the latch hole.

• Read, understand and follow all operating safety precautions specified in all supplementary documentation.

• The use of an industry-standard multiple-hole lockout hasp is recommended, especially when more than one person is servicing the machine. This allows each person to install their own lock and tag.

Close the lockout hasp and place lock(s) through the latch hole(s).

• Install a DO NOT START ENGINE sign on the electrical panel and in the engine compartment when making repairs to the machine. Before performing maintenance or repair work on any equipment, consult the instruction manual provided by the manufacturer and follow the recommended procedures.

A

B

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

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

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

6000017

A Battery Disconnect Key Switch (Lockout Hasp Not Shown) B Wait to Disconnect Light

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

1.13

Safety

Tigercat 6050 Carbonator WARNING

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

• Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down.

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

• Do not begin service work until the surface or system temperature has cooled down to below 38°C (100°F).

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

WARNING

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

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

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

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

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

• 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.

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

1.14

Tigercat 6050 Carbonator

Safety

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

PRIOR TO WELDING Special precautions are necessary before undertaking any welding on the machine: 1. Clean up the work area. Remove excess oil or grease, debris, or flammable materials from the vicinity.

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

2. Keep a fire extinguisher on hand in the work area.

3. Situate the welding ground clamp on the machine such that current will not pass through any bearings —especially the swing bearing.

4. Turn OFF the battery disconnect key switch.

• Dispose of fluids properly. Do not pour fluids into the ground, stream, pond or lake.

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

5. Remove the battery compartment cover and disconnect the negative battery cable from the negative battery terminal. Refer to BATTERY BOOSTING in SECTION 2.

The following steps protect the sensitive electronics on the machine: 6. Disconnect all electronic components on the engine. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

• 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.

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

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

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

CAUTION Wear a respirator at all times when cleaning out the carbonizing chamber.

1.15

7. Disconnect the two multi-pin connectors from the XC10-C1 and XC10-C2 modules in the electrical panel.

When welding work is complete: 1. Re-connect all connectors.

2. Connect the negative battery cable to the negative terminal. The connection must be tight, clean, and secure.

3. Turn ON the battery disconnect key switch.

Safety

Tigercat 6050 Carbonator

MACHINE STABILITY AND TRACTION This machine is designed to operate in rugged terrain.

However, ground conditions vary greatly according to soil type, slope, moisture level, temperature, season, geology, and vegetation. These factors affect the machine's stability and tractive capabilities. The machine may not be suitable for some ground conditions. Use caution when assessing the terrain in the work area Observe the following approaches to minimize the risk of tipping:

A 6000124

A Maximum 5°

• Do not travel across a slope or hillside exceeding 5 degrees.

• When crossing obstacles (boulders, stumps, or ditches) the machine can shift rapidly, greatly affecting its stability. Move slowly over obstacles, to reduce the risk of the machine shifting rapidly.

A

A

6000104

A Maximum 15°

• Do not travel up or down a slope exceeding 15 degrees.

• When climbing a slope, position the track drive gearbox at the rear of the machine.

• When descending a slope, position the track drive gearbox at the front of the machine.

1.16

Tigercat 6050 Carbonator

Safety

FLUID INJECTION INJURY

Prevention is the best defence against fluid injection injuries.

WARNING

When searching for possible fluid leaks:

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

• Do not use bare hands. Wear thick protective gloves at all times.

• Wear safety goggles; a face shield is also recommended.

• Keep all body parts well away from the potential leak zone.

Hydraulic oil and diesel fuel systems in forestry equipment operate at very high pressures – often above 200 bar (3000 psi).

If a hose fitting becomes loose or a hose ruptures, the leak point will emit a fine, high velocity stream of fluid.

Even in systems that operate at pressures as low as 7 bar (100 psi), a fluid stream can penetrate human skin as if it were hypodermic needle.

An accidental hypodermic fluid injection may, at first, create only slight stinging sensation. Within a short time, however, the wound will begin to throb painfully, indicating that tissue has already been damaged.

If fluid injection penetrates a blood vessel, it can rapidly spread throughout the body's circulatory system. The body is unable to purge this toxin.

Time is a critical factor that influences fluid injection injuries. If a fluid injection injury occurs, or is suspected, it is vitally important to seek medical attention immediately. Tissue damage will continue to occur until the injury is treated.

Although fluid injection injuries are relatively rare, the resulting injuries have, on occasion, resulted in the amputation of fingers, hands, or entire limbs. The longer the delay in seeking medical attention, the further up the limb the tissue damage will reach. An injury of this nature can have extremely grievous consequences —including death —if not treated promptly and correctly.

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

• Seek professional medical attention immediately.

1.17

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

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

• Recognize the leak source and the fluid stream itself may be nearly invisible. Pooling of fluid may be the clearest evidence of a leak.

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

• Do not grab hold of any hydraulic or diesel fittings or hoses that are pressurized.

• Use the correct hoses and fittings for repairs; they must be rated for the pressures to which they will be subjected.

• Do not use hoses or fittings if defects or damage are suspected.

Safety

Tigercat 6050 Carbonator

GREASE INJECTION INJURY– PNEUMATIC GREASE GUNS Pneumatic grease guns can pump grease at pressures ranging from 17-400 bar (245-5800 psi). Fluids at pressures as low as 7 bar (100 psi) can penetrate human skin.

Seek professional medical attention immediately in the event of a grease injection injury. Provide the attending physician with as much information as possible: the type of grease, the pressure setting of the gun, and related details.

In the event of a grease injection injury, the volume of material injected, the pressure at which it was injected, and the time elapsed between injection and medical treatment will influence the chance of successful recovery.

Before using a pneumatic grease gun: • All users must be trained to operate it properly.

• All users must be familiar with the hazards involved, and necessary safety precautions.

When using a pneumatic grease gun: • Wear protective clothing, such as gloves, safety goggles, and safety helmet.

• Inspect the grease gun equipment for damage or wear; replace damaged or worn parts.

• Verify that protective shrouds are installed at the grease gun nozzles.

• Remove dirt and old grease from grease fittings prior to pumping fresh grease.

• Replace any defective or damaged grease fitting on equipment with new fittings.

• Replace awkwardly situated fittings with angled or swivel fittings for ease of access.

1.18

Tigercat 6050 Carbonator

Safety

LIGHTNING SAFETY AWARENESS

LIGHTNING SAFETY

WHAT IS A LIGHTNING STRIKE? Lightning is a discharge of the electricity produced by a thunderstorm. As the thunderstorm develops, many small particles of ice within the storm clouds bump together. These collisions create a positive charge at the top of a cloud and a negative charge at the bottom.

As this continues a second positive charge builds up on the ground beneath the cloud, concentrated around high objects such as hills, trees, buildings, equipment and even people.

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.

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

Loggers can increase their chances of avoiding a lightning strike by following a few simple safety practices: • 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 • Do not start or continue any work that cannot be stopped immediately, when a storm moves nearby.

The electrical potential in a lightning strike can be as much as 100 million volts. Lightning strikes can occur over very large distances, even as much as 60 km (37 miles). Lightning travels both in front of and behind a thunderstorm and so strikes happen even when rain has not started or has stopped. Lightning can hit in the same place, many times and often spreads out over 18 m (60 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.

1.19

• 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.

• Obey the rule - If you see lightning, Flee. If you hear thunder, Clear. Do not follow the now obsolete guideline to take shelter when the time between seeing lightning and hearing thunder is 30 seconds or less. This does not provide sufficient time to ensure safety.

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

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

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

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

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

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

Tigercat 6050 Carbonator IF INSIDE A MOTOR VEHICLE OR FULLY ENCLOSED ROPS EQUIPMENT CAB: • Under no circumstances whatsoever step outside of the vehicle or off the equipment to move to another shelter. Very dangerous electrical pathways to ground may go through you.

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

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

Heavy forestry equipment such as a processor, 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.

• 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.

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

Note the rubber tires on motor vehicles and heavy equipment do not increase safety from lightning strikes.

Lightning has already travelled a great distance through the air to strike the vehicle. In comparison a few inches of rubber in a tire offers absolutely no additional insulation.

WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER IF YOU CAN, GET INSIDE: Run to the nearest building, motor vehicle or fully enclosed ROPS equipment cab immediately. Being anywhere outside is not safe.

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.

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

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

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

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

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

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

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

• Avoid entering any small enclosures or shelters.

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

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

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

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

• Do not use the telephone except for emergencies.

1.20

Tigercat 6050 Carbonator

Safety

WHAT TO DO IF YOU FEEL YOUR SKIN TINGLING, YOUR HAIR STANDS ON END, LIGHT METAL OBJECTS VIBRATE OR YOU HEAR A CRACKLING SOUND: • Lightning is probably about to strike. You only have a few seconds to act.

• Put your feet together. Crouch down like in a baseball catcher’s position. Hold your head down.

Cover your ears to protect them against the noise of the thunder.

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

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

There is no danger to anyone helping this person.

You can touch him or her immediately.

• Call your local emergency response telephone number immediately.

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

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

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

1.21

Safety

FIRE PREVENTION

Tigercat 6050 Carbonator • Steam clean the engine, hydraulic pumps, transmission, brake, fuel and hydraulic oil tank compartments and all machine belly pans at least once each month, or more frequently when working in conditions with high volumes of forest debris • Use only non-flammable solutions for cleaning the machine and components.

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

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

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

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

Refer to CLEANING COOLER PACKAGE in SECTION 3 .

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

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

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

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

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

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

Do not operate the machine until exhaust leaks are repaired.

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

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

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

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

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

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

• Do not smoke in the vicinity of the machine.

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

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

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

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

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

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

1.22

Tigercat 6050 Carbonator

Safety • 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.

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

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

HOW TO PREPARE FOR A MACHINE FIRE • Inspect and maintain all machine systems on a routine basis.

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

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

• Verify the correct types of fire extinguishers are available at the work site. Most fires involving mobile forestry equipment will be Class A or B. Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A. • 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.

• Class C fires apply to energized electrical equipment.

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

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

IN CASE OF A MACHINE FIRE If a machine fire occurs: 1. Lower all working attachments to the ground.

2. Turn OFF the engine.

3. Activate the fire suppression system as applicable.

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

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

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

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

Before deciding to fight the fire, be certain that:

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

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

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

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

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

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

1.23

1. The fire is small and not rapidly spreading.

2. There is 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.

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

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

Safety

Tigercat 6050 Carbonator

When fighting a fire:

AFTER A MACHINE FIRE

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

Before returning a machine to operations:

2. Immediately afterwards use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by debris or hot machine components in the area. Water cools the area, reducing the chances of re-ignition.

3. Use the fire extinguisher PASS method:

1. Determine the cause of the fire.

2. Complete all necessary repairs.

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

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

Pull the safety pin at the top of the extinguisher that prevents the discharge lever from being depressed.

Break the plastic seal as the pin is pulled.

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

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

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

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

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

822C-190

Typical Fire Extinguisher Access Port

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

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

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

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

1.24

Tigercat 6050 Carbonator

Safety

DRY CHEMICAL CLEANUP PROCEDURES

WET CHEMICAL CLEANUP PROCEDURES

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

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

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

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

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

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

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

Wipe all surfaces with a damp cloth.

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

Neutralize the acidic paste on large surfaces by spraying or washing these areas with a mixture of three parts hot water to one part baking soda. Allow this mixture to stand for several minutes before rinsing with warm water. Wash the area with a mild soap and water solution. Rinse thoroughly with water. Blow-dry to remove all residual water.

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

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

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

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

1.25

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

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

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

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

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

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

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

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

Safety

SAFETY LABELS Inspect and clean safety labels to preserve legibility.

Replace any illegible, damaged, or missing labels immediately.

Tigercat 6050 Carbonator REMOVE IGNITION KEY BEFORE SERVICING THE MACHINE

OPERATOR'S MANUAL LOCATION

This label shows where the operator's manual is stored.

The label is placed on the outside of the operator's manual case.

Read and understand the operator's manual before operating the machine. Take note of the warnings and hazard identifications. Study all safety messages in the manual and on machine labels.

Turn OFF the engine, remove the ignition switch key, and store it in a safe place before performing maintenance or service work on the machine.

KEEP BACK 45 M/150 FT

This label warns personnel to keep back at least 45 m (150 ft) from a working machine due to the risk of flying debris.

When approaching an operating machine on foot, stay at least 45 m (150 ft) away until the operator recognizes your presence. Make certain that all equipment has been shut down before advancing any closer to the machine.

1.26

Tigercat 6050 Carbonator

Safety

ELECTROCUTION HAZARD

ELECTRICAL SHOCK HAZARD

This label indicates a potential electrocution hazard.

Contact with electric lines can result in death or serious injury.

This label indicates a severe electrical shock hazard.

Before beginning work in any area, study the terrain carefully. Become familiar with potential hazards, such as overhead power lines.

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

1.27

Turn OFF the battery disconnect key switch before accessing the battery compartment. Disconnect the positive battery cables before servicing the electrical system.

Do not short the battery terminals for any reason. An explosion and/or serious burns can result.

Safety

Tigercat 6050 Carbonator

BURN HAZARD

CRUSH HAZARD

This label indicates hot machine and/or component surfaces. Surfaces and grab handles in and around the engine, hydraulic oil tank, and cooling system can become very hot when the machine has been running.

Do not touch these surfaces; contact with hot surfaces can cause injury.

This label indicates a vertical crush zone.

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

Use a thermometer to check surface and system temperatures. Do not begin service work until the surface or system temperature has cooled below 38°C (100°F).

Clear all personnel from the machine area before turning the engine ON. Do not allow any personnel in areas where crush hazards exist while the machine is running.

Maintain a safe operating distance between the machine and other personnel. Operators must verify that no person enters the hazard zone: within 30 m (100 ft) of the machine.

Do not service the machine until the machine is correctly parked, and the engine is turned OFF.

1.28

Tigercat 6050 Carbonator

Safety

EXPLOSIVE RELEASE OF COOLING SYSTEM FLUID

NO RIDERS

33952AUNI R0

This label indicates a pressure and fluid spray hazard when the coolant is hot.

Do not loosen the radiator cap when the radiator and coolant are hot. The explosive release of pressurized fluids can cause serious burns.

Turn OFF the engine and allow the radiator to cool to the point that it can be touched with bare hands before removing the cap. Slowly loosen the cap to the first stop.

Allow pressure to release. When the hissing stops, press down on the cap and continue turning to remove.

1.29

Do not carry passengers anywhere on the machine.

Personnel riding on the outside of the machine are subject to a range of hazards, including: falls, crush hazards, thrown objects, falling objects, and others that can result in death or serious injury.

If any person approaches or attempts to climb on to the machine during operation, stop the machine immediately.

Clear all personnel beyond the hazard zone before operating the machine.

Safety

Tigercat 6050 Carbonator

EXPLOSION HAZARD

PORTABLE FIRE EXTINGUISHER

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

This label indicates an explosion hazard.

The engine is equipped with an electric heater starting aid. Do not use ether or chemicals to assist in engine starting. Ether will explode on contact with the electric heater, causing death or serious injury.

DO NOT TOW FROM THIS POINT

This label indicates portable fire extinguisher storage locations.

FIRE EXTINGUISHER ACCESS PORT

This label indicates a location on the machine that should not be used as a tow point.

This label appears at each fire extinguisher access port.

1.30

Tigercat 6050 Carbonator

Safety

FIRE PREVENTION

CHECK DAILY

This label describes essential fire prevention measures:

This label underscores daily fire prevention checks for combustible debris, fluid leaks, damaged wiring or hoses, and properly functioning fire-fighting equipment.

Read, understand, and follow the fire prevention guidelines in this manual.

Do not allow combustible material to build up in the machine.

Repair and clean up fluid leaks and spills immediately.

Inspect exhaust components for wear or damage.

1.31

Safety

Tigercat 6050 Carbonator

NOTICE LABELS ENGINE IDLE (T4F ENGINES) Inspect and clean notice labels to preserve legibility.

Replace any illegible, damaged, or missing labels immediately.

This label reminds operators to idle the engine for no longer than one hour at a time, to prevent damage to the emission control system.

