Tigercat C87 Tier 2 Engine Operation & Maintenance Manual - PDF DOWNLOAD

OPERATION AND MAINTENANCE MANUAL

C87 Tier 2 Engine

IMPORTANT! CATASTROPHIC ENGINE FAILURES CAN BE PREVENTED WITH PROPER MAINTENANCE. LISTED BELOW ARE SOME OF THE MAJOR CAUSES OF DOWNTIME AND SERIOUS ENGINE DAMAGE. • WATER IN FUEL • CONTAMINATION IN FUEL • PLUGGED AIR FILTERS • IMPROPER OIL CHANGE INTERVALS REFER TO THIS MANUAL AND THE MACHINE’S OPERATOR’S AND/OR SERVICE MANUALS FOR PROPER MAINTENANCE INTERVALS AND PROCEDURES.

Tigercat

Tigercat FPT C87 Tier 2

INTRODUCTION

This manual is provided by Tigercat to assist the dealer, customer, and operator in becoming familiar with the safety, operation and maintenance of the Tigercat FPT C87 Tier 2 engine.

OPERATION AND MAINTENANCE

Only trained personnel should be allowed to work on this engine. The information contained in this manual is current at time of printing.

Tigercat reserves the right to make changes to the engine after the release date of this manual. Such changes will not be reflected in the manual until the next revision.

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

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

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.

47512AMUL

ISSUE 1.0, May, 2018

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Tigercat

Contents Battery safety.................................................................................................................................................................7 Component location diagrams................................................................................................................................14 CONTROLS AND MAINTENANCE.......................................................................................................................................18 ACCIDENT PREVENTION.................................................................................................................................................18 FLUID CAPACITIES.................................................................................................................................................... 20, 26 MAINTENANCE SCHEDULE............................................................................................................................................19 Replacement of alternator belt.....................................................................................................................32 replacement of CRANKCASE VENTILATION filter..........................................................................................30 Replacement of engine oil and filter............................................................................................................23 Replacement of fuel filter................................................................................................................................30 COOLING SYSTEM......................................................................................................................................................... 8, 17 electrical component locations...........................................................................................................................26 ENGINE IDENTIFICATION...................................................................................................................................................12 SERIAL NUMBER LOCATION...........................................................................................................................................12 engine oil chart.............................................................................................................................................................35 ENGINE TECHNICAL DATA..................................................................................................................................................13

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Tigercat ENGINE USE COLD START HEATER......................................................................................................................................................16 PRELIMINARY CHECKS...................................................................................................................................................16 STARTING AND STOPPING THE ENGINE.......................................................................................................................16 TO PREVENT ENGINE DAMAGE.....................................................................................................................................17 Fuel circuit............................................................................................................................................................... 17, 28 PRIMARY FUEL FILTER COMPONENTS.........................................................................................................................29 Fuel System diagram....................................................................................................................................................27 GENERAL INFORMATION......................................................................................................................................................5 IN CASE OF AN EMERGENCY............................................................................................................................................10 In case of fire..............................................................................................................................................................10 LUBRICATION CIRCUIT DIAGRAM.....................................................................................................................................21 MOVING THE ENGINE.........................................................................................................................................................32 OIL LEVEL CHECK...............................................................................................................................................................22 SAFETY PRECAUTIONS, GENERAL....................................................................................................................................7 SAFETY SYMBOLS................................................................................................................................................................6 SIGNAL WORDS.....................................................................................................................................................................6 3

Tigercat SPECIAL WARNINGS...........................................................................................................................................................17 Engine Coolant Level low......................................................................................................................................17 Engine Coolant Temperature High.....................................................................................................................17 Fuel Level low.............................................................................................................................................................28

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Tigercat GENERAL INFORMATION

Authorization by any other person is unacceptable.

NON-APPROVED FIELD PRODUCT CHANGES

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.