1.32

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

Tigercat 6050 Carbonator SECTION 2 – CONTROLS AND OPERATION Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 2

ISSUE 2.0, OCTOBER 2020

A

ALARMS EMERGENCY STOP ACTIVE............................................................................................................................... 2.10 HYDRAULIC OIL LEVEL LOW.............................................................................................................................. 2.19 HYDRAULIC OIL TEMPERATURE HIGH............................................................................................................. 2.19 HYDRAULIC OIL TEMPERATURE LOW............................................................................................................. 2.19

B

BATTERY BOOSTING.............................................................................................................................................. 2.30 BATTERY BOOSTER CABLE WITH CLAMPS.................................................................................................... 2.30

C

CHAR AUGER/CONVEYOR CONNECTIONS........................................................................................................ 2.33 CONTROLS............................................................................................................................................................... 2.10 CHAR AND FUNCTIONS CONTROL SCREEN................................................................................................... 2.20 ENGINE DATA SCREEN........................................................................................................................................ 2.18 HOME SCREEN..................................................................................................................................................... 2.16 CHAR AND FUNCTIONS SCREEN BUTTON.................................................................................................. 2.17 ENGINE DATA SCREEN BUTTON.................................................................................................................... 2.17 MAIN MENU SCREEN BUTTON....................................................................................................................... 2.17 MAIN MENU............................................................................................................................................................ 2.22 ADJUST MENU................................................................................................................................................... 2.25 MEASURE MENU............................................................................................................................................... 2.24 PREFERENCES.................................................................................................................................................. 2.27 SYSTEM MENU.................................................................................................................................................. 2.23 REMOTE, 60500001 - 60500102............................................................................................................................ 2.12 AUGERS.............................................................................................................................................................. 2.13 CAMERA.............................................................................................................................................................. 2.13 DATA SCREEN.................................................................................................................................................... 2.13 ENGINE SPEED.................................................................................................................................................. 2.13 E-STOP BUTTON................................................................................................................................................ 2.13 HYDRAULIC OIL COOLER (AUX 1).................................................................................................................. 2.13 OVER AIR FAN.................................................................................................................................................... 2.13 TRACK MODE..................................................................................................................................................... 2.13 UNDER AIR FAN................................................................................................................................................. 2.13 REMOTE, 60500103 - 60500500............................................................................................................................ 2.14 AUGERS.............................................................................................................................................................. 2.15 CAMERA.............................................................................................................................................................. 2.15 CHAR AUGER/CONVEYOR.............................................................................................................................. 2.15 DATA SCREEN.................................................................................................................................................... 2.15 ENGINE SPEED.................................................................................................................................................. 2.15 E-STOP BUTTON................................................................................................................................................ 2.15 OVER AIR FAN.................................................................................................................................................... 2.15 TOP FEED ROLL................................................................................................................................................ 2.15 TRACK MODE..................................................................................................................................................... 2.15 TRACK SPEED................................................................................................................................................... 2.15

M

Controls and Operation

Tigercat 6050 Carbonator

MACHINE OVERVIEW................................................................................................................................................ 2.5 CROSS SECTION VIEWS....................................................................................................................................... 2.7 O

OPERATING THE MACHINE................................................................................................................................... 2.35 INTERMEDIATE SUPPRESSION......................................................................................................................... 2.40 MACHINE STARTUP............................................................................................................................................. 2.35 LOADING AND LIGHTING................................................................................................................................. 2.35 REQUIRED TOOLS FOR IGNITION OF MATERIAL IN THE CARBONIZING CHAMBER........................... 2.35 START-UP PROCEDURE................................................................................................................................... 2.35 PERMANENT SUPPRESSION............................................................................................................................. 2.41 RESTARTING THE FIRE....................................................................................................................................... 2.41 STARTING THE ENGINE...................................................................................................................................... 2.35 STOPPING THE MACHINE................................................................................................................................... 2.39 OPERATION TIPS..................................................................................................................................................... 2.34 OPERATOR’S MANUAL CASE................................................................................................................................ 2.11

P

PICTOGRAMS............................................................................................................................................................. 2.3

R

REFUELLING............................................................................................................................................................. 2.31

S

SITE PREPARATION................................................................................................................................................ 2.32

T

TRACK DRIVE OPERATION AND WEAR PREVENTION............................................................................................................ 2.42

W

WARNING LIGHT........................................................................................................................................................ 2.9

2.2

Tigercat 6050 Carbonator

Controls and Operation

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

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

Engine Emission Inhibit Mode Engine Emission System Temperature Engine Percentage of Load

Engine Oil Pressure

12 V, Power 24 V, Power

Engine Oil Temperature

Adjustment Menu Icon

Engine Run

Alert Message Symbol

Engine Speed – rpm

Battery CONNECT

Engine Start

Battery DISCONNECT

Engine Stop

Diesel Exhaust Fluid (DEF) Engine WAIT TO START Diesel Exhaust Fluid Warning Engine Fuel Consumption Engine Boost Pressure

Fuel – Diesel

Engine Charge Air Pressure Filter

Fuel Information

Engine Charge Air Temperature

Fuel Pressure

Engine Coolant Temperature

Fuel Reset

Engine Diagnostics

Fuel – Temperature

Engine Emission Filter 2.3

Controls and Operation

Tigercat 6050 Carbonator

Fuel – Water in Fuel

Temperature

Home Track LEFT FORWARD/ REVERSE and TRAVEL

Hours – Engine

Track RIGHT FORWARD/REVERSE

Hours – Machine

Hydraulic OIL FILTER BYPASS

Hydraulic Oil Tank

Hydraulic Oil GRADE

Hydraulic Oil LEVEL

Hydraulic Oil TEMPERATURE Menu Metric/Imperial Toggle

Serial Number

Speed FAST or HI Speed SLOW or LOW Switch OFF Switch ON

2.4

Tigercat 6050 Carbonator

Controls and Operation

MACHINE OVERVIEW C

A

D

B

G

6000084

A B C D E

I

J

Rear Door Primary Carbonizing chamber Camera Camera Arm Over Air Fan

F

E

H F G H I J

Hydraulic Valve Compartment Over Air Manifold Ignition Port Doors Track – Fan Side Char Augers

The feedstock serves as its own fuel source for the pyrolysis process. Debris can be continually fed into the carbonizing chamber. The thermal ceramic walls are designed for operating at consistent temperatures exceeding 1370°C (2,500°F).

The 6050 Carbonator performs two functions: • Material reduction of whole and processed clean wood debris.

• Production of a carbon-based bioenergy product, commonly known as biochar.

The carbonizing process (high temperature pyrolysis) efficiently and effectively reduces the volume of material approximately 90% with throughput rates ranging from 13.5-18 tonnes (15-20 tn) per hour, while outputting biochar.

Feedstock is unprocessed wood and vegetative debris such as tree limbs, logs and stumps. The process of manufacturing biochar sequesters approximately 25% of the wood debris potential CO2 emissions and effectively sequesters carbon.

The 6050 Carbonator is not dependent on a specific sized material or a maximum moisture content level so the material does not have to be pre-processed or dried.

The carbonizing chamber accepts whole logs, limbs and stumps.

2.5

The ceramic wall design and air manipulation system harnesses the heat energy produced through the secondary combustion of liberated gases, ensuring that the entire primary carbonizing chamber reaches and sustains the desired operating temperature.

Both over air and under air flows are provided to ensure an efficient carbonizing process. Thermal oxidation to a depleted carbon product is prevented by the system design. The biochar product passes through a grate and then is quenched and discharged with an auger system.

Controls and Operation A

D

Tigercat 6050 Carbonator B

E

C

G

F

H

I

6000086

A B C D E

Over Air Fan Carbonizing chamber Over Air Manifold Electrical Panel Engine Compartment

F G H I

2.6

Engine Compartment Door Track – Non-Fan Side Fuel Filler Cap Hydraulic Oil Level Gauge

Tigercat 6050 Carbonator

Controls and Operation

MACHINE CROSS SECTION VIEWS I

J

K

L

A

A

M H

G

SECTION A– A A

B

C

D

6000085

A B C D E F G

Under Air Fan Auger Drive Motors Auger Drive Chains Auger Troughs Char Augers Char Auger Discharge Refractory Panels

H I J K L M

2.7

Floor Grating Auger 1 – Fan Side Auger 2 – Mid Auger 3 – Non-Fan Side Track – Fan Side Track – Non-Fan Side

E

F

Controls and Operation

Tigercat 6050 Carbonator

WATER HOOKUP

C

The water hook-up on the fan side of the machine provides quenching water to the augers.

Prior to operating the machine: 1. Connect a 4 bar (60 psi) water line to the water hook-up connection.

Flow rate from the water supply pump should be 11-20 L/m (3-5 US gpm).

2. Turn ON the water inlet valve (if equipped) and all auger water flow valves.

Turn OFF the auger valves when the augers are not in use.

IMPORTANT! In cold weather, check all water lines are free of ice buildup prior to sending water into the system.

NOTICE

B

A

6000267

Do not operate the augers until all auger water flow valves are in the open position.

Configuration #2

A Water Hook-up Connection B Water Drain Valve C Auger Water Flow Valves

There are three configurations available for the water hookup:

C

C

A B

A

Configuration #3

6000266 6000267

A Water Hook-up Connection B Water Inlet Valve C Auger Water Flow Valves

Configuration #1

A Water Hook-up Connection B Water Inlet Valve C Auger Water Flow Valves

B

6000268

NOTE: Configuration 3 is equipped with a flow detection switch in the inlet line. If water flow drops below the minimum requirement an error message is sent to the computer home screen and the warning light on the camera arm will flash.

2.8

Tigercat 6050 Carbonator

Controls and Operation

CAMERA

WARNING LIGHT The amber warning light mounted on the camera arm will flash when a machine error message is displayed on the screen.

A

Investigate the warning and perform the required service or repairs to correct the machine error.

B

C

6000096

A Camera B Warning Light C Camera Arm

Camera

6000269

Warning Light

A

B 6000088

Control Panel

A Camera ON/OFF Switch B Battery Disconnect Key Switch

Prior to operating the machine: 1. Turn ON the battery disconnect key switch.

2. Use the camera ON/OFF switch on the control panel to turn ON the camera.

NOTICE Do not ignite the fire in the carbonizing chamber until the camera is in the raised position. Do not lower the camera into the resting position until the carbonizing chamber has cooled to ambient temperature.

2.9

Controls and Operation

Tigercat 6050 Carbonator

CONTROLS EMERGENCY STOP BUTTONS

A

A

6000082

Remote 60500001 – 60500102

A Emergency Stop Button

A 6000080

B

6000257

Remote 60500103 – 60500500

A Emergency Stop Button

There are three emergency stop (E-stop) buttons on the machine: • Control panel – front of machine.

6000081

Emergency Stop Buttons– Machine

A Control Panel B Rear Non-Fan Side of Machine

• Rear non-fan side of machine near rear door latch.

• Remote.

Press any of the emergency stop buttons down, to immediately turn OFF the engine and all machine systems.

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

NOTICE Do not use the emergency stop button to turn OFF the engine during normal operation.

2.10

Tigercat 6050 Carbonator

Controls and Operation

OPERATOR’S MANUAL CASE

EMERGENCY STOP ACTIVE

A

6000118

When an emergency stop button is pressed, an alarm warning screen will appear on the computer display advising that one of the buttons is active.

6000277

Engine Compartment

A Operator's Manual Case

The machine will not start until all emergency stop buttons are popped up.

The operator's manual case is located on the inside of the engine compartment on the right side of the machine.

The case houses the operator's manual and other documentation associated with the features and accessories installed on the machine at the factory.

2.11

Controls and Operation

Tigercat 6050 Carbonator

REMOTE, 60500001 – 60500102

A

R

Q

B

ASH AUG ON

TRACK LT FORWARD

ASH AUG OFF

P

O

N

TRACK RT FORWARD TRACK FAST / SLOW

TRACK LT REVERSE

TRACK RT REVERSE

AUX 1 OFF

AUX 2 OFF

AUX 1 ON

AUX 2 ON

TRACK MODE

CAMERA UP

OVER AIR UP

THROTTLE UP

Fn

C

D

E

F

CAMERA DOWN

M

OVER AIR DOWN

THROTTLE DOWN

G

L

H

K

I

J

6000001

A B C D E F G H I

E-Stop Button Track Right FORWARD 2nd Button Function Track Right REVERSE, +FN Track Speed Shift Aux 2 ON, +FN Aux 2 OFF Engine Speed UP, +FN Camera Arm UP Engine Speed DOWN, +FN Camera Arm DOWN Screen Select Power ON/OFF

J K L M N O P Q R

2.12

Data Screen Screen Select DOWN Screen Select UP Over Air Fan DOWN Over Air Fan UP, +FN Track Mode Aux 1 ON, +FN Aux 1 OFF Track Left REVERSE Augers ON, +FN Augers OFF Track Left FORWARD

Tigercat 6050 Carbonator

Controls and Operation

STORAGE AND CHARGING LOCATION

TRACK MODE Press the track mode button (Fn TRACK MODE) to engage the tracks. Track alarm will sound. The machine can now be moved using the track forward and reverse buttons. Press the track mode button again to turn OFF track mode. Track alarm will continue to sound until track mode is turned OFF.

A

B

ENGINE SPEED Press the THROTTLE UP button to increase engine speed. Press the THROTTLE DOWN button to decrease engine speed.

C

CAMERA Press the CAMERA UP button to raise the camera arm into position. Press the CAMERA DOWN button to lower the camera arm to the down position.

6000083

Remote in Charging Station

A Remote B Charging Station C Main Electrical Panel – Front of Machine

OVER AIR FAN

The remote is attached magnetically to a charging station on the side of the main electrical panel inside the control panel. When not in use, return the remote to the charging station to maintain maximum charge during operation.

E-STOP BUTTON

Press the OVER AIR UP button to increase the over air fan speed. Press the OVER AIR DOWN button to decrease the over air fan speed.

AUGERS Press the AUG ON button to turn ON the augers. Press the AUG OFF button to turn OFF the augers.

DATA SCREEN The data screen shows the following information: Screen Parameter

A 6000082

A Emergency Stop Button – Remote

Press the button to emergency stop the machine. To reset, twist the button until it pops up.

2.13

Description

1

Engine Speed (rpm)

2

Engine Load (%)

3

Fuel Rate – L/h (US gph)

4

Engine Hours

5

Coolant Temperature – °C (°F)

6

Fuel Pressure – bar (psi)

7

Oil Pressure – bar (psi)

8

Boost Pressure – bar (psi)

Controls and Operation

Tigercat 6050 Carbonator

REMOTE, 60500103 – 60500500

A

B

D

C

F

E

H

G

J

I

L

K

N

M

P

O

6000257

A B C D E F G H

E-Stop Button Data Screen 2nd Function for Track Mode and Track Speed Power ON/OFF Char Auger/Conveyor ON/OFF Augers ON/OFF Engine Speed UP Engine Speed DOWN

I J K L M N O P

2.14

Over Air Fan UP Over Air Fan DOWN Camera Arm DOWN and FUNCTION – TRACK SPEED Camera Arm UP and FUNCTION – TRACK MODE Right Track FORWARD Left Track FORWARD Right Track REVERSE Left Track REVERSE

Tigercat 6050 Carbonator

Controls and Operation

STORAGE AND CHARGING LOCATION

DATA SCREEN The data screen shows the following information: Screen Parameter

A

Description

1

Engine Speed (rpm)

2

Boost Pressure – bar (psi)

3

Coolant Temperature – °C (°F)

4

DEF Level

5

Hydraulic Oil Temperature – °C (°F)

6

Fuel Level

AUGERS Press AUGERS to turn ON the augers. Press AUGERS again to turn OFF the augers.

B

CHAR AUGER/CONVEYOR Press CHAR FWD to turn ON the char auger or conveyor. Press CHAR FWD again to turn OFF the char auger or conveyor.

ENGINE SPEED

6000262

Press and hold ENGINE+ to increase engine speed.

Release the button when desired speed is attained.

Remote in Charging Station

A Remote B Main Electrical Panel – Front of Machine

The remote is attached magnetically to a charging station on the side of the main electrical panel inside the control panel. When not in use, return the remote to the charging station to maintain maximum charge during operation.

Press and hold ENGINE – to decrease engine speed.

Release the button when desired speed is attained.

OVER AIR FAN Press OVER AIR+ to increase the over air fan speed.

Press OVER AIR– to decrease the over air fan speed.

CAMERA

E-STOP BUTTON

Press the CAM UP button to raise the camera arm into position. Press the CAM DOWN button to lower the camera arm to the down position.

A

TRACK MODE Press and hold FUNCTION and press and hold TRACK MODE (2nd function of CAM UP button) to engage the tracks. Track alarm will sound and display will indicate track mode activation. The machine can now be moved using the track forward and reverse buttons. Press and hold both buttons again to turn OFF track mode.

Track alarm will continue to sound until track mode is deactivated.

TRACK SPEED Press and hold FUNCTION and press and hold TRACK SPEED (2nd function of CAM DWN button) to set track speed range at HIGH or LOW. The low setting provides the slowest travel speed with maximum torque or driving force. The high setting provides a faster travel speed range but with lower driving force.

6000257

A Emergency Stop Button – Remote

Press the button to emergency stop the machine. To reset, twist the button until it pops up.

2.15

Controls and Operation

Tigercat 6050 Carbonator

HOME SCREEN

C

A

6000107

A Engine Data Screen Button B Char and Functions Screen Button

C Main Menu Screen Button

2.16

B

Tigercat 6050 Carbonator

Controls and Operation

This home screen appears at the start-up of the machine. The touch screen allows navigation through the computer.

ENGINE DATA SCREEN BUTTON Press to access the Engine Data screen.

CHAR AND FUNCTIONS SCREEN BUTTON Press to access the Char and Functions screen.

MAIN MENU SCREEN BUTTON Press to access the Main menu.

2.17

Controls and Operation

Tigercat 6050 Carbonator

ENGINE DATA SCREEN A

B

C

D

E

F

G

H

I

J K L M N

O

P

6000120

A B C D E F G H I J K

V

U

T

S

R

Engine Speed Digital Readout and Gauge – rpm Engine Speed Adjust DEF Gauge and Indicators Engine Wait to Start Indicator Engine Stop Indicator – Red Engine Stop Indicator – Yellow Engine Failure or Malfunction Indicator – Yellow Engine Failure or Malfunction Indicator – Red Emissions System Malfunction Indicator – Red SPN: Suspect Parameter Number FMI: Failure Mode Indicator

Q L M N O P Q R S T U V

CNT: Occurrence Count Hydraulic Oil Temperature – °C or °F Fuel Level Gauge – Later Design Metric or Imperial Units Button Return to Home Screen Button Machine Controls Voltage Engine Hours Engine Boost Pressure – bar or psi Engine Oil Pressure – bar or psi Engine Coolant Temperature – °C or °F Engine Fuel Consumption – L/h or US gph

ENGINE SPEED – RPM

ENGINE SPEED ADJUST

This display provides a digital readout of the engine speed in rpm. The gauge indicates the percentage of HIGH engine speed where the engine is operating.

To increase engine speed, press and hold the FAST button until the desired speed is attained. To decrease engine speed, press and hold the SLOW button until the desired speed is attained.

MAINTAINING CORRECT ENGINE RPM It is important that engine speeds be correct at all times: LOW: 800 rpm (No Load) HIGH: 2050 rpm (No Load) NOTE: The above values are measured with the hydraulic and engine oil at normal operating temperatures and no functions activated.

DEF GAUGE AND INDICATORS This gauge indicates the level of DEF in the DEF tank.

When the level is in the acceptable range, the left indicator light will illuminate yellow. When the level is low, the right indicator light will continuously flash red.

Engine speed defaults to LOW at startup.

2.18

Tigercat 6050 Carbonator

Controls and Operation

MACHINE CONTROLS VOLTAGE

IMPORTANT! Engine components are powered by a 12 V electrical system.

Machine controls are powered by a 24 V electrical system.

This display indicates machine controls voltage levels.

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

ENGINE FUEL CONSUMPTION

6000116

If hydraulic oil temperature is below operating temperature, a low temperature alarm message will appear on the computer display. Allow hydraulic oil to warm to operating temperature before loading machine.