Unauthorized changes made of any kind to this Tigercat product could affect the product’s ability to perform as originally intended. The product’s integrity, 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.

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.

Official approval to make changes or install options is only to be undertaken as follows: i) The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat.

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.

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

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

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Tigercat SAFETY

SAFETY SYMBOLS

The following information is intended to encourage caution when using the engine, to avoid damage to persons or property as a result of improper or incorrect behavior.

The engines must only be used for the purposes indicated by the Manufacturer.

The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere.

When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

Any tampering, modification and use of non-original spare parts may compromise proper operation and safe use of the engine; never make modifications to the wiring or electrical components, or connect them to other power systems.

Understanding Signal Words

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

Pay particular attention to moving parts of the engine, to high temperature components and to circuits containing pressurized fluids. The exhaust fumes produced by the engine are bad for your health.

WARNING

The engine must be handled using suitable lifting equipment, making use of the lifting eyelets provided on the engine.

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

The engine must not be started up and used until the machine in which it is installed has satisfied all necessary safety requirements, or until the machine has been guaranteed to comply with local laws and regulations.

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

All repairs must only be carried out by persons of proven experience, equipment and tools considered suitable by Tigercat .

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Tigercat

SAFETY PRECAUTIONS 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.

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.

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

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

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

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

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

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Tigercat

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

WARNING

Shut off engine. Only remove coolant filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

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

WARNING Never use a liquid staring aid to start an engine.

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

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.

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Tigercat

WARNING

Conduct maintenance inspections at least as frequently as recommended in section 3 of the Machine Operators Manual.

Warning, HOT FLUIDS and hot machine surfaces can cause serious burns!

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

•

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

•

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

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

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Tigercat  IN CASE OF AN EMERGENCY

2. Do not attempt to remove pieces of clothing that may have stuck to the skin;

To ensure that the user is working in safe conditions, the instructions listed in this manual and on the engine labels must be followed, and any engine modifications must be authorized in writing by the Tigercat Engineering Manager.

Should improper use result in injury, seek first aid immediately.

3. In the case of scalding, immediately but carefully remove any clothing that may be soaked in the hot liquid; 4. Cover the burn with a special burn dressing or sterile bandage.

In an emergency situation, and while awaiting the arrival of first aid specialists, follow the instructions given below.

Carbon monoxide intoxication (CO) Carbon monoxide from the engine exhaust is odorless, and is dangerous because it is both toxic, and when combined with air it forms an explosive mixture.

Engine malfunctions In the event that an engine malfunctions, immediately lower all attachments to the ground, and shut off the engine.

In closed rooms, carbon monoxide is extremely dangerous, as it can reach critical concentrations within a very short time. When assisting a person who has been exposed in a closed room:

In case of fire Extinguish the fire using the proper fire-fighting equipment, and in the manner indicated by Fire prevention authorities (fire-fighting equipment for certain machines and equipment is compulsory under current safety legislation).

1. Ventilate the room immediately, to reduce the concentration of gas.

2. When entering the room, hold your breath, do not light flames, lights or ring electric doorbells or phones, to avoid the risk of explosion.

Burns and scalds 1. Extinguish any flames on the burned person’s clothing, by:

3. Carry the person out into the fresh air or into a well ventilated room, resting him on one side if he is unconscious.

-- throwing water over them; -- using a powder fire-extinguisher, without directing the jet at the person’s face; -- covering with blankets or rolling the victim on the ground.

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Tigercat Electrocution A. The engine’s 12 V or 24 V electrical system does not involve the risk of electrocution, however, in the event of a short-circuit caused, for example, by a metal tool, there is a risk of burning due to overheating of the object through which the electrical current runs. In these circumstances:

Prevent contaminated irrigation solution from running onto unaffected skin.

Remove contaminated clothes.