This display indicates the total fuel consumption of the engine in L/h or US gph.

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

If temperature rises above the recommended temperature, alarm will sound, check the following: • Plugged cooler package air intake screens in doors and access panels.

• Plugged oil cooler.

Do not continue to operate machine.

Refer to CLEANING COOLER PACKAGE in SECTION 3.

ENGINE OIL PRESSURE

6000117

If hydraulic oil temperature is above operating temperature, a high temperature alarm message will appear on the computer display. Stop machine immediately.

HYDRAULIC OIL LEVEL

This display indicates operating engine oil pressure.

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

6000121

ENGINE HOURS This display indicates the number of hours the engine has been operating.

HYDRAULIC OIL TEMPERATURE This gauge indicates the temperature of hydraulic oil in the hydraulic oil tank. A temperature sensor sends a continuous signal to the control panel.

6000115

If the level in the hydraulic oil tank drops to a low level, a low hydraulic oil level alarm message will appear on the computer display. If the oil level becomes critically low, the computer will automatically lower the engine speed.

2.19

Controls and Operation

Tigercat 6050 Carbonator

CHAR & FUNCTIONS CONTROL SCREEN A

B

C

D

E

F

G

6000282

A B C D E F

H

Engine Speed Increase Button Engine Speed Reduce Button Engine Speed Display – rpm Fuel Level Gauge Carbonizing Chamber Temperature Gauge Fan Control Buttons A

I

J

K

L

Machine Equipped with Char Auger G H I J K L

B

C

Augers FORWARD/REVERSE Buttons Camera Arm UP/DOWN Buttons Hydraulic Oil Cooler RUN/PURGE Buttons Char Auger RUN Button Char Auger Speed Adjustment Buttons Return to Main Menu Button

D

E

F

6000297

A B C D E F

G

Engine Speed Increase Button Engine Speed Reduce Button Engine Speed Display – rpm Fuel Level Gauge Carbonizing Chamber Temperature Gauge Fan Control Buttons

H

I

J

Machine Equipped with Char Conveyor G H I J K

2.20

K

Augers FORWARD/REVERSE Buttons Camera Arm UP/DOWN Buttons Hydraulic Oil Cooler RUN/PURGE Buttons Char Conveyor RUN Button Return to Main Menu Button

Tigercat 6050 Carbonator

Controls and Operation

ENGINE SPEED

HYDRAULIC OIL COOLER CONTROLS

Press the FAST button to increase engine speed. Press the SLOW button to reduce engine speed. The engine speed in rpm is displayed on the screen.

Press the RUN button to turn ON the hydraulic oil cooler fan. Press the PURGE button to reverse the fan direction to clean the hydraulic oil cooler. The indicators to the right illuminate green to show selection.

EXTERNAL WALL TEMPERATURE The gauge indicates the external wall temperature of the carbonizing chamber. A thermocouple mounted on the right side wall of the chamber provides the input.

NOTE: On machines equipped with proportional hydraulic temperature gauge, the oil cooler will start automatically. The RUN button will not appear on the display.

FAN CONTROL

CHAR AUGER – IF EQUIPPED

Press the OFF button to turn OFF the over air fan and under air fan. The indicator will illuminate green when the fans are off.

Press the RUN button to turn ON the char auger.

The indicator will illuminate green when the circuit is operating. Press the +/- buttons to adjust the auger speed. The auger speed in rpm will be displayed on the screen.

Press the IDLE, LOW, MEDIUM or HIGH button to set over air fan speed to the desired setting. The indicator will illuminate green when the selection is made.

CHAR CONVEYOR – IF EQUIPPED

NOTE: The under air fan speed is preset and is nonadjustable.

Press the RUN button to turn ON the char conveyor.

The indicator will illuminate green when the circuit is operating.

AUGERS FORWARD/REVERSE Press the FWD or REV button to turn ON/OFF the augers and select the direction. The indicators to the right illuminate green to show selection.

CAMERA ARM CONTROLS Press the UP or DOWN button to raise or lower the camera arm. The indicators to the right illuminate green to show selection.

2.21

Controls and Operation

Tigercat 6050 Carbonator

MAIN MENU

6000107

Home Screen – Main Menu.

Home Screen – Main.

The Main menu displays the following selections: • System • Measure • Adjust • Preferences The back button

returns to the previous screen.

The home button

returns to the home screen.

2.22

Tigercat 6050 Carbonator

Controls and Operation

SYSTEM MENU

MODULES MENU

Home Screen – Main – System.

Home Screen – Main – System– Modules.

The System menu displays the following selections:

The Modules menu displays the information and status of the installed machine modules that form the computer system.

• Info • Modules

Tap on the desired module to view the module details, status and alert messages relative to each module.

• Logs INFO MENU

LOGS MENU

Home Screen – Main – System– Info.

The info page provides system information, such as the program name and version.

Home Screen – Main – System– Logs.

The Logs menu displays the following options: • MD4-7[0] log • MC43FS [1] Log • Engine Log • Service Mode • Warnings Tap the above selections to view the history of each log.

2.23

Controls and Operation

Tigercat 6050 Carbonator

MEASURE MENU

INPUTS

Home Screen – Main – Measure.

Home Screen – Main – Measure – Inputs.

The measure menu displays the following selections:

The Inputs menu displays the value of all active inputs.

• Engine • Inputs

OUTPUTS

• Outputs ENGINE

The Outputs menu displays the value of all active outputs.

Home Screen – Main – Measure – CAT Engine.

NOTE: Slide your finger up or down on the screen to view all entries.

The CAT Engine inputs menu displays the engine performance.

NOTE: Slide your finger up or down on the screen to view all entries.

2.24

Tigercat 6050 Carbonator

Controls and Operation

ADJUST MENU

REMOTE

Home Screen – Main – Adjust.

Home Screen – Main – Adjust – Remote.

The Adjust menu displays the following selections:

The Remote menu displays the following selections: • Pause Function

• Remote • Auxiliary Hydraulics Settings that can be adjusted are identified with a Reset button . Adjustments can be performed in two ways: VALUE CHANGE

Tap the / buttons to adjust the value to the desired setting. Tap the check mark button to reset.

RESET VALUE TO FACTORY DEFAULT Tap the Reset button the menu.

and then tap 'Reset...' from

Home Screen – Main – Adjust – Remote – Pause Function.

This function sets how long an operating function displays on the screen before moving to the next function.

Tap the / function time.

Tap the check mark button to reset the selected option to the default value or tap the cancel button exit.

to

2.25

buttons to set the desired pause

Tap the check mark button cancel button to exit.

to accept or tap the

Controls and Operation

Tigercat 6050 Carbonator

AUXILIARY HYDRAULICS

Home Screen – Main – Adjust – Auxiliary Hydraulics.

The Auxiliary Hydraulics menu displays the following selections: • Auxiliary Hydraulic Option

Tap '0000' to enter the temporary PIN code and tap the OK button.

Tap the selection to choose: • Char Auger • Char Conveyor

2.26

Tigercat 6050 Carbonator

Controls and Operation

PREFERENCES

DISPLAY

Home Screen – Main – Preferences.

The preferences menu displays the following functions: • Display • Date/Time

Home Screen – Main – Preferences – Display.

Tap the / buttons to change the value for the following information: • Backlight (20 – 100% in increments of 10%) • Screen saver (Screen: Off– Dimmed – Black)

2.27

Controls and Operation

Tigercat 6050 Carbonator

DATE/TIME

Home Screen – Main – Preferences – Date/Time.

The date/time menu displays the following functions: • Date • Time DATE

Home Screen – Main – Preferences – Date/Time – Date Settings.

Tap the day.

/

buttons to change the year, month, or

Tap the check mark button cancel button to exit.

2.28

to accept or tap the

Tigercat 6050 Carbonator

Controls and Operation

TIME

Home Screen – Main – Preferences – Date/Time – Time Settings.

Tap the

/

buttons to change the hour and minute.

Tap the check mark button cancel button to exit.

to accept or tap the

2.29

Controls and Operation

BATTERY BOOSTING NOTICE This machine has a 12 V starting system.

Use the same voltage when boosting with an auxiliary battery. Boosting from a higher or lower voltage source will seriously damage the engine's electrical system.

Tigercat 6050 Carbonator BATTERY BOOSTER CABLE WITH CLAMPS 1. Situate the machines as close as possible to the boosting source without touching.

2. Confirm the boosting source uses a 12 V battery/ electrical system.

3. Turn OFF the ignitions of both machines.

4. Remove the battery cover.

A

6000275

Battery Compartment – Front of Machine

A Batteries

The batteries are located in the battery compartment at the front of the machine. Remove the rubber battery cover for complete access to the batteries.

The two batteries are connected in parallel.

6000276

A

B

Battery Terminals

A Positive (Red) Battery Terminal B Negative (Black) Battery Terminal

5. Locate the red positive (+) and black negative ( – ) battery terminals.

6. Connect the clamp of the red booster cable to either positive (+) terminal of the dead batteries.

7. Connect the other clamp of the red booster cable to the positive (+) terminal of the good battery.

8. Connect the clamp of the black booster cable to the negative ( – ) terminal of the good battery.

9. Connect the other clamp of the black booster cable to either negative ( – ) terminal of the dead batteries.

10. Turn ON the engine with the good battery.

11. Turn ON the engine with the dead batteries.

12. Disconnect the clamp of the black booster cable from the negative ( – ) terminal of the dead battery.

13. Disconnect the clamp of the black booster cable from the negative ( – ) terminal of the good battery.

14. Disconnect the clamp of the red booster cable from the positive (+) terminal of the good battery.

15. Disconnect the clamp of the red booster cable from the positive (+) terminal of the dead battery.

2.30

Tigercat 6050 Carbonator

Controls and Operation

REFUELLING

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

WARNING

Do not refuel while smoking or while near an open flame or sparks.

Refuelling of the machine is a critical component of proper operation. It is important to follow the proper procedures based on the refuelling options available for your machine. It is also important to verify the proper type and grade of fuel is used in your machine. Refer to REFUELLING PROCEDURE in SECTION 3 for complete details.

IMPORTANT! Do not idle the engine longer than one hour. Damage to the emission control system will result. When this machine idles for an extended period, excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon, at full load, immediately after a long idle period, generates excess heat which causes damage to emission control system components.

2.31

Controls and Operation

Tigercat 6050 Carbonator

SITE PREPARATION

G

C

D

E

B

F

A 6000103

A B C D

Prevailing Wind Direction Debris Pile Fan Side of Machine Loader

E Char Conveyor or Auger (Optional) F Minimum Distance from Debris Pile – 6 m (20 ft) G Minimum Operating Downwind Clearance – 45 m (150 ft)

• Park the system on solid ground. Avoid soft soil which can settle under the weight of the equipment.

Refer to PARKING THE MACHINE in SECTION 1.

• Position the machine with the prevailing wind direction working in unison with the flow direction of the over air atop the carbonizing chamber.

• Determine the predominant prevailing wind direction when positioning the machine. Hot embers will escape during operation. Areas downwind of the machine must be continually monitored.

• Consider biochar storage methods and required space. Provide collection containers under the char conveyor that provide ease of handling and transportation of char.

• Provide sufficient space on the fan side of the machine for the loader and at the discharge end of the machine for the optional char auger or conveyor and optional char collection containers.

• Position the machine in correct proximity to the char auger or conveyor no closer than 6 m (20 ft) from the debris pile with the fan side of the machine facing the pile.

2.32

Tigercat 6050 Carbonator

Controls and Operation

CHAR AUGER/CONVEYOR CONNECTIONS

A

B

C

6000278

Right Rear of Machine

A Return to Tank B Pressure Line C Case Drain Return

The hydraulic quick connections for the char auger or char conveyor are located at the right rear of the machine.

The connections are colour-coded to match the corresponding connections on the auger or conveyor.

IMPORTANT! Turn OFF the machine and char auger/conveyor before connecting or disconnecting the lines.

2.33

Controls and Operation

Tigercat 6050 Carbonator

OPERATION TIPS B

E

A

C D

6000102

A Over Air Flow and Prevailing Wind Direction B Camera Arm– Raised Position (Non-Fan Side of Machine) C Fan Side of Machine

CAUTION Be aware of camera arm position at all times when loading the carbonizing chamber. Contact between the loader boom and the camera arm will cause serious damage to both machines and risk injury to personnel on the ground.

D Loader E Char Conveyor or Auger (Optional)

• Do not keep loader grapple suspended over the carbonizing chamber for an extended period of time.

• Load smaller amounts of material more frequently.

Do not overload the carbonizing chamber.

• Meter dense materials more slowly. To achieve maximum efficiency the carbonizing chamber must maintain high and constant temperature.

• Maintain a clean work site. To minimize the risk of fire, remove all loose flammable and combustible material around the machine.

• Use the most combustible material for start-up. Preselect materials based on size and moisture content, minimizing the use of green material.

• Allow the initial charge of material to fully engulf for 10 – 15 minutes before adding additional materials.

• Load the carbonizing chamber of the machine from the fan side only.

• When loading the carbonizing chamber, swing the loader boom towards the discharge end of the machine. Avoid swinging towards the camera end of the machine.

2.34

Tigercat 6050 Carbonator

Controls and Operation

OPERATING THE MACHINE

MACHINE STARTUP

NOTE: The following procedure applies to machines that have previously been in service. When starting a new machine for the first time, consult Tigercat Service for proper start-up and additional procedures.

LOADING AND LIGHTING

STARTING THE ENGINE 1. Before starting the machine do a visual inspection for any worn or damaged components.

Ignite the entire initial charge of material to achieve an even fire across the length of the primary carbonizing chamber. Start the fire from the bottom of the initial pile to make sure all debris ignites.

REQUIRED TOOLS FOR IGNITION OF MATERIAL IN THE CARBONIZING CHAMBER

2. Perform any needed daily checklist maintenance.

• Pressurized spraying device.

3. Clear personnel from the area before starting the engine.

• Propane “weed burner” torch.

• Diesel fuel.

4. Turn the battery disconnect key switch to the ON position.

• Striker.

5. Turn the ignition key switch to the run position.

START-UP PROCEDURE

6. Press the green system reset button until it illuminates.

1. Park the machine on level ground with the air fans turned OFF. Refer to PARKING THE MACHINE in SECTION 1.

7. Turn the ignition key switch to the start position to crank the engine.

8. When the engine starts, release the ignition key switch to the run position.

F

NOTE: If the engine does not start after three attempts, check the fuel supply system.

9. Maintain engine speed at LOW. Wait three to five minutes before operating with a load.

10. Increase the engine speed gradually to adequately lubricate the bearings and stabilize the oil pressure.

If the engine stalls while operating the machine, turn the ignition key switch to the off position and repeat steps 1 – 7.

A

B

C

D

E

CAUTION Do not attempt to start the engine by shorting across the starter terminals. Personal injury can occur.

6000088

A B C D E F

WARNING Do not use ether to start the engine! The engine is equipped with an electrical starting aid. Ether can cause an explosion and serious injury.

Control Panel

System Reset Button (Green Light) Ignition Key Switch Camera ON/OFF Switch Battery Disconnect Key Switch Wait to Disconnect Light Computer Display

2. Turn ON battery disconnect key switch.

3. Start the engine. Refer to STARTING THE ENGINE in THIS SECTION.

NOTICE

4. Maintain engine speed at LOW until engine reaches operating temperature.

Allow a cold engine to warm up at LOW speed for at least 5 minutes before applying any load.

Monitor all measured values on the computer display during warmup.

2.35

Controls and Operation

Tigercat 6050 Carbonator

5. Press the green system reset button.

NOTE: If the system reset button remains illuminated, check for an emergency stop button that is still pressed or refer to the computer display for active alarms. Once the engine is running check if the green system reset button is illuminated. If it is illuminated, press it to clear.

NOTE: No screen or remote functions will operate until the green system reset button is cleared.

6. Raise the camera arm. Refer to CAMERA in THIS SECTION. 7. Move the char bin underneath the conveyor to collect the end product. Connect hydraulic lines to char conveyor. Refer to CHAR CONVEYOR CONNECTIONS in THIS SECTION. C

A

B

6000095

A Rear Door B Rear Door Latch C Ratchet Handle

13. Open the rear door. Use the ratchet handle to rotate the door latch away from the door.

14. Inspect the grate. Remove the grate to remove non-combustibles from the inside of the carbonizing chamber.

CAUTION

6000007

Char and Functions Screen

8. On the Char and Functions screen, press Char Conveyor Run to turn ON the conveyor. Confirm the conveyor is rotating before proceeding.

9. Turn ON the water supply to the augers (valve in full ON position). Refer to WATER HOOKUP in THIS SECTION. 10. Turn ON the augers. Run the augers and char conveyor (if equipped) until the augers are no longer carrying dirt, nails, material etc. onto the conveyor.

Ensure that water is free flowing through augers and down the auger troughs to avoid blockages.

Do not enter the carbonizing chamber to remove material or clean the grate. Remove the grate from the chamber to clean it.

If it is necessary to enter the carbonizing chamber remove, clean and replace the grate before entering. Do not enter the carbonizing chamber without the clean grate in place.

Wear a dust mask or similar PPE while in the carbonizing chamber. Fine particles may be present and are a respiratory irritant.

11. Turn OFF the engine. Follow lock out/tag out procedures.

12. Turn OFF the water supply.

2.36

Tigercat 6050 Carbonator

Controls and Operation 18. Turn ON the augers FWD function. Check that water flow is still at a steady state.

19. Turn ON the char conveyor or char auger.

20. Load the most combustible material available, (smaller, dryer, cleaner wood) into the carbonizing chamber so that it is approximately half full (1 to 1.5 m (3 to 5 ft) deep) and evenly spread throughout.

IMPORTANT! Keep ignition port doors closed during this step.

21. Check that all three augers are still rotating.

A

C

B

6000089

A

6000093

Ignition Port Doors– Fan Side

A Ignition Port Doors

6000094

C

B

A

A Rear Door B Rear Door Latch C Ratchet Handle

6000090

15. Close the rear door after the machine is cleaned.

Use the ratchet handle to tighten the door latch until the rear door is fully seated. Position the ratchet handle in the vertical position.

16. Turn ON the water supply to the augers (valve in full ON position). Refer to WATER HOOKUP in THIS SECTION. Check that water is free flowing through augers and down the auger troughs.

17. Start the engine. Set engine speed at 1050 rpm.

2.37

6000091

Open Ignition Port Doors

22. Open all three ignition port doors. Spray approximately 1 litre (1 quart) of diesel fuel onto the debris through all three ignition doors. Spray the diesel fuel using an approved hand pump pressurized sprayer.

Controls and Operation 23. Light the material through the ignition port closest to the engine compartment using a propane torch.

Insert the torch until the debris is ignited.

Tigercat 6050 Carbonator 32. Press the Fan Control HIGH button after loading the machine to the full level. This will maintain carbonizing temperatures.

24. Light the material through the centre ignition port door. Insert the torch until the debris is ignited.

NOTE: The wisps of black/white smoke will be gone and a clear heat vapour will be visible.

25. Light the material through the rear ignition port door.

Insert the torch until the debris is ignited.

DANGER Do not use highly volatile accelerants such as gasoline or kerosene to light the fire. These fluids ignite almost explosively and may cause injury or death.

6000090

DANGER Do not open the ignition port doors while material is carbonating in the carbonizing chamber. This may cause injury or death.

6000092

Close Ignition Port Doors

26. Close and lock the ignition port doors when the fire has a good visible flame. Ensure the latch is secured down in the locked position.

NOTE: The latch will not be all the way horizontal when the door is securely locked in place.

27. Turn ON the fans by pressing the Fan Control IDLE button.

NOTE: Pressing any button on the Fan Control display turns on both the under air fan and over air fan.

NOTE: Under air fan speed is non-adjustable.

28. Set engine speed at HIGH. 29. Press the Fan Control LOW button when the entire carbonizing chamber is engulfed and flames are visible out the top of the carbonizing chamber.

30. Press the Fan Control MEDIUM button when the smoke clears and only heat vapours are rising from the top of the carbonizing chamber.

31. Load material at a constant rate. Slowly fill the entire carbonizing chamber evenly until full. Keep material approximately 0.5 m (1.5 ft) below the top of the carbonizing chamber.

NOTE: As carbonizing temperatures increase, the material feed rate can be increased.

2.38

Tigercat 6050 Carbonator

Controls and Operation

STOPPING THE MACHINE The shutdown process may take 1 – 2 hours to complete.

CAUTION Do not use your hand to check auger water temperature. Use a hand-held thermometer.

1. Allow the material in the carbonizing chamber to carbonize down until the chamber is mostly empty.

Do not feed further material into the machine once this process has been started.

2. Press the Fan Control IDLE button on the computer display. Maintain engine speed at HIGH.

NOTICE

3. Run the augers for an additional 20 minutes to remove any final char as the material carbonates down in the chamber and the machine cools down.

Do not turn off the battery disconnect key switch until the amber 'wait to disconnect' light beside the switch goes out. Failure to do this will result in premature engine DEF system failure.

4. Set engine speed at LOW. Keep augers, fans, water and char auger/conveyor running.

F

A

B

C

D

E

6000088

A B C D E F

Control Panel

System Reset Button (Green Light) Ignition Key Switch Camera ON/OFF Switch Battery Disconnect Key Switch Wait to Disconnect Light Computer Display

5. When the water coming out of the augers has cooled down to 40°C (100°F): a. Press Fan Control OFF button. b. Turn OFF the water supply to the augers. c.

Turn OFF the augers.

d. Turn OFF the char auger or conveyor. e. Turn OFF the engine with the ignition key switch. f.

Wait for the 'wait to disconnect' light to go out.

g. Turn OFF the battery disconnect key switch.

2.39

Controls and Operation

Tigercat 6050 Carbonator

INTERMEDIATE SUPPRESSION The intermediate suppression procedure is to be used when fire calming/flame control during operation is required.

WARNING The following procedure will not extinguish the fire in the carbonizing chamber. If the sequence is not followed, the wood chips will combust and the fire will gain strength.

Follow all CARBONIZING PROCESS SAFETY PRECAUTIONS in SECTION 1 when performing this procedure.

1. Turn OFF the over air and under air fans.

CAUTION With the over air and under air fans turned OFF, smoke and water vapour release will be created.

Follow all CARBONIZING PROCESS SAFETY PRECAUTIONS in SECTION 1.

3. To prolong the suppression, spray water down the centre of the machine on top of the wood chips.

NOTE: The suppressed fire will continue to smolder below the layer of wood chips.

CAUTION Avoid water contact with the refractory panels in the carbonizing chamber or damage to the panels will occur.

Do not climb on the machine to spray the wood chips with water. Use proper elevation devices.

4. To re-start the fire, turn ON the under air fan and resume loading the carbonizing chamber. The machine will return to normal operating mode after the wood chips have been carbonized. Refer to OPERATING THE MACHINE – MACHINE STARTUP in THIS SECTION.

B

A

6000125

Carbonizing Chamber Loading

A Typical Loading of Carbonizing Chamber B Wood Chips Layer – 0.6 m (2 ft) Minimum Depth

2. Smother the fire with a layer of wood chips of a minimum depth of 0.6 m (2 ft) above the carbonizing layer of material. Approximately 12 – 24 cu. metres (15-30 cu. yards) of chips will be required.

Feed the chips into the carbonizing chamber at a rate faster than the machine can carbonize.

Utilize a large front end loader capable of reaching over the carbonizing chamber side walls, or a large grappler/bucket on an excavator. Dumping sufficient quantities of wood chips all at once into the carbonizing chamber is required.

NOTE: Use fresh cut wood chips and/or pre-soaked chips with 40% minimum moisture content.

2.40

Tigercat 6050 Carbonator

Controls and Operation

PERMANENT SUPPRESSION

RESTARTING THE FIRE 1. After the fire is out and the machine has sufficiently cooled, remove the grate for cleaning.

WARNING

2. Thoroughly clean around the refractory panels and in the auger troughs before reinstalling the grate and starting a new burn. Refer to OPERATING THE MACHINE – MACHINE STARTUP in THIS SECTION.

Follow all carbonizing process safety precautions in SECTION 1 when performing this procedure.

1. Turn OFF the augers, over air fan and under air fan.

2. Smother the fire with a minimum of 0.3 m (1 ft) of dirt to extinguish the fire. Approximately 5 – 10 cu. metres (7-15 cu. yards) of dirt will be required.

Feed the dirt into the machine at a rapid rate. Utilize a large front end loader capable of reaching over the carbonizing chamber side walls, or a large grappler/bucket on an excavator. Dumping sufficient quantities at once into the carbonizing chamber is required.

NOTE: The carbonizing wood under the dirt will continue to smolder for as long as some oxygen can reach the wood from the bottom of the chamber.

CAUTION With the over air and under air fans turned OFF, smoke and water vapour release will be created.

Follow all CARBONIZING PROCESS SAFETY PRECAUTIONS in SECTION 1.

3. To cool the fire down in a shorter period of time, spray water down the centre of the machine on top of the dirt.

CAUTION Avoid water contact with the refractory panels in the carbonizing chamber or damage to the panels will occur.

2.41

Controls and Operation

TRACK OPERATION AND WEAR PREVENTION PROTECTING STEEL TRACKS Steel tracks are designed to perform in tough underfoot conditions. Take these steps to maximize service life and reduce operating costs.

START EVERY SHIFT WITH A CLEAN UNDERCARRIAGE When mud and debris build up on the lower part of your machine, components wear at a faster rate. Do not begin work until the undercarriage area is clean.

INSPECT THE UNDERCARRIAGE BEFORE YOU START WORKING In addition to ensuring the undercarriage is clean, spend a couple of minutes on a visual inspection. Check for loose bolts, leaky seals and abnormal wear patterns.

When you spot potential problems early, you can often prevent them from turning into bigger issues that reduce component life significantly or cause expensive unscheduled downtime.

DON'T SPIN THE TRACKS

Tigercat 6050 Carbonator MAKE GRADUAL TURNS INSTEAD OF COUNTER-ROTATIONS Counter-rotating accelerates wear on the tracks and other undercarriage components. Don't use that technique unless job conditions demand it. Instead, turn the machine gradually while slowly moving forward or reverse. Gradual turns minimize cuts, tears and excessive wear in the undercarriage. They also reduce damage to soft or sensitive work surfaces.

WORK UP OR DOWN A SLOPE WHEN POSSIBLE Working across a slope can shorten undercarriage component life, so try to structure the job with minimal cross-slope activity.

WATCH TRANSITION AREAS Try to minimize travel over transition obstacles as this accelerates undercarriage wear. If you must go across a transition, position the machine 90° to the transition.

Without ground support, the undercarriage is subjected to side stresses that can result in rapid, excessive wear.

EXTENDED MACHINE TRAVEL

Track spinning, reduces production, it increases fuel consumption, without a corresponding increase in productivity. And it accelerates undercarriage wear, so your costs escalate. Grouser bars are especially prone to wear problems associated with track slippage.

Avoid machine travel over distances of 1 km (0.60 miles) or greater. Extended travel, especially in warm weather, risks overheating the track rollers and burning the oil inside the roller assemblies. The rollers on new machines are especially vulnerable to overheating. (The break-in period for rollers is approximately 200 hours.)

AVOID UNNECESSARY REVERSE OPERATION

If it is absolutely necessary to drive the machine over an extended distance, observe the following essential precautions:

Operating in reverse-even at slow speeds-compounds bushing and sprocket wear as the track tension loads are applied to the top side of the chain. So avoid an unproductive reverse operation.

ALTERNATE TURNING DIRECTIONS If you're turning in the same direction, the undercarriage components on one side of the machine will wear at a different rate than those on the other side. To ensure even wear, pay attention to the way you're turning-and change directions when possible.

1. Stop the machine frequently.

2. At each stop, use a suitable hand-held temperature sensor to measure the surface temperatures of the rollers.

3. If any roller surface temperature reaches or exceeds 80°C (175°F), pause for at least 30 minutes to permit cooling.

Completing just one extended travel without suitable precautions can ruin the oil inside the roller assemblies and cause roller failure. Replace rollers immediately in the event of failure. Operating the machine with failed rollers places excessive strain on other drive train components.

2.42

Tigercat 6050 Carbonator

Controls and Operation

OTHER FACTORS Application refers to the type of work you do. Shovel logging, loading, grading, digging and trenching are a few examples. This factor is largely beyond your control, but generally speaking, the more you work in high horsepower, high-torque applications, the faster your undercarriage will wear.

Material type is another key contributor to undercarriage wear that is outside your control, the more abrasive the material, the more rapid the wear rate.

Terrain, a third uncontrollable factor, describes the contours and slopes at your job site. The more time you spend in rugged, sloped areas, the faster your undercarriage will wear out.

Configuration refers to the way your machine is equipped and is therefore something you can control. To minimize undercarriage wear on steel-track machines, use the narrowest track shoe possible that meets your flotation requirements. If you work in very sticky materials, consider using centre-punched track shoes to reduce material packing in the undercarriage area.

Maintenance discipline plays a big role in undercarriage component life. One of the most critical maintenance practices is track adjustment. Tight track is the numberone track killer. But whether your track is too loose or too tight, improper adjustment accelerates wear which can increase downtime and repair costs. Follow the manufacturer's recommendations for track adjustment, and perform the adjustment in the machine's working environment. A second important maintenance process is cleaning the undercarriage. To maximize wear life, remove mud and debris at the end of every shift, or more frequently if necessary.

Talk to the experts: Undercarriage components are expensive! To get long life and maximum value from your investment, consult with a dealer or factory rep that really knows the undercarriage business. Ask for advice on operating techniques. Explore relevant application, material and terrain issues. Fine-tune your maintenance processes.

Working together with an undercarriage expert, you can manage your equipment investment over the long term.

2.43

Controls and Operation

Tigercat 6050 Carbonator

2.44

LUBRICATION AND MAINTENANCE.................................................................................................................3

Tigercat 6050 Carbonator SECTION 3– LUBRICATION AND MAINTENANCE Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 3

ISSUE 2.0, OCTOBER 2020

A

AFTERTREATMENT SYSTEM (TIER 4F MACHINES ONLY)............................................................................... 3.47 AIR INTAKE SYSTEM............................................................................................................................................... 3.44 AIR CLEANER........................................................................................................................................................ 3.45 AIR CLEANER UNLOADER VALVE..................................................................................................................... 3.46 AIR FILTER RESTRICTION INDICATOR............................................................................................................. 3.44 AIR FILTER RESTRICTION SENSOR................................................................................................................. 3.44 CHANGING FILTER ELEMENTS.......................................................................................................................... 3.45 ENGINE AIR PRECLEANER................................................................................................................................. 3.44 IMPROPER SERVICING....................................................................................................................................... 3.45 OVER SERVICING................................................................................................................................................. 3.45 APPROVED HYDRAULIC OILS............................................................................................................................... 3.13 AUGER BEARING LUBRICATION........................................................................................................................... 3.23 AUGER CHAINS........................................................................................................................................................ 3.21 ACCESSING........................................................................................................................................................... 3.21 CHAIN TENSION.................................................................................................................................................... 3.22

B

BATTERY CARE........................................................................................................................................................ 3.38 BELTS, ENGINE........................................................................................................................................................ 3.35

C

CARE OF THE MACHINE......................................................................................................................................... 3.48 CLEANING COOLER PACKAGE............................................................................................................................. 3.50 COMMERCIAL WOOD, WEIGHTS.......................................................................................................................... 3.62

F

FILTERS ENGINE OIL............................................................................................................................................................ 3.39 FUEL........................................................................................................................................................................ 3.39 HYDRAULIC OIL RETURN.................................................................................................................................... 3.31 MAIN PUMP LOW PRESSURE............................................................................................................................. 3.32 OVER AIR FAN PUMP CHARGE PRESSURE.................................................................................................... 3.33 PRIMARY FUEL FILTER/WATER SEPARATOR.................................................................................................. 3.40 SECONDARY FUEL FILTER................................................................................................................................. 3.41 FIRE PREVENTION.................................................................................................................................................... 3.7 FLUID ANALYSIS PROGRAM.................................................................................................................................... 3.4 FLUID ANALYSIS KITS............................................................................................................................................ 3.4 FLUID SAMPLING PROGRAM.................................................................................................................................. 3.5 FLUID SAMPLE COLLECTION PROCEDURES................................................................................................... 3.5 FUEL, REFUELLING PROCEDURE........................................................................................................................ 3.43 FUEL TANK................................................................................................................................................................ 3.42 CAPACITY............................................................................................................................................................... 3.42 FUEL FILL CAP...................................................................................................................................................... 3.42 FUEL LEVEL SENDER.......................................................................................................................................... 3.42 FUSES AND RELAYS............................................................................................................................................... 3.36

H

HYDRAULIC OIL OPERATING RANGE CHART.................................................................................................... 3.13 HYDRAULIC SYSTEM.............................................................................................................................................. 3.27 CASE DRAIN STRAINER...................................................................................................................................... 3.34 FILTER RESTRICTION PRESSURE SWITCH.................................................................................................... 3.31

Lubrication and Maintenance

Tigercat 6050 Carbonator

HYDRAULIC OIL TANK.......................................................................................................................................... 3.28 ADDING OIL........................................................................................................................................................ 3.29 CLEAN OUT COVER.......................................................................................................................................... 3.29 DRAINING........................................................................................................................................................... 3.29 OIL LOW LEVEL SENDING UNIT...................................................................................................................... 3.28 OIL TEMPERATURE SENDING UNIT............................................................................................................... 3.28 REFILLING.............................................................................................................................................................. 3.30 N

NEW MACHINE MAINTENANCE FIRST 125 HOUR INSPECTION REPORT............................................................................................................ 3.3 INITIAL PRE-DELIVERY INSPECTION................................................................................................................. 3.3 TIGHTENING POINTS............................................................................................................................................. 3.3

P

PRESSURE AND SPEED SETTINGS..................................................................................................................... 3.55 PRESSURE WASHING............................................................................................................................................. 3.49 PREVENTIVE MAINTENANCE SCHEDULE............................................................................................................ 3.3 PUMP DRIVE GEARBOX......................................................................................................................................... 3.20 CHECKING OIL LEVEL......................................................................................................................................... 3.20 DRAINING AND REFILLING................................................................................................................................. 3.20

R

REFILLING THE HYDRAULIC SYSTEM................................................................................................................. 3.30 REFRACTORY PANEL REPAIR............................................................................................................................... 3.26 REFUELLING PROCEDURE................................................................................................................................... 3.43

S

SCHEDULED MAINTENANCE GENERAL................................................................................................................................................................. 3.6 FREQUENTLY.......................................................................................................................................................... 3.8 8 HOURS................................................................................................................................................................... 3.9 125 HOURS............................................................................................................................................................. 3.10 250 HOURS............................................................................................................................................................. 3.10 500 HOURS............................................................................................................................................................. 3.11 1000 HOURS........................................................................................................................................................... 3.11 2000 HOURS........................................................................................................................................................... 3.12 SEASONAL............................................................................................................................................................. 3.12 SERVICE AND LUBRICATION POINTS.................................................................................................................. 3.14 STRAINERS CASE DRAIN.......................................................................................................................................................... 3.34

T

TORQUE CHART, FLUID CONNECTIONS................................................................................................... 3.58 – 3.60 TORQUE CHART, GENERAL................................................................................................................................... 3.57 TORQUE CHART, SPECIFIC................................................................................................................................... 3.56 TRACK DRIVE GEARBOX....................................................................................................................................... 3.18 FILLING................................................................................................................................................................... 3.18 OIL DRAINING AND REPLACEMENT................................................................................................................. 3.19 TRACKS MEASURING TRACK SAG.................................................................................................................................... 3.52 TRACK DRIVE NOTES – IMPORTANT................................................................................................................. 3.52 TRACK SAG ADJUSTMENT................................................................................................................................. 3.53 TRACK SHOE RETAINING BOLTS...................................................................................................................... 3.54 UNDERCARRIAGE BOLTS – TORQUING............................................................................................................ 3.54

U

UNDER AIR CLEAN OUT PORTS........................................................................................................................... 3.24

3.2

Tigercat 6050 Carbonator

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE

WARNING

NEW MACHINE MAINTENANCE INITIAL PRE-DELIVERY INSPECTION Perform the initial pre-delivery inspection using Tigercat form numbers TBA and TBA: PDI and 125 hour inspection report.