Special situations If contamination with metallic lithium, sodium, potassium, or magnesium has occurred, irrigation with water can result in a chemical reaction that causes burns to worsen. In these situations, the area should be covered with mineral oil and the metallic pieces should be removed with forceps and placed in mineral oil. If forceps are not available, soak the area with mineral oil and cover it with gauze soaked in mineral oil.

1. Remove the object that caused the short-circuit, using means that provide sufficient insulation.

2. Switch off the power at the main switch, if there is one.

Injuries and fractures The vast number of possible circumstances and the specific nature of operations required means that the intervention of a medical team is necessary.

If contamination with white phosphorus has occurred, thoroughly irrigate the area with water then cover the area with water-soaked gauze. Keep the area moist at all times.

The area can also be covered with petroleum jelly.

1. In the event of bleeding, keep the wound under compression 2. If there is any suspicion of a fracture, do not move the injured part and only move the patient if absolutely necessary.

If eye exposures have not been irrigated, then this should be started immediately. Immediate removal of caustic substances in the eye is critical

Caustic burns Caustic skin burns are caused by contact with extremely acidic or alkaline substances.

For electric maintenance technicians these are typically caused by acid from batteries. Prompt wound irrigation is the most critical aspect in limiting the extent of burns to the skin from exposure to caustic substances

If either battery acid, lubricants or diesel come into contact with the eyes: wash the eyes with water for at least 20 minutes, keeping the eyelids open so that the water flows over the eyeball (move the eye in all directions to wash more thoroughly).

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Tigercat ENGINE IDENTIFICATION The engine identification label is located on the top of the engine, beside the oil filler cap.

This label provides important information about the engine and should not be removed or modified without authorization from Tigercat.

See the following page for Technical Code.

The engine serial number is also stamped on side of the engine, below the exhaust manifold.

SERIAL NUMBER LOCATION

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Tigercat IMPORTANT! Any alteration of the above mentioned specifications are strictly prohibited, and will result in the product warranty policy and

ENGINE TECHNICAL DATA C87 The technical code and serial number are indicated on a plate, which is located on different parts of the engine, according to the model: flywheel casing, tappet cover, other.

the certification on the modified product becoming NULL and VOID.

C87 Engine family

F2C

Cycle

4-stroke diesel

Number of cylinders

6, in line

Bore x stroke

117 x 135 mm

(4.6 x 5.3 in.)

Total displacement

8,709 cm3

(531 in.3)

Air system

Turbocharged - aftercooled

Injection type Direct - high pressure pump supply and common rail system Engine direction of rotation

counterclockwise (seen from flywheel side)

Compression ratio

15.9 : 1

Cooling

Liquid

Dry weight

800 kg

Electrical system

24V

(1764 lbs)

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Tigercat 9

7

16

6 2 5

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Component location diagrams 1. Turbocharger 2. Lifting eyelet

2

3. Alternator 4. Crankshaft pulley

21

5. Oil supply to turbocharger 6. Oil cap

3

7. Electrical harness 8. Oil dipstick 9. Diesel fuel filter

12

10. Oil cooler 11. Damper

13

12. Drive belt

15

11

13. Belt tensioner

19

14. Oil filler neck

1

15. Engine air inlet 16. Turbo air outlet to air cooler

8 4

18

20

14

10

14

17. Engine air inlet from air cooler 18. Water pump 19. Oil filter 20. Oil drain plug 21. Thermostat housing

Tigercat 13

6

2

12

Component location diagrams 1

1. Turbocharger

2

2. Lifting eyelet 3. Alternator 4. Engine flywheel

5

5. Oil cap

11

6. Electrical harness 7. Fuel pump 8. Diesel fuel filter 3 10

7

9. Engine ECU 10. Engine air inlet from air cooler 11. Crankcase ventilation filter

8

12. Coolant outlet from engine

9

13. Turbo air outlet to air cooler

4

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Tigercat  ENGINE USE

STARTING AND STOPPING THE ENGINE The start-up and shut-down operations described below are for general information only. Tigercat vehicles have customized instrument panels, and these operations may vary according to the various machine models.