FIRST 125 HOUR INSPECTION AND SERVICE REPORT With the owner's mechanic present, perform an inspection and service according to the Tigercat form numbers TBA and TBA: PDI and 125 hour inspection report.

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 verify it is safe to begin service work.

This must be completed within the first 125 hour time frame.

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

IMPORTANT! To qualify for continued warranty, this report must be completed and returned to the Tigercat Industries Inc. Warranty department.

CAUTION

TIGHTENING POINTS: All hydraulic connections

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.

Hose clamps All cylinder pin retainers Engine mounting bolts

SET TRACK SAG

Pump mounting bolts

IMPORTANT! Before moving the machine, make sure the track tension (sag) is set correctly. Track sag may be set less than specified for shipping purposes.

Track shoe bolts Track roller retaining bolts Track sprocket retaining bolts Track drive gearbox mounting bolts

Refer to TRACKS – TRACK SAG ADJUSTMENT in THIS SECTION and SECTION 11 of the SERVICE MANUAL.

Track drive motor mounting bolts Any other loose nut, bolt or fitting All hydraulic connections NOTE: Use of filters other than genuine Tigercat replacement filters is not recommended.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

3.3

Lubrication and Maintenance

Tigercat 6050 Carbonator

TIGERCAT FLUID ANALYSIS PROGRAM

TIGERCAT FLUID ANALYSIS KITS

Using the Tigercat Advanced Fluid Analysis Program on a regular basis is an excellent preventative maintenance tool.

Each kit includes a Prepaid Sample Bottle and Sample Information Form. Preprinted mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

Studies have shown that it is possible to receive a 10 to 1 payback when looking at the amount saved on repair costs in relation to the amount invested in a scheduled fluid analysis program. Some of the benefits of a sampling program include: • Detecting problems early and before they become major catastrophic failures.

• Better ability to schedule downtime and forecast cost of repairs.

• Monitoring maintenance schedules and practices and confirming the required maintenance is being done on time.

The same type of sample bottle can be used for all types of fluid 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 to properly collect, prepare and ship the fluid samples.

Contact your Tigercat Dealer Parts Department to order kits.

• Increase used equipment value by providing proof of proper maintenance.

This Program uses the most modern technology available to analyze all fluid samples. Most test results are available within 24 hours after receipt of the sample and are supplied in an easy to understand report, which calls for specific action and makes detailed recommendations. The report is available as a mailed or faxed hardcopy, sent via e-mail or it can be viewed on the Internet.

This program will provide Tigercat machine owners access to an Advanced Fluid Analysis Program for all major machine components including Engines, Hydraulic Circuits, Axles, Final Drives, Gearboxes, etc.

Tigercat Fluid Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required follow-up fluid samples.

Refer to FLUID SAMPLING PROGRAM in THIS SECTION for sample valve and drain plug locations.

6000 Series Location

First Sample

Follow-up Samples

Hydraulic Oil

125 hours

Every 1000 hours or 6 months

Track Drive Gearboxes

125 hours

Every 1000 hours or 6 months

Pump Drive Gearbox

125 hours

Every 1000 hours or 6 months

3.4

Tigercat 6050 Carbonator

Lubrication and Maintenance

TIGERCAT FLUID SAMPLING PROGRAM

HYDRAULIC OIL SAMPLES

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

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

Collection of clean fluid samples that are representative of the main body of fluid are essential if meaningful lab results are to be obtained. Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all followup samples should be consistently taken from the same location using the same techniques as all previous samples.

• All sample valves and drain plugs must be clean and free of debris.

• Remove the dust cover from the sample valve and attach the bleed hose (supplied with the machine) to the sample valve connection.

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

• 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.

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

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

3.5

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

• Purge the bleed hose before taking a representative oil sample. Drain a minimum of 90 – 120 ml (3 – 4 oz) of oil into a separate container and discard this oil using approved recycling methods.

• Remove the bleed hose and replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

GEARBOX SAMPLES: • These samples can be taken during the oil change process.

• To obtain a representative oil sample, the oil must be warm and must not have settled (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.

Lubrication and Maintenance

Tigercat 6050 Carbonator

GENERAL

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

CAUTION

• Clean away all branches, bark and chips. Clean up all traces of oil to avoid fires.

All handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow, ice and forest debris.

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

• Clean around fill caps before checking or adding fluids.

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

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

• Clean up spills as soon as possible.

• Use clean oil and containers.

• Drain dirty oil while still warm.

• Do not exceed recommended fluid levels.

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

• Keep a fire extinguisher on hand at all times.

• Install door safety struts when working on the machine.

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

• Check and clean fire suppression system sensors on a regular basis (if equipped).

• Clean up oil spills in engine enclosure immediately.

• Before welding on machine, disconnect all electrical connections and follow all servicing safety precautions as outlined in the WELDING, PRIOR TO in SECTION 1.

* Oil Lost From Leakage Lost Oil (Litres) Leakage Rate

Lost Oil (US Gallons)

Per Day

Per Month

Per Year

Per Day

Per Month

Per Year

One drop In TEN Seconds

0.424

12.72

152

0.112

3.36

40

One drop In FIVE Seconds

0.852

25.6

306.6

0.225

6.75

81

One drop per second

4.26

127.76

1533.1

1.125

33.75

405

Three Drops per Second

14.2

425.86

5110.31

3.75

112.5

1350

Drops Break Into Stream

90.83

2725.5

32706

24.0

720

8640

3.6

Tigercat 6050 Carbonator

Lubrication and Maintenance

FIRE PREVENTION

FIRE EXTINGUISHER

Proper maintenance of your machine will greatly extend its life and reduce your operating costs.

A

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

CAUTION After transporting (trucking) a machine from one job sight to the next, open all doors and access panels and blow off any debris that may have repositioned itself onto the engine and exhaust parts due to wind turbulence during the journey.

1. When allowed to accumulate, forest debris and fine organic material (twigs, pine needles, branches, bark, leaves, sawdust, small wood chips, etc.) and any other combustible materials form a fuel source that is extremely difficult to extinguish when ignited. A thorough program of regular cleaning and washing will reduce the possibility of a fire starting.

In the event a fire does start, the regular cleaning program will improve the chances of successfully extinguishing a fire.

2. Pay close attention to wiring and plumbing routes during maintenance. ALL wiring harnesses and hydraulic hoses must be properly restrained and clamped to prevent damage from chaffing.

6000265

A Portable Fire Extinguisher

A portable fire extinguisher is located at the left front of the machine.

Check the extinguisher daily to ensure it is charged. The pointer on the charge gauge should point to the green region. If the indicator falls out of this green area, service the extinguisher immediately.

Maintain a charged fire extinguisher close to the machine at all times and know how to use it.

Refer to the manufacturer's use and information manual for proper usage, additional information and recommended inspection and maintenance intervals.

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

4. In case of fire, turn OFF the engine before discharging the fire suppression system.

Refer to FIRE PREVENTION in SECTION 1 for additional information.

3.7

Lubrication and Maintenance

Tigercat 6050 Carbonator

SCHEDULED MAINTENANCE

WARNING

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

FREQUENTLY • Check for water in primary fuel filter/water separator.

• Visual engine check.

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

• Check the engine cooling air intake screens for possible restriction.

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

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

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

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

3.8

Tigercat 6050 Carbonator

Lubrication and Maintenance

EVERY 8 HOURS

EVERY 24 HOURS

PERFORM

PERFORM

• FREQUENTLY Maintenance.

• FREQUENTLY Maintenance.

• Drain primary fuel filter/water separator.

• 8 HOURS Maintenance.

• Conduct an overall visual inspection.

CHECK

CHECK

• Under air clean-out ports. Refer to UNDER AIR CLEAN OUT PORTS in THIS SECTION.

• Engine coolant level.

• Over air discharge nozzles.

• Engine oil level at dipstick.

• Over air fines build-up on fan rotor.

• Air intake precleaner.

• Under air fines build-up on rotor.

• Air intake filter restriction indicator.

Clean if required.

• Replace primary filter if indicator is in red zone.

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

• 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.

• Hydraulic oil tank level.

• Pump drive gearbox oil level at dipstick.

• For leakage around hydraulic components and flexible hoses.

• For loose nuts, bolts and fittings.

• Condition and tension of belts.

• Condition of tracks.

• Exhaust system for leaks.

• Fire extinguisher for sufficient charge.

CLEAN • Hydraulic oil cooler, engine radiator and charge air cooler.

• Remove potentially damaging limbs or sticks and all debris.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

3.9

Lubrication and Maintenance

Tigercat 6050 Carbonator

EVERY 125 HOURS

EVERY 250 HOURS

PERFORM

PERFORM

• FREQUENTLY Maintenance.

• FREQUENTLY Maintenance.

• 8 HOURS Maintenance.

• 8 HOURS Maintenance.

• 24 HOURS Maintenance.

• 24 HOURS Maintenance.

LUBRICATE • Auger bearings: 3 fittings – 4 shots.

• Auger chains: Grease as required.

CHECK • Hydraulic oil return filter restriction pressure gauge on hydraulic oil tank with engine speed at HIGH with oil flow. Refer to HYDRAULIC SYSTEM– FILTER RESTRICTION PRESSURE GAUGE in THIS SECTION. • Oil level in track drive gearbox. Check with level plug at nine o'clock position and drain plug at six o'clock position. Fill with SAE 75W-90 gear oil.

• Fluid level in batteries unless maintenance free.

• All hydraulic pressures.

• Hydraulic pump and motor securing bolts.

• Torque tightening points as per new machine maintenance.

• All carbonizing chamber gaskets and seals for wear.

• Auger drives, sprockets, chains.

• 125 HOURS Maintenance.

CHECK • Fire extinguisher and turn it to mix contents.

• Condition of engine serpentine belt.

DRAIN AND REFILL • Oil in track drive gearboxes with level plug at nine o'clock position and drain plug at six o'clock position.

Fill with SAE 75W-90 oil.

• Oil in pump drive gearbox.

REPLACE • Engine oil and filter. * • Engine fuel filter. * • Primary fuel filter/water separator filter. * • DEF dosing module filter (Tier 4f machines only). * Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

• Char augers.

• Auger trough wear strips.

• Bar grate.

• Under air plates.

• Auger locking bolts.

• Auger bearings.

VISUALLY INSPECT FOR DAMAGE TO • Track components.

• Refractory panels.

Complete repairs immediately.

VISUALLY INSPECT FOR • Frayed electrical wiring and hydraulic hoses.

• Wear in any other components.

NOTE: Neglecting the proper maintenance of these items can result in fire.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

3.10

Tigercat 6050 Carbonator

Lubrication and Maintenance

EVERY 500 HOURS

EVERY 1000 HOURS

PERFORM

PERFORM

• FREQUENTLY maintenance.

• FREQUENTLY maintenance.

• 8 HOURS Maintenance.

• 8 HOURS Maintenance.

• 24 HOURS Maintenance.

• 24 HOURS Maintenance.

• 125 HOURS Maintenance.

• 125 HOURS Maintenance.

• 250 HOURS Maintenance.

• 250 HOURS Maintenance.

• 500 HOURS Maintenance.

LUBRICATE

REPLACE

• Door hinges: 2 fittings – 1 shot.

• Engine serpentine belt.

CHECK

• Air cleaner unloader valve.

• All hydraulic pressures.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

• DEF fill strainer for cleanliness. Remove and clean particles and debris as required.

• Track rollers for leakage. Rollers are filled with oil and are considered to be maintenance free. If oil leakage is detected the rollers must be replaced.

• Track idlers for leakage. The bearing is filled with oil and is considered to be maintenance free. If oil leakage is detected the idler must be replaced.

• Torque on track drive gearboxes and motor mounting bolts.

REPLACE • Hydraulic oil return filters. * • Main pump low pressure filter. * • Over air fan pump charge pressure filter. * • Engine crankcase ventilation filter. * (Tier 4f machines only.)

Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL for replacement instructions.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

3.11

Lubrication and Maintenance EVERY 2000 HOURS PERFORM • FREQUENTLY Maintenance.

• 8 HOURS Maintenance.

• 24 HOURS Maintenance.

• 125 HOURS Maintenance.

• 250 HOURS Maintenance.

• 500 HOURS Maintenance.

• 1000 HOURS maintenance.

CHECK • All hydraulic system components especially cooling fan for proper operation after hydraulic oil has been replaced.

• Air intake precleaner.

DRAIN AND REFILL • Hydraulic oil tank with recommended hydraulic oil.

Refer to APPROVED HYDRAULIC OILS in THIS SECTION. It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results.

Make sure the hydraulic oil type selected on the computer display matches the oil type being used.

Adjust oil type if needed. Refer to COMPUTER CONTROL SYSTEM – HYDRAULIC OIL GRADE SELECTION in SECTION 2 or SECTION 6 of the SERVICE MANUAL, for selecting hydraulic oil type setting procedure.

Tigercat 6050 Carbonator REPLACE • All air intake rubber components such as elbows and connectors – High temperatures in this area can cause the rubber to harden.

• NOTE: High-temperature silicone connectors do not need to be replaced unless they are damaged.

• NOTE: Refer to AIR INTAKE SYSTEM in THIS SECTION. • Hydraulic oil tank breather.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

EVERY 2 YEARS REPLACE • Engine coolant. Antifreeze must comply with international specifications ASTM D-6210.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

SEASONAL REPLACE • Drain and refill hydraulic oil tank with recommended hydraulic oil if required to meet operating temperature range.

Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

NOTE: When refilling the hydraulic system, vent pumps, motors and valves of air by opening a plug or hose fitting located near or on top of the pumps, motors and valves until oil free of air is seen flowing out of the plug or hose fitting. Failure to vent air from the hydraulic system could cause serious damage to hydraulic components. Tighten plugs or fittings and clean up any spilled oil when completed.

NOTE: Changing diffuser/strainers, filters and replacing the hydraulic oil tends to aerate the oil.

For maximum pump life, do not operate the machine for one hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

REPAIR • Patch refractory panels with Tigercat patching compound.

3.12

Tigercat 6050 Carbonator

Lubrication and Maintenance

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

3.13

Lubrication and Maintenance

Tigercat 6050 Carbonator

11

2FTG/125

8

10 9

16

6

21

17

14

19

5

15

3.14

2

13

18

3FTG/125

6000018

4

20

1

Tigercat 6050 Carbonator

Lubrication and Maintenance Tigercat Model 6050

SERVICE AND LUBRICATION POINTS

ENGINE OIL/FILTER

CHK

•

35

9.2

•

•

REP •

CRANKCASE VENTILATION FILTER

DESCRIPTION QTY

2000 

1000 

500 

250  REP

•

USG

2

CHANGE COOLANT EVERY 2 YEARS

CHK

LITRES

COOLING SYSTEM

125 

8

ITEM

1

3

CAPACITY

SERVICE EVERY

POINT NO.

SERVICE

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

REFER TO ENGINE OPERATION AND MAINTENANCE MANUAL FOR REQUIRED ANTIFREEZE SOLUTION AND MIXTURE.

1

REP

4

FUEL FILTER (ENGINE)

5

FUEL FILTER/WATER SEPARATOR

6

DEF FILTER

7

INTANK FUEL STRAINER

8

AIR INTAKE PRECLEANER

CHK

AIR INTAKE PRIMARY ELEMENT

CHK

1

AIR INTAKE SAFETY ELEMENT

CHK

1

10

AIR CLEANER UNLOADER VALVE

CHK

11

AIR INTAKE CONNECTIONS

CHK

REP

12

HYDRAULIC OIL TANK (LEVEL INDICATOR ON TANK)

CHK

D/R

13

HYDRAULIC OIL TANK BREATHER

DRN

•

1

REP

1

REP

1 CHK

1

9

REP

15

MAIN PUMP LOW PRESSURE FILTER

16

OVER AIR FAN PUMP CHARGE PRESSURE FILTER

17

TRACK DRIVE GEARBOXES

18

PUMP DRIVE GEARBOX

19

AUGER CHAINS

LUB

20

AUGER BEARINGS

LUB

21

REAR DOOR HINGES

LUB

REFER TO ENGINE OPERATION AND MAINTENANCE MANUAL.

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

CHECK FILTER RESTRICTION INDICATOR ON FILTER HEADS WITH ENGINE RUNNING AT HIGH IDLE AND WITH OIL FLOW.

1

†

REP

1

†

CHK

1

4

†

REP

CHK ††

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENANCE IN SECTION 3 OF THE MANUAL FOR DETAILS.

1

REP

CHK

CLEAN AS REQUIRED. INSPECT IMPELLER FOR WEAR OR DAMAGE. REPLACE AS NECESSARY.

DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE. SEE APPROVED HYDRAULIC OILS IN SECTION 3 OF THE MANUAL.

REP

HYDRAULIC OIL RETURN FILTERS (2 ELEMENTS)

REFER TO ENGINE OPERATION AND MAINTENANCE MANUAL FOR DETAILS.

1 CHK

14

• REFER TO ENGINE OPERATION AND MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS.

D/R

6

1.5

2

D/R

7.7

2.0

1

3.15

FILL WITH API GL-5, 75W-90. SYNTHETIC GEAR OIL IS RECOMMENDED FOR SEVERE DUTY APPLICATIONS. †† CHECK OIL WITH PLUGS AT 6 AND 9 O'CLOCK POSITIONS.