PRELIMINARY CHECKS Before starting the engine each time: Check all fluid levels (fuel, engine oil, and coolant), and top-up if necessary.

For detailed start-up/shut-down procedures, please refer to your machines Operator’s Manual.

Make sure that the air intake filter is not blocked or obstructed. Check the filter restriction indicator connected to the outlet side of the air filter. Service to the air filter is required when the indicator shows RED. If the engine is equipped with an air filter restriction sensor, a signal will be sent to the machine computer control system in the event of filter restriction.

Note: See section 3 of the machine operator’s or service manual for AIR FILTER MAINTENANCE.

CAUTION Make sure that no combustible vapours or gasses are present in the area in which the engine is to operate.

Ensure that closed areas are adequately ventilated and fitted with a suitable exhaust extraction system.

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

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

COLD START HEATER The engine is equipped with cold start heater, which is a heating grid that preheats the charge air as it enters the intake manifold. Preheating the intake air reduces start-up time, thereby reducing wear on the starter motor and battery.

WARNING

CAUTION Do not attempt to start engine by shorting across starter terminals, as personal injury could occur.

Start engine only from operator’s seat.

Do not use ether! Engine is equipped with an electric heater starting aid. Use of ether may cause an explosion and severe injury.

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Tigercat SPECIAL WARNINGS

TO PREVENT ENGINE DAMAGE Do not hold the key in the start position after the engine has

Engine Coolant Level low

started.

This message will be displayed, alarm light will flash and alarm will sound when the coolant level drops below a safe operating level.

It is not efficient to leave the engine running at minimum

speed while waiting for it to reach the proper working temperature; it is preferable that, after approximately three to five minutes from start-up, you gradually increase the engine load.

If this light comes on when the engine is running, stop the engine immediately and correct the fault.

Do not leave the engine running at minimum speed for long,

Refer to SERVICE AND LUBRICATION POINTS CHART in SECTION 3 of MACHINE OPERATOR’S MANUAL.

as this increases the production of harmful emissions and does not guarantee the best performance.

CAUTION

The engine speed must be increased and decreased

gradually, to allow regular combustion and proper operation of all engine components.

Explosive release of fluids from

pressurized cooling system can cause serious burns.

Shut off engine. Only remove coolant filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

The running speed and power values must comply

with the specifications on the technical and commercial documentation.

IMPORTANT! Allow a cold engine to warm up at LOW IDLE for 3 to 5 minutes before applying any load. Check all gauges often during the warm-up period.

Engine Coolant Temperature High This message will be displayed, alarm light will flash, and alarm will sound when engine temperature exceeds 225°F (107°C).

When this alarm is activated check for: • Plugged air intake access panel screens • Plugged radiator.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in MACHINE OPERATOR’S MANUAL.

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Tigercat

 CONTROLS AND MAINTENANCE

When working in the engine compartment, pay particular attention to how you move, to avoid contact with moving parts or high temperature components.

Wear goggles and use high pressure air nozzle to clean (maximum air pressure 200 kPa (2 bar, 30 psi, 2 kg/cm2).

Wear a protective helmet when working in an area were there are suspended loads or systems installed at headheight.

MAINTENANCE PERSONNEL The engine control and maintenance operations described in the following chapter require training, experience and compliance with current safety regulations; for this reason they must be carried out by special technicians, as indicated below.

Controls: by workshop technicians or the machine user if necessary.

Periodic maintenance: by qualified personnel using suitable equipment and adequate means of protection.

Special maintenance: by qualified personnel from Authorized Service Centres who have detailed technical information and specific equipment.

The most qualified Assistance Centres are Authorized Tigercat Dealers.

Use protective hand creams.

Immediately replace wet overalls and store cloths in flame-proof containers.

Always keep the engine clean, removing oil, grease and coolant