4

LITHIUM BASE EP2 GREASE 

4 SHOTS

3

LITHIUM BASE EP2 GREASE 

2 SHOTS

2

LITHIUM BASE EP2 GREASE 

Lubrication and Maintenance

Tigercat 6050 Carbonator

ENGINE/HYDRAULIC COMPARTMENT A

T

B

C

S

D

R

E

Q

F

G

P

O

H

N

I

M

6000099

A B C D E F G H I J

Hydraulic Oil Cooler Main Pump Low Pressure Filter Batteries Main Control Valve Fuel Tank DEF Pump/Filter DEF Tank Catalytic Converter (SCR) Engine Air Precleaner Air Cleaner

Machine Front View K L M N O P Q R S T

3.16

Over Air Fan Pump Charge Pressure Filter Primary Fuel Filter/Water Separator Engine Fuel Filter Crankcase Ventilation Filter Engine Oil Filter Radiator Fuel Cooler Charge Air Cooler Hydraulic Oil Tank Control Panel

J

L

K

Tigercat 6050 Carbonator A

B

Lubrication and Maintenance

C

D

E

F

G

H

I

J

S

R

Q

P

O

N

M

6000100

A B C D E F G H I J

Air Cleaner Engine Air Precleaner Catalytic Converter (SCR) DOC Radiator Charge Air Cooler Hydraulic Oil Tank Hydraulic Oil Cooler Control Panel Batteries

Machine Rear View K L M N O P Q R S

3.17

Fuel Tank Main Pump Low Pressure Filter Main Control Valve DEF Pump/Filter DEF Tank Hydraulic Oil Return Filters Pump Drive Gearbox Over Air Fan Pump Main Pump

L

K

Lubrication and Maintenance

Tigercat 6050 Carbonator

TRACK DRIVE GEARBOX Check the oil level in the track drive gearboxes every 125 hours.

FILLING THE GEARBOX B

800372

Track Drive Gearbox Fill Level

7. Fill from the upper port 'B' until gear oil flows out of port 'B'. Use 75W-90 gear oil.

A 800371

Track Drive Gearbox

A Track Drive Gearbox Plug 'A' (6 o'clock position) B Track Drive Gearbox Plug 'B' (9 o'clock position)

8. Install plug 'B'.

9. Operate the gearbox for a few minutes, stop and check the oil level.

Refer to SECTION 11 of the SERVICE MANUAL for further information.

To top up the track drive gearboxes: 1. Park the machine on level ground with the track drive gearbox drain plug 'A' at the six o'clock position and the fill plug 'B' at the 9 o'clock position.

2. Park the machine on level ground with the attachment resting squarely on the ground.

3. Apply the swing brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Remove plug 'B'.

3.18

Tigercat 6050 Carbonator

Lubrication and Maintenance

OIL DRAINING AND REPLACEMENT B

800372

A

Track Drive Gearbox Fill Level

800371

8. Fill from the upper port 'B' until gear oil flows out of port 'B'.

Track Drive Gearbox

A Track Drive Gearbox Plug 'A' (6 o'clock position) B Track Drive Gearbox Plug 'B' (9 o'clock position)

9. Install plug 'B'.

10. Operate the gearbox for a few minutes, stop and check the oil level.

Drain and replace the gear oil in the track drive gearboxes every 250 hours. Use 75W-90 gear oil.

To drain the track drive gearboxes: 1. Park the machine on level ground with the track drive gearbox drain plug 'A' at the six o'clock position and the fill plug 'B' at the 9 o'clock position.

2. Park the machine on level ground with the attachment resting squarely on the ground.

3. Apply the swing brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Remove plugs 'A' and 'B' and allow oil to drain into a suitable container.

NOTE: Dispose of waste oil according to local regulations.

7. Install plug 'A'.

3.19

Refer to SECTION 11 of the SERVICE MANUAL for further information.

Lubrication and Maintenance

Tigercat 6050 Carbonator

PUMP DRIVE GEARBOX The pump drive gearbox is located on the rear of the engine. It has one gear oil reservoir that requires draining and filling.

Check the pump drive gearbox oil level every 8 hours.

Drain and replace the pump drive gearbox gear oil every 250 hours.

CHECKING PUMP DRIVE GEARBOX OIL LEVEL 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

NOTE: The machine must be level when checking pump drive gearbox oil level.

A

3. Remove the dipstick and read the level. The fluid level should fall between the ADD and FULL marks on the dipstick. Wait at least 5 minutes after stopping the engine before taking the reading.

4. If gearbox oil level is low, remove the breather and carefully add oil checking the level regularly with the dipstick. Do not overfill.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for gearbox oil capacity and recommended gearbox oils.

5. Replace and tighten the fill plug.

6. Replace the dipstick.

DRAINING AND REFILLING PUMP DRIVE GEARBOX NOTE: Drain the pump drive gearbox when the oil is cold. This will allow particulate that has settled to the bottom of the pump drive gearbox to be removed when the gear oil is drained.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

NOTE: The machine must be level when draining and refilling the pump drive gearbox.

2. Clean around the dipstick and breather.

3. Remove the breather.

NOTE: Do not remove the drain plug until the breather has been removed.

4. Remove the drain plug.

5. Drain the gear oil into a suitable container.

NOTE: Dispose of the waste gear oil according to local regulations.

6000101

A B C D E

B

Breather/Oil Fill Dipstick Drain Plug Main Pump Fan Pump

D

C

Pump Drive Gearbox

2. Clean around the dipstick.

E

6. Remove the magnetic plug on the bottom of the gearbox and clean off any filings that have collected.

7. Install the gearbox drain plug and magnetic plug.

8. Fill the gearbox with the correct quantity of gear oil.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for gearbox oil capacity and recommended gear oils.

9. Install and tighten the breather.

3.20

Tigercat 6050 Carbonator

Lubrication and Maintenance

AUGER CHAINS Apply grease liberally to the auger chains every 125 hours through the access holes on the under air elbow.

ACCESSING THE AUGER CHAINS D

A 6000020

C

6000021

A

B

A Auger Chains – Quantity 4

D

A

6000022

A B C D

A

Machine Frame Hidden for Clarity

Under Air Duct Elbow Fasteners – To Frame Fasteners – To Vertical Duct Duct Bracket Holes

6000019

A Under Air Elbow – Closed

6. Close the elbow and replace all fasteners.

To access the auger chains: 1. Park the machine on level ground.

2. Remove the eleven fasteners holding the under air duct elbow to the frame.

3. Remove the ten fasteners holding the under air duct elbow to the vertical under air duct.

4. Rotate the under air duct elbow towards the front of the machine.

5. Insert two bolts into the duct bracket holes to hold the elbow up.

3.21

Lubrication and Maintenance

Tigercat 6050 Carbonator

AUGER CHAIN TENSION NOTE: Check chain tension monthly. Chains will stretch from regular use.

B

B

E

E

D

C

A

C

A

C

6000024

A Lower Chain B Side Chain C Sprocket

Machine Frame Front Plate Hidden for Clarity

D Motor Mounting Plate E Bolt – Motor Mounting Plate (4 Per Plate)

Tension the lower auger chains so the sprockets are free-moving and not binding.

To tension lower chains: 1. Set chains with approx. 25 mm (1 in) of deflection sprocket to sprocket.

2. If chain deflection exceeds this value, or are skipping on the sprockets, shorten the chain by removing links.

To tension the side chains: 1. Loosen the four outer bolts holding the chain drive motor mounting plate to the frame and push the mounting plate upward.

2. Tighten the bolts when the desired tension is achieved.

3.22

D

Tigercat 6050 Carbonator

Lubrication and Maintenance

AUGER BEARING LUBRICATION Apply four shots of grease to each bearing every 125 hours.

A

6000023

Auger Bearing Grease Fittings

A Grease Fittings – 3 Locations

The auger bearing grease fittings are located on the underside of the frame at the front of the machine.

3.23

Lubrication and Maintenance

Tigercat 6050 Carbonator

UNDER AIR CLEAN OUT PORTS Check all six under air clean out ports every 24 hours and clean out debris as necessary.

A 6000273

B 6000270

Underside of Carbonizing Chamber

A Under Air Clean Out Ports – Closed B Under Air Clean Out Ports – Open for Cleaning

3.24

Tigercat 6050 Carbonator

Lubrication and Maintenance

OPENING UNDER AIR CLEAN OUT PORTS

1. Remove the retaining bolt, hex nut and washers.

2. Carefully lower the port and rest it on the ground.

3. Remove all debris from inside the port.

4. Return the port to the closed position and reinstall the retaining bolt, nut and washers.

WARNING Support the port when removing the retaining bolt. The ports are heavy and will drop quickly once the bolt is removed.

A

Wear a dust mask or similar PPE while cleaning out the ports. Fine particles may be present and are a respiratory irritant.

B

6000271

6000272

A Under Air Clean Out Port B Retaining Bolt

3.25

Lubrication and Maintenance

Tigercat 6050 Carbonator

REFRACTORY PANEL REPAIR Inspect the condition of the refractory panels in the carbonizing chamber every 125 hours.

If refractory material is missing, fill the imperfections to extend the life of the panels.

Cracks will form during the life of the panel and do not require repair until material is missing.

NOTE: When making repairs to the refractory panels use only Tigercat patching compound which is available from Tigercat Parts Department.

NOTE: For best results repairing large areas of damage, remove the affected panel and place in a horizontal position.

To repair the panels: 1. Remove all loose material from the damaged area with a wire wheel or chisel.

2. Lightly wet the cleaned surfaces.

3. Using a trowel, pack the patching compound into the areas where refractory materials are missing. To achieve proper thickness, trim off excess material with a sharp flat blade or the side of the trowel.

4. Allow the material to harden before placing the machine back in service. The machine should be operated within 24 hours of hardening of patching compound.

NOTE: For best results repairing large areas of damage, remove the affected panel and place in a horizontal position.

3.26

Tigercat 6050 Carbonator

Lubrication and Maintenance

HYDRAULIC SYSTEM

IMPORTANT! Before servicing the hydraulic system, park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

NOTICE

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil. Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit. Contaminants in unfiltered oil can cause significant and costly damage to hydraulic system components.

The cleanliness of hydraulic oil cannot be guaranteed unless it is pre-filtered before use.

Use of filters other than genuine Tigercat replacement filters is not recommended. Replace filters at the recommended time intervals.

Refer to SCHEDULED MAINTENANCE in THIS SECTION.

WARNING

Hot hydraulic oil and hot machine surfaces can cause serious burns!

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

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

• Do not begin service work until the surface or system temperature has cooled down to below 38°C (100°F).

3.27

Lubrication and Maintenance HYDRAULIC OIL TANK

Tigercat 6050 Carbonator HYDRAULIC OIL LOW LEVEL SWITCH

The hydraulic oil tank is situated in the front of the frame.

It has a capacity of 295 L (78 US gal). Return oil passes through individual return ports on the top of the tank.

A

HYDRAULIC OIL LEVEL SIGHT GAUGE

A

6000274

Hydraulic Oil Tank – Top

A Oil Level Sight Gauge

A low level switch is installed in the tank. A message is sent to the computer display when the hydraulic oil tank level is low. The alarm light will flash and the alarm will also sound.

Refer to ALARMS – HYDRAULIC OIL LEVEL LOW in SECTION 2.

Allowing the level to drop below the sight level gauge can result in severe damage to hydraulic components.

6000039

Hydraulic Oil Tank – Front

A Oil Level Sight Gauge

An oil level sight gauge, viewable from the front of the machine indicates the level of the hydraulic oil.

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

HYDRAULIC OIL TEMPERATURE SENDING UNIT

Maintain the hydraulic oil at the top of the sight gauge.

Check oil level with all cylinder fully retracted to obtain an accurate level reading. Overfilling the tank may cause excess oil to discharge from the breather vent.

Add oil to the tank when no oil is visible in the sight gauge.

A 6000040

Hydraulic Oil Tank – Right Side

A Oil Level Sight Gauge

A temperature sending unit activates the hydraulic oil temperature gauge on the computer display main screen. A message is sent to the computer display when the hydraulic oil temperature exceeds the recommended operating range for the type of hydraulic oil in use. The alarm light will flash and the alarm will also sound.

Refer to ALARMS – HYDRAULIC OIL TEMPERATURE HIGH in SECTION 2.

3.28

Tigercat 6050 Carbonator

Lubrication and Maintenance

HYDRAULIC OIL TANK – ADDING OIL

CLEAN OUT COVERS

Prior to adding hydraulic oil to the tank, determine and repair the source of the oil loss.

The clean out covers are located on the left side of the hydraulic oil tank.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

Removing the clean out covers provides access into the hydraulic oil tank for cleaning, inspection and mounting of components.

2. Remove the hydraulic oil tank breather and add oil until the level is at the top of the sight gauge.

IMPORTANT! Remove the clean out covers only when the hydraulic oil tank has been completely drained of hydraulic oil. Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – DRAINING in THIS SECTION.

CAUTION Direct contact with oil implies a risk of skin complaints. Wash off oil on skin immediately with soap and water. Refer to WORKING WITH OIL in SECTION 1.

To remove the clean out cover: A

B

HYDRAULIC OIL TANK – DRAINING To drain the hydraulic oil tank: 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

6000041

A Clean Out Cover B Fastener (Qty 1)

A

1. Remove the clean out cover fastener.

6000040

A Drain Plugs

Hydraulic Oil Tank

2. Remove the clean out cover.

Hydraulic Oil Tank

3. Clean any debris from the bottom of the tank and wipe it clean.

2. Remove both magnetic drain plugs on the bottom of the tank and clean off any filings that have been collected.

4. Inspect the lip gasket for damage.

3. Drain the hydraulic oil into a suitable container.

NOTE: Dispose of the waste hydraulic oil according to local regulations.

4. Reinstall the magnetic drain plugs.

3.29

NOTE: Install a new lip gasket if damaged before reinstalling the clean out cover.

Lubrication and Maintenance

Tigercat 6050 Carbonator

REFILLING THE HYDRAULIC SYSTEM When filters are replaced, there is a nominal amount of oil loss through leakage and oil contained in the filters.

This requires a hydraulic system top-up or refill.

Before refilling, verify which oil type is selected to ensure the same type and grade of oil is used to refill the system.

It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results.

Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – ADDING OIL in THIS SECTION. NOTE: Changing strainers, filters and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, the machine should sit for one hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

When refilling the hydraulic system, vent pumps, motors and valves of air by opening a plug or hose fitting located near or on top of the pumps, motors and valves until oil free of air is seen flowing out of the plug or hose fitting.

Failure to vent air from the hydraulic system could cause serious damage to hydraulic components. Tighten plugs or fittings and clean up any spilled oil when completed.

Check all hydraulic system components especially the cooling fan for proper operation after hydraulic oil has been replaced.

3.30

Tigercat 6050 Carbonator

Lubrication and Maintenance

HYDRAULIC OIL RETURN FILTER

FILTER RESTRICTION PRESSURE GAUGE A filter restriction pressure gauge is installed in the filter assembly. When an oil pressure differential in excess of 1.4 bar (20 psi) is encountered at the return filters, this pressure gauge will read in the RED zone on the gauge.

A

B

FILTER SERVICE NOTE: The return filter should be checked/changed when the filter restriction pressure gauge is reading in the RED zone.

C

IMPORTANT! Do not use the RED zone warning as a substitute for changing the hydraulic oil return filter elements at regular intervals as per SCHEDULED MAINTENANCE in THIS SECTION.

D

This information is assuming that operating conditions and running temperatures are normal.

6000028

A B C D

Hydraulic Oil Tank – Rear View

Filter Cover Plate Upper Filter Element Lower Filter Element Filter Restriction Pressure Gauge

The return oil from the hydraulic oil cooler entering the hydraulic oil tank passes through a tank-mounted filter containing two filter elements. The filter is mounted on the top of the hydraulic oil tank.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION.

3.31

Lubrication and Maintenance

Tigercat 6050 Carbonator

MAIN PUMP HIGH PRESSURE FILTER

FILTER CHANGE PROCEDURE – HIGH PRESSURE FILTER 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

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

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

A

4. Remove the filter housing using a wrench on the bottom hex nut and remove the old filter. Wear face protection to avoid oil spray.

5. Dispose of old filter and any oil properly.

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

B

7. The new filter has an attached gasket. Apply hydraulic oil to the gasket surface.

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

9. Hand tighten filter an additional ½ turn only.

6000026

A Main Pump High Pressure Filter B Removal Nut

10. Replace the filter housing and tightening the bottom hex nut.

11. Start the engine and check for leaks.

The main pump high pressure filter is located on the fan side of the machine in front of the main control valve. The filter is on the output line of the main pump, downstream of the main control valve.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION.

3.32

Tigercat 6050 Carbonator

Lubrication and Maintenance

OVER AIR FAN PUMP CHARGE PRESSURE FILTER

FILTER CHANGE PROCEDURE – CHARGE PRESSURE FILTER 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

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

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

4. Remove the old filter. Wear face protection to avoid oil spray.

5. Dispose of old filter and any oil properly.

A

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

7. The new filter has an attached gasket. Apply hydraulic oil to the gasket surface.

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

9. Hand tighten filter an additional ½ turn only.

10. Start the engine and check for leaks.

6000027

60500001 – 60500102

A

6000260

60500103 – 60500500

A Over Air Fan Pump Charge Pressure Filter

The over air fan pump charge pressure filter is located on the left side of the engine in front of the pump drive gearbox. The filter is on the output side of charge pump on the over air drive pump.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION. 3.33

Lubrication and Maintenance

Tigercat 6050 Carbonator

CASE DRAIN STRAINER 60500103 – 60500500 A

6000259

A Case Drain Strainer

The case drain strainer is located in the engine compartment. The case drain strainer is used to filter all case drain oil from the pumps and motors before it returns to the hydraulic oil tank.

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

IMPORTANT! The case drain strainer element is not a filter element.

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

3.34

Tigercat 6050 Carbonator

Lubrication and Maintenance

ENGINE BELT A

B

6000029

A Serpentine belt B Spring-Loaded tensioner

The alternator is driven by the serpentine belt. Belt tension is controlled by a spring-loaded tensioner. Check the belt for signs of incision, cracks, excessive wear in grooves and signs of end or surface grinding every 8 hours.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for details of the engine belt.

3.35

Lubrication and Maintenance

Tigercat 6050 Carbonator

FUSES AND RELAYS B

C

B

6000037

A Fuses B Relays C Busbar

Engine Fuse and Relay Panel– Fan Side of Machine

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

IMPORTANT! The components in this panel support the 12 V electrical system to the engine.

3.36

A

Tigercat 6050 Carbonator

Lubrication and Maintenance

11

12

14 15

1 7 2

16

3 8

4 5

9 17 10 13

6000038

1 2 3 4 5 6

Engine ECM Glow Power Aftertreatment System Spare Electric Priming Pump Starter

7 8 9 10

Starter Electric Priming Pump Aftertreatment System Glow Power

11 12 13 14 15 16 17

Battery Starter Glow Plugs Aftertreatment System Engine ECM Engine ECM/Glow Plugs Starter/Aftertreatment System/Electric Priming Pump

Fuses

Relays

Studs

3.37

6

Lubrication and Maintenance

Tigercat 6050 Carbonator

BATTERY CARE Tigercat uses two types of batteries dependant on the machine application, model and design.

• Absorbed Glass Mat (AGM) • Flooded Lead Acid (FLA).

NOTICE Before charging the battery, it is important to identify which type of battery you have.

Read and follow the battery and charger manufacturer's instructions prior to connecting or charging a battery.

All batteries are sensitive to overcharging. Charging or maintaining AGM batteries requires the use of a smart charger with an AGM setting. The peak charging voltage for AGM batteries varies slightly between battery manufacturer's. Exceeding this voltage can cause permanent battery damage. Refer to the BATTERY MANUFACTURER'S charging instructions for more information.

Refer to BATTERY MANUFACTURER'S instructions for charging or maintaining FLA batteries.

3.38

Tigercat 6050 Carbonator

Lubrication and Maintenance

ENGINE FILTERS – REMOVE AND REPLACE

FUEL FILTERS

IMPORTANT! Failure to service and replace engine filters at the proper intervals specified in the ENGINE OPERATION AND MAINTENANCE MANUAL, could cause damage to the machine and result in the product warranty becoming NULL and VOID. Check the Tigercat parts catalogue for replacement filters.

Refer to the appropriate ENGINE OPERATION AND MAINTENANCE MANUAL for the oil and fuel filter replacement procedure. Read and understand the SAFETY section in each of THESE MANUALS.

These engines use filters with a very fine micron rating.

If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in SCHEDULED MAINTENANCE in THIS SECTION. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended to drain the fuel filter/ water separator bowl daily.

NOTICE

ENGINE OIL FILTER

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the fuel system caused by unfiltered fuel. Unfiltered fuel used to pre-fill filters enters directly into the fuel circuit. Contaminants in unfiltered fuel can cause significant and costly damage to fuel system components. The cleanliness of fuel cannot be guaranteed unless it is pre-filtered before use.

A

Use of filters other than genuine Tigercat replacement filters is not recommended. Replace filters at the recommended time intervals.

Refer to SCHEDULED MAINTENANCE in THIS SECTION. To prolong the operating life of the fuel filter, the fuel supply storage tank must be clean and free of water and the fuel must be pre-filtered prior to adding it to the machine.

6000030

A Engine Oil Filter

The engine oil filter is located on the left side of the engine.

When installing a new oil filter, do not pre-fill with engine oil as this may result in engine damage. This type of failure is not warrantable by the engine manufacturer.

For service and replacement intervals refer to SERVICE AND LUBRICATION POINTS in THIS SECTION. Refer also to ENGINE OPERATION AND MAINTENANCE MANUAL for more detailed information.

3.39

Lubrication and Maintenance

Tigercat 6050 Carbonator

PRIMARY FUEL FILTER/WATER SEPARATOR

CHANGING FUEL FILTER/WATER SEPARATOR Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS SECTION for filter replacement intervals.

B

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Drain the fuel from the filter/water separator as described previously in this section.

D

A

3. Disconnect the wiring harness.

4. Wearing eye and face protection (in case of a fuel spray) use the tool supplied by the ENGINE MANUFACTURER to remove the water separator bowl from the filter head.

5. Dispose of any fuel properly .

6. Remove and discard the O-ring from the top of the separator bowl.

7. Clean the separator bowl.

C

6000031

A B C D

Primary Fuel Filter/Water Separator Vent Plug Drain Valve with Hose Barb Fuel Supply to Secondary Fuel Filter

The fuel filter/water separator is located on the left side of the engine.

DRAINING PRIMARY FUEL FILTER/WATER SEPARATOR 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

8. Remove the filter cartridge from the filter head (pressure fit) and discard properly.

9. Place the new filter into position on the filter head.

10. Lubricate the O-ring with clean engine oil and install at the top of the separator bowl.

11. Install (screw) separator bowl onto the filter head hand tighten.

12. Reconnect the wiring harness.

13. Prime the fuel system following the instructions in the ENGINE OPERATION AND MAINTENANCE MANUAL. 14. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

WARNING

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

3. Place a suitable container under the filter and/or place rags below to catch the spillage of fuel.

To lower the risk of causing accidental fires, Do not leave fuel or oil soaked rags laying around.

4. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for draining instructions.

NOTE: A drain hose can be attached to the drain valve if required.

5. Close the drain valve.

WARNING Drain fuel filter into a container and dispose of all fluids properly.

The fuel filter/water separator is a combination unit, with a replaceable fuel filter and a removable water sediment bowl on the bottom of the unit. The water sediment bowl is only replaced if it becomes damaged or non-functional. For service and replacement intervals, refer to SERVICE AND LUBRICATION POINTS in THIS SECTION.

3.40

Tigercat 6050 Carbonator

Lubrication and Maintenance

SECONDARY FUEL FILTER

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Allow machine to cool.

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

4. Place rags below to catch the spillage of fuel.

WARNING

A

Drain fuel filter into a container and dispose of all fluids properly.

5. Wearing face protection (in case of a fuel spray) unscrew the old fuel filter. Dispose of any fuel and the fuel filter properly.

6000031

6. Check the seating area for the O-ring on the filter head and wipe clean.

A Engine Secondary Fuel Filter

The engine fuel filter is located on the left side of the engine.

7. Lubricate the O-ring on top of the new filter with clean engine oil. Do not pre-fill the new filter.

8. Screw the new filter onto the filter head as specified by the filter manufacturer. Note: Mechanical over tightening can damage the filter element.

WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high pressure fuel. Do not loosen any fittings while the engine is running.

Personal injury and property damage can result.

9. Prime the fuel system following the instructions in the ENGINE OPERATION AND MAINTENANCE MANUAL. 10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

3.41

Lubrication and Maintenance

Tigercat 6050 Carbonator

FUEL TANK COMPONENTS

FUEL LEVEL SENDER – LATER DESIGN

FUEL FILL CAP A

A

B

B

6000032

A Fuel Fill Cap B Visual Fuel Level Gauge – Earlier Design

The fuel tank is located at the front of the machine. The fuel tank has a usable capacity of 473 L (125 US gal).

The fuel fill cap is located on the front of the tank.

6000033

A Fuel Level Sender B Fuel Tank

The fuel level sender is located on the top of the fuel tank behind the batteries. It sends a signal to the computer which displays an on-screen fuel level gauge.

3.42

Tigercat 6050 Carbonator

Lubrication and Maintenance

REFUELLING PROCEDURE

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

IMPORTANT!

2. Allow machine to cool.

3. Clear obstructions from access the fuel tank.

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

5. Clear any debris from around the fuel fill cap.

6. Remove the fuel fill cap slowly to allow pressure to escape from the tank.

S≤15 mg/kg

7. Inspect the fuel fill cap gasket.

8. Insert the fuel nozzle into the fuel fill tube.

ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

Use only ultra low sulfur diesel (ULSD) fuel in Tigercat FPT engines equipped with Tier 4f aftertreatment systems. Using fuel with sulfur levels greater than 15 ppm (S≤15 mg/kg) maximum will permanently damage the engine and aftertreatment system within a short period of time.

WARNING

Do not refuel while smoking or while near an open flame or sparks.

CAUTION Do not leave the machine unattended during the refuelling process.

3.43

9. Fill the tank until the fuel level reaches the bottom of the fuel fill tube. Do not leave the fuel nozzle unattended or spillage may occur.

10. Remove the fuel nozzle and the ground strap (if applicable).

11. Install fuel fill cap hand-tight.

NOTE: Before restarting the machine, Refer to STARTING ENGINE in SECTION 2.

Lubrication and Maintenance

Tigercat 6050 Carbonator

AIR INTAKE SYSTEM

AIR FILTER RESTRICTION SWITCH

ENGINE AIR PRECLEANER A

The engine is also equipped with an engine air filter restriction switch which continually sends the intake restriction level to the computer display. The sensor will send an alert message to the computer in the event of filter restriction.

Refer to AIR INTAKE SYSTEM– AIR CLEANER – OVER SERVICING and AIR INTAKE SYSTEM– AIR CLEANER – IMPROPER SERVICING in THIS SECTION.

6000034

A Engine Air Precleaner

The engine air precleaner cleans engine air before it reaches the air cleaner filter elements. It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self-powered and self-cleaning requiring virtually no maintenance.

IMPORTANT! Check the precleaner every 8 hours for foreign materials that may have plugged the intake area or the discharge louvre area. Clean as required.

A plugged precleaner will create a restriction to airflow, resulting in reduced engine performance and increased fuel consumption.

If the machine is operated with a plugged precleaner, excessive air intake restriction will damage the rubber air intake tube which will lead to ingestion of dirt into the engine resulting in engine failure. The air intake filter restriction indicator may not function properly if the air intake tube is damaged.

3.44

Tigercat 6050 Carbonator

Lubrication and Maintenance

AIR CLEANER

In addition to the SCHEDULED MAINTENANCE in THIS SECTION, the following instructions should also be noted: NOTE: Replace secondary (safety) filter every third primary filter change.

The most common and most damaging air intake servicing problems are over servicing and improper servicing.

OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that is dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond the engine manufacturer’s guidelines, should be replaced.

A

IMPROPER SERVICING Engine exposure to dust during servicing is the largest single factor contributing to engine damage due to dust. Abrasive dust can easily enter the intake system once the air cleaner element has been removed for replacement. The safety element reduces the risk, however it must also be replaced at every third primary element change.

6000034

A Air Cleaner

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS

B

1. Release the cover latches gently to reduce the amount of dust dislodged.

2. Avoid dislodging dust from filter element(s) by gently pulling the element out of the housing.

3. Check your old filter sealing surfaces. This will help detect foreign material on the sealing surface that is causing leakage.

NOTE: Do not clean and reuse filter elements.

Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media.

The dust is then drawn directly into the engine.

A

4. Clean the inside of the housing.

726D-006

5. Clean the sealing surface before inserting a new filter element.

A Primary Element B Secondary (Safety) Element

The air cleaner on this machine uses two filter elements; a primary element and a secondary (safety) element. It is accessible through the service compartment access door on the rear of the machine.

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

3.45

6. Inspect the new filter for damage.

7. Insert the new filter properly. Apply pressure to the filter frame not the pleated filter surface.

8. Check connections hoses and tubes for an air tight fit. All clamps, bolts and connections must be tight.

Check rubber elbows for splits or wear points. Leaks in these locations send dust directly to the engine.

Lubrication and Maintenance

Tigercat 6050 Carbonator

AIR CLEANER UNLOADER VALVE

A

6000034

A Air Cleaner Unloader Valve

Check the rubber air cleaner unloader valve on the air cleaner housing every 8 hours. If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective.

Replace the unloader valve every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. A good valve should be soft and flexible. Check and clean the valve. If it is plugged, check the filter elements as they may also need to be replaced. Reattach the valve to the tube. The valve should suck closed at about one-third of HIGH engine speed. When operating in high dust conditions this valve should be checked and squeezed every two hours to release dust buildup.

3.46

Tigercat 6050 Carbonator

Lubrication and Maintenance

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

AFTERTREATMENT SYSTEM Tier 4f machines are equipped with a combination Diesel Oxidation Catalyst (DOC) and high efficiency Selective Catalytic Reduction (SCR) aftertreatment system to limit the nitrogen oxide exhaust gas values (NOx) to meet Tier 4 final emission standard requirements with low fuel consumption. This process is electronically controlled by the DENOX 2.2 system.

The DOC uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). In addition the DOC converts nitrogen oxide (NO) into nitrogen dioxide (NO2). Increased NO2 levels enhance the performance of the SCR catalyst at low temperatures and increase the effectiveness of the DOC/SCR aftertreatment system as a whole.

The high efficiency SCR process is based on a series of chemical reactions which involve the reaction of ammonia with the oxygen in the exhaust gas to reduce nitrogen oxides (NOx) in the exhaust gas by transforming it into inert compounds: free nitrogen (N2) and water vapour (H2O). In addition the high efficiency catalytic converter includes a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the aftertreatment system and the engine.

NOTE: Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for details of the aftertreatment system.

3.47

IMPORTANT! Do not idle the engine longer than one hour. Damage to the emission control system will result. When this machine idles for an extended period, excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon, at full load, immediately after a long idle period, generates excess heat which causes damage to emission control system components.

Lubrication and Maintenance

Tigercat 6050 Carbonator

CARE OF THE MACHINE

• All fluid levels must be at the proper level. Refer to SCHEDULED MAINTENANCE in THIS SECTION. • Lubricate all grease points at the required intervals.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION. • Do not allow branches, twigs, leaves or pine needles to build up around radiator intake doors or anywhere else on the machine. Clean as operating conditions warrant but at least once a day all debris must be remove from the machine interior.

• Do not apply load to a cold engine.

• Never park machine with cylinders raised. Be sure all cylinders are in the closed position before servicing or parking the machine. Refer to PARKING THE MACHINE in SECTION 1.

• SAFETY FIRST! Follow all safety rules and regulations as outlined in SECTION 1.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the after treatment system and the engine.

3.48

Tigercat 6050 Carbonator

Lubrication and Maintenance

PRESSURE WASHING

PRESSURE WASHING PROCEDURE

Pressure washing is one of the easiest and most economical ways to preserve your investment.

Accumulated mud can damage track rollers, sand will grind down pins and bearings and wood debris buildup in machine enclosures is a serious fire hazard. Pressure washing is also good practice before and after servicing equipment.

1. Start the engine. Maintain engine speed at LOW. 2. Position attachment in the vertical position and swing the boom to the side of machine.

3. Using a hydraulic jack, lift the track clear off the ground.

4. Use blocks to support the undercarriage frame in a raised position.

5. Rotate the track to shake off mud and dirt.

CAUTION To avoid slips, trips or falls, all handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow, ice, and forest debris.

CAUTION

6. Repeat steps 2 – 5 for the other track.

7. Clean the undercarriage and tracks with a shovel and a broom to remove all debris before pressure washing.

8. Pressure wash the tracks and undercarriage.

9. Pressure wash the drive motor compartments.

10. Pressure wash the cooler package, hydraulic oil cooler and enclosure screens.

11. Pressure wash the engine compartment.

12. Pressure wash the pump area.

13. Pressure wash the main control valve area.

Use personal protective equipment to guard against flying debris.

IMPORTANT! Use a high volume, low pressure fan nozzle or nozzle setting for all equipment cleaning. High pressure spray can damage paint, penetrate electrical connections and remove labels. Use a mild detergent and make sure pressure settings are below 83 bar (1200 psi).

A

14. Close engine enclosure doors.

IMPORTANT! Allow the engine to cool down before pressure washing the engine compartment. Pressure washing a hot engine with cold water could crack the engine block or other components.

To avoid damaging sensitive machine components, do not allow water to come in contact with electrical/ electronic components or air ducts and filters inside the vehicle.

Due to the sensitive electronics on this machine use only warm water, a mild detergent and a gentle pressure wash setting.

B

845C-242

A Pressure Washer Extension B Platform Ladder

To clean hard-to-reach areas, use a platform ladder or attach an extension wand to your pressure washer, extend it to the desired height and lock it in place.

3.49

Lubrication and Maintenance

Tigercat 6050 Carbonator

CLEANING COOLER PACKAGE Check the cooler package every 8 hours or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. Also check all engine enclosure doors.

A

B

6000036

Hydraulic Oil Cooler

A Hydraulic Oil Cooler Fan B Fan Motor D

C

B

A

6000035

A B C D

Radiator Fuel Cooler Charge Air Cooler Hydraulic Oil Cooler

A hydraulic motor-driven fan is located behind the hydraulic oil cooler. In normal operation, the fan draws air from the engine/hydraulics compartment blowing it out the front of the machine through the hydraulic oil cooler.

The cooler package is located at the front of the machine.

The cooler package consists of the radiator, charge air cooler (CAC) and the fuel cooler. The hydraulic oil cooler is located separately at the front of the machine. The cooler package is cooled by the engine fan.

3.50

Tigercat 6050 Carbonator

Lubrication and Maintenance

CLEANING PROCEDURE

NOTE: The cooler package and hydraulic oil cooler must be checked daily and may have to be thoroughly cleaned on a daily, weekly or monthly basis, depending on operating conditions. Use personal protective equipment (eye wear) to guard against flying debris. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces. Care must be taken not to set the pressure too high otherwise damage to the components could result.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Open all engine compartment and valve compartment access doors.

3. Remove any accumulated debris.

4. Use compressed air or water for cleaning.

CAUTION

Pay particular attention to cleaning in the corners of the cooler as these areas usually plug deeply. For more information on fire prevention refer to FIRE PREVENTION in SECTION 1.

Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris being blown into contact with hot surfaces.

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the ability of the fans to remove dust and dirt particles.

If using compressed air for cleaning, use at 2 bar (30 psi) or less.

Use personal protective equipment (eye wear) to guard against flying debris.

5. When the units have been cleaned, close all access covers and doors and return all cooling components to their operating position.

CAUTION Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Use care when cleaning to ensure debris removed from one area of the machine does not accumulate on other areas of the machine.

3.51

Lubrication and Maintenance

TRACKS

Tigercat 6050 Carbonator MEASURING TRACK SAG

IMPORTANT TRACK DRIVE NOTES

1. Swing the boom to side of machine; apply the swing brake.

NEW MACHINE

2. Using a hydraulic jack, lift the track clear off the ground.

Set track sag correctly before driving a new machine.

Track sag may be factory set at less than the specified value for shipping purposes. It must be adjusted before beginning operations.

During the initial operating period, frequent track sag adjustments are necessary.

3. Use blocks to support the undercarriage frame in a raised position.

4. Rotate track in forward and reverse several times.

Stop the track while in reverse. Do not clean the track.

5. Turn OFF the engine.

TRACK SAG Inspect track sag often. Maintaining correct track sag increases track assembly life by as much as 50%. A track that is set too tight will wear out prematurely due to excessive chain tension.

B A

B

C 853ILL8

A Underside of Track Guard B Sag Dimension C Upper Surface of Track Shoe

6. Measure distance between top surface track shoe at centre of lower surface of track frame.

7. The dimension must be 102 – 152 mm (4 – 6 in) for normal operations.

NOTE: If track sag is less than specified, track chain wear accelerates. If track sag is excessive, it is possible for the track to jump off the sprocket.

Refer to TRACKS – TRACK SAG ADJUSTMENT in THIS SECTION for the track chain tension adjustment procedure.

8. Repeat this procedure for the opposite track.

3.52

Tigercat 6050 Carbonator

Lubrication and Maintenance

TRACK SAG ADJUSTMENT

TIGHTEN TRACK 1. Attach the valve coupler onto the fill valve.

WARNING

2. Connect a grease gun to the grease fitting on the coupler.

Hydraulic oils or grease under pressure can penetrate the skin and could result in death or serious injury.

3. Add grease until the track sag dimension is within recommended limits.

Refer to TRACKS – MEASURING TRACK SAG in THIS SECTION for recommended limits.

CAUTION

4. Remove the grease gun from the coupler fitting.

5. Store the valve coupler in a safe place.

Do not remove the fill valve. The grease in the idler is under very high pressure.

LOOSEN TRACK 1. Slowly loosen the fill valve until grease begins to escape through the vent passage in the valve body housing.

Grease will vent around the valve body threads.

Remove grease until the track sag dimension is within recommended limits.

Refer to TRACKS – MEASURING TRACK SAG in THIS SECTION for recommended limits.

A

2. Tighten the valve body when the track sag is correct.

NOTE: The track sag fill valve is not mechanically restricted from being removed completely.

D

802706 802707

A B C D

C

B

Track Sag Fill Valve

Track Valve Coupler Fill Valve Grease Fitting Fill Valve (Do Not Remove)

CAUTION The grease is under very high pressure. Do not remove the adjustment fitting valve body from the idler adjusting cylinder.

3.53

Lubrication and Maintenance TORQUING UNDERCARRIAGE BOLTS

Tigercat 6050 Carbonator TRACK SHOE RETAINING BOLTS

It is important to check the torque values of the master track shoe retaining bolts, track shoe retaining bolts, and the top and bottom roller retaining bolts at the NEW MACHINE MAINTENANCE time period (first 125 hours) and then every 125 hours. Refer to SCHEDULED MAINTENANCE – EVERY 125 HOURS in SECTION 3.

When installing new components, all traces of paint and dirt must be removed from all mating surfaces including the contact area under the bolt head and nut.

Both the bolt and the nut on the track shoes should be lightly lubricated with SAE 30 oil and tightened using the torque-turn method.

The torque-turn method involves torquing the bolt to an initial predetermined value, plus an additional ⅓ turn (not the value shown in the torque charts) to ensure a more accurate and consistent torquing of the bolts, with less likelihood of the bolt/nut coming loose later.

When checking the torque values at the first 125 hours and every 125 hours thereafter use the CHECKING TORQUE values listed in the following paragraphs.

Once checked, they should be removed, surfaces cleaned, and reused using the torque-turn method. If the shoe is not loose but a single bolt is low on torque, loosen the bolt and repeat the torque-turn method.

If loose or under torqued bolts are discovered any time after the 125 hour check, the bolts and nuts must be replaced with new ones, surfaces cleaned, and repeat the torque-turn method.

860C-333

Torque Procedure

Track shoes must be fastened together applying the exact torque values and using the torque-turn method described in TORQUE CHART, SPECIFIC in THIS SECTION. Track shoe bolts and nuts are designed specifically for this purpose and should not be substituted with standard off the shelf hardware.

CAUTION The torque-turn method involves torquing the bolt to an initial predetermined value, plus an additional ⅓ turn (not the value shown in the torque charts) to ensure a more accurate and consistent torquing of the bolts, with less likelihood of the bolt/nut coming loose later.

Only bolts with grade 12.9 or 170 designation forged in the head are approved.

When checking the torque values at the first 100 hours and every 125 hours thereafter use the checking torque values.

Refer to SECTION 11 of the SERVICE MANUAL for torquing procedure and torque values.

3.54

Tigercat 6050 Carbonator

Lubrication and Maintenance

PRESSURE AND SPEED SETTINGS – 6050 Location

Pressure bar

Engine Speed– rpm psi

Engine LOW (No Load)

800

HIGH (No Load)

2050

Main Control Valve Under Air Fan

350

5075

800

Track Motor – Air Side

350

5075

800

Track Motor – Non-Air Side

350

5075

800

Track Brake

200

2900

800

Auger Drive

200

2900

800

Conveyor Disconnects

200

2900

800

Hydraulic Cooler Fan Motor

200

2900

800

Camera Arm Cylinder

200

2900

800

NOTES: 1. Hydraulic system to be at operating temperature when setting pressures.

2. All pressures measured in bar (psi).

3. Pressure and speed values are for reference purposes only. Refer to SERVICE MANUAL for setting procedures.

3.55

Lubrication and Maintenance

Tigercat 6050 Carbonator

TORQUE CHART – 6050 Location

Thread Diameter

Torque (Lubricated) N-m lbf-ft

3/4 UNF M16-2 (10.9) 7/8"-9 UNC (G8) M20-2.5 (10.9) M20-2.5 (10.9) M20-2.5 (8.8)

T/T* 237 610 515 515 373

Engine Mounting Bolts, bracket to chassis Pump Mounting Main Pump to Gearbox Over Air Pump to Gearbox Undercarriage Track shoe bolts Idler bolts Roller mounting bolts Sprocket bolts Gearbox mounting bolts Drive motor mounting bolts

T/T* 175 450 380 380 275

*T/T represents Torque-Turn, this is a method of torquing the track shoe bolts. Refer to SECTION 11 for a complete description on this method of applying torque.

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

3.56

Tigercat 6050 Carbonator

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS IMPERIAL GRADE 5 BOLTS

The torque values listed below are for general use only.

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

GRADE 8 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS LUBRICATED COARSE N-m lbf-ft THREAD 1/4" - 20 9-9 6-7 5/16" - 18 18 - 19 13 - 14 3/8" - 16 31 - 35 23 - 25 7/16" - 14 50 - 55 37 - 41 1/2" - 13 77 - 84 57 - 62 9/16" - 12 111 - 122 82 - 90 5/8" - 11 153 - 168 113 - 124 3/4" - 10 271 - 298 200 - 220 7/8" - 9 437 - 480 322 - 354 1" - 8 654 - 720 483 - 531 1 1/8" - 7 808 - 888 596 - 655 1 1/4" - 7 1139 - 1253 840 - 924 FINE LUBRICATED THREAD N-m lbf-ft 1/4" - 28 10 - 11 7-8 5/16" - 24 20 - 22 14 - 16 3/8" - 24 36 - 39 26 - 29 7/16" - 20 56 - 62 41 - 46 1/2" - 20 86 - 95 64 - 70 9/16" - 18 123 - 136 91 - 100 5/8" - 18 173 - 190 127 - 140 3/4" - 16 302 - 332 223 - 245 7/8" - 14 482 - 530 355 - 391 1" - 14 735 - 808 542 - 596 1 1/8" - 12 906 - 996 668 - 735 1 1/4" - 12 1262 - 1388 930 - 1023

DRY N-m lbf-ft 11 - 13 8-9 24 - 26 17 - 19 42 - 46 31 - 34 67 - 74 49 - 54 102 - 112 75 - 83 147 - 162 109 - 120 203 - 224 150 - 165 361 - 397 267 - 293 582 - 640 429 - 472 873 - 960 644 - 708 1077 - 1185 794 - 874 1519 - 1671 1121 - 1233 DRY N-m lbf-ft 13 - 14 10 - 11 26 - 29 19 - 21 47 - 52 35 - 38 75 - 82 55 - 61 115 - 127 85 - 93 164 - 181 121 - 133 230 - 253 170 - 187 403 - 443 297 - 327 642 - 706 474 - 521 979 - 1077 722 - 795 1207 - 1328 890 - 980 1682 - 1850 1241 - 1365

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

LUBRICATED DRY N-m lbf-ft N-m lbf-ft 12 - 13 9 - 10 16 - 18 12 - 13 25 - 27 18 - 20 33 - 37 25 - 27 44 - 49 33 - 36 59 - 65 44 - 48 71 - 78 52 - 58 95 - 104 70 - 77 108 - 119 80 - 88 144 - 159 106 - 117 156 - 172 115 - 127 208 - 229 154 - 169 215 - 237 159 - 175 287 - 316 212 - 233 383 - 421 282 - 310 510 - 561 376 - 414 616 - 678 455 - 500 822 - 904 606 - 667 924 - 1016 681 - 750 1232 - 1355 909 - 999 1310 - 1441 966 - 1063 1746 - 1921 1288 - 1417 1848 - 2033 1363 - 1499 2464 - 2710 1817 - 1999 LUBRICATED DRY N-m lbf-ft N-m lbf-ft 14 - 15 10 - 11 18 - 20 14 - 15 28 - 30 20 - 22 37 - 41 27 - 30 50 - 55 37 - 41 67 - 74 49 - 54 79 - 87 58 - 64 106 - 116 78 - 86 122 - 134 90 - 99 163 - 179 120 - 132 174 - 192 128 - 141 232 - 255 171 - 188 244 - 268 180 - 198 325 - 358 240 - 264 427 - 469 315 - 346 569 - 626 420 - 462 680 - 748 502 - 552 907 - 997 669 - 736 1037 - 1141 765 - 841 1383 - 1521 1020 - 1122 1468 - 1615 1083 - 1191 1958 - 2154 1444 - 1588 2046 - 2250 1509 - 1660 2728 - 3000 2012 - 2213

METRIC

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

SIZE PITCH LUBRICATED mm N-m lbf-ft M6 1 8-9 6-7 M8 1.25 20 - 22 15 - 16 M10 1.5 39 - 43 29 - 32 M12 1.75 68 - 75 50 - 55 M14 2 109 - 120 80 - 89 M16 2 169 - 186 125 - 137 M18 2.5 234 - 257 172 - 190 M20 2.5 330 - 364 244 - 268 M22 2.5 451 - 496 332 - 366 M24 3 571 - 628 421 - 463 M27 3 837 - 921 618 - 679 M30 3.5 1135 - 1249 837 - 921 M33 3.5 1545 - 1699 1139 - 1253 M36 4 1985 - 2183 1464 - 1610

CLASS 10.9 LUBRICATED DRY N-m lbf-ft N-m lbf-ft N-m lbf-ft 11 - 12 8-9 11 - 12 8-9 15 - 17 11 - 12 26 - 29 19 - 21 27 - 30 20 - 22 36 - 40 27 - 30 52 - 57 38 - 42 54 - 60 40 - 44 72 - 79 53 - 59 91 - 100 67 - 74 94 - 104 70 - 77 126 - 138 93 - 102 145 - 160 107 - 118 151 - 166 111 - 122 201 - 221 148 - 163 226 - 248 166 - 183 234 - 257 173 - 190 312 - 343 230 - 253 312 - 343 230 - 253 323 - 356 239 - 262 431 - 474 318 - 350 441 - 485 325 - 357 457 - 503 337 - 371 610 - 670 450 - 495 601 - 661 443 - 487 623 - 686 460 - 506 831 - 914 613 - 674 761 - 838 562 - 618 790 - 869 583 - 641 1053 - 1159 777 - 855 1116 - 1228 823 - 906 1158 - 1274 854 - 940 1544 - 1699 1139 - 1253 1514 - 1665 1116 - 1228 1570 - 1727 1158 - 1274 2094 - 2303 1544 - 1699 2060 - 2266 1519 - 1671 2137 - 2351 1576 - 1734 2849 - 3134 2102 - 2312 2646 - 2911 1952 - 2147 2745 - 3020 2025 - 2227 3661 - 4027 2700 - 2970 DRY

3.57

CLASS 12.9 LUBRICATED DRY N-m lbf-ft N-m lbf-ft 13 - 14 10 - 11 18 - 19 13 - 14 32 - 35 24 - 26 43 - 47 31 - 35 63 - 70 47 - 51 84 - 93 62 - 68 110 - 121 81 - 90 147 - 162 109 - 119 176 - 194 130 - 143 235 - 259 173 - 191 274 - 301 202 - 222 365 - 401 269 - 296 378 - 416 279 - 307 504 - 554 372 - 409 534 - 588 394 - 433 712 - 784 525 - 578 728 - 801 537 - 591 971 - 1068 716 - 788 923 - 1016 681 - 749 1231 - 1354 908 - 999 1354 - 1489 998 - 1098 1805 - 1985 1331 - 1464 1835 - 2019 1354 - 1489 2447 - 2692 1805 - 1985 2498 - 2747 1842 - 2026 3330 - 3663 2456 - 2702 3208 - 3529 2366 - 2603 4278 - 4706 3155 - 3471

Lubrication and Maintenance

Tigercat 6050 Carbonator

Parker

ASSEMBLY TORQUE The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts. The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head onto the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

A B C

D E F

FLANGE PORT ASSEMBLY The steps to properly assemble the flange port clamping bolts are:

FLANGE.JPG

A B C D E F

4-Bolt Split Flange Components

1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

Washers Bolts Flange Clamp Flange Head O-Ring Tapped Holes

2. Lubricate the o-ring.

3. Position flange and clamp halves.

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

5. Hand tighten bolts.

• 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 washers Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque Nm

8 12 16 20 24 32 40 48 56 64 80

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

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

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

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

FLANGE2.JPG

A

Flange Bolt Tightening Sequence

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

Table T6– Code 61 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32

1/2 3/4 1 1 1/4 1 1/2 2

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

17 +/- 2 30 +/- 4.5 46 +/- 4.5 69 +/- 6 125 +/- 8 208 +/- 20

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

Table T7– Code 62 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

3.58

Tigercat 6050 Carbonator

Lubrication and Maintenance

Parker

ASSEMBLY TORQUE JIC 37 Degree Flare

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

Thread Size 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

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR NA NA 2 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 1 1 1

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

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

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

1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

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

Thread Size NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

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

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok SAE Dash Size

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

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

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

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

Thread Size 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

Tube Connection Swivel or Hose Connection TFFT TFFT 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

3.59

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

Lubrication and Maintenance

Tigercat 6050 Carbonator

EATON Aeroquip

ASSEMBLY TORQUE

Recommended Parallel Connection Assembly torque

Eaton recommends that a Torque wrench be used to assure proper fitting assembly of these connections.

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

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

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

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32

The values listed are for steel connections. Contact Teaton for torque values for other materials.

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

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

ORS

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

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

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

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

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

SAE 37º (JIC) Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

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

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

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

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

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

Swivel Nut Torque lb.-ft.

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

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

BSPP Straight Adapter or Locknut Torque lb.-ft.

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

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

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

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.60

Tigercat 6050 Carbonator

Lubrication and Maintenance

COMMON CONVERSIONS To Convert...

Into...

Multiply By

To Convert...

Into...

Multiply By

bar

psi

14.5

in3

cm3

16.39

cm

in

0.06102

°F

°C

(°F − 32) / 1.8

3

3

°C

°F

(°C × 1.8) + 32

lb

kg

0.4535

kg

lb

2.205

hp

kW

0.7457

kW

hp

1.341

US Gal

L

3.785

L

US Gal

0.2642

in

mm

25.4

mm

in

0.03937

lbf•ft

N-m

1.356

N-m

lbf•ft

0.7375

lbf

N

4.4482

N

lbf

0.22481

in Hg

psi

0.4912

psi

bar

0.06896

in H2O

psi

0.03613

3.61

Lubrication and Maintenance

Tigercat 6050 Carbonator

WEIGHTS OF COMMERCIAL WOOD

kg/m3

lb/ft3

kg/m3

lb/ft3

46

Maple, Big Leaf

Ash, White

769

48

Maple, Black

865

Aspen, Quaking

689

54

43

Maple, Red

801

50

Bald Cypress Basswood, American

817

51

Maple, Silver

721

45

673

42

Maple, Sugar

897

56

Beech, American

865

54

Oak, Black

1009

63

Birch, Paper

801

50

Oak, Chestnut

977

61

Birch, Yellow

929

58

Oak, Red

1009

63

Cedar, Alaska

577

36

Oak, Red, Swamp

1073

67

Cedar, Incense

721

45

Oak, Swamp Chestnut

1041

65

Cedar, Northern White

449

28

Oak, White

993

62

Cedar, Port-Orford

897

36

Oak, White, Swamp

1105

69

Cedar, Western Red

433

57

Pine, Jack

801

50

Cherry, Black

721

45

Pine, Loblolly

993

62

Cottonwood, Eastern

785

49

Pine, Lodgepole

625

39

Douglas Fir, Coast

881

55

Pine, Long Leaf

993

62

Douglas Fir, Inland North

577

36

Pine, Norway, Red

673

42

Elm, American

865

54

Pine, Short Leaf

993

62

Fir, Alpine

449

28

Pine, Slash

993

62

Fir, Balsam

721

45

Pine, Sugar

817

51

Fir, Nobel

481

30

Pine, Western Yellow

721

45

Fir, Red

769

48

Pine, White-Western

561

35

Fir, Silver

577

36

Pine, White-Eastern

577

36

Fir, White

753

47

Poplar, Yellow

609

38

Gum, Black

721

45

Redwood

801

50

Gum, Blue

1121

70

Spruce, Black

513

32

Gum, Red

801

50

Spruce, Engleman

625

39

Gum, Tupelo

897

56

Spruce, Red

545

34

Hemlock, Eastern

801

50

Spruce, Sitka

529

33

Hemlock, Western

657

41

Spruce, White

545

34

Hickory, Pecan

993

62

Sweetgum

801

50

Hickory, True

1009

63

Sycamore, American

833

52

Larch, Western

769

48

Tamarack

753

47

Locust, Black

929

58

Walnut, Black

929

58

Magnolia, Cucumber

785

49

Willow, Black

801

50

Alder, Red

Species

737

NOTE: The values shown are green weights.

3.62

Species

753

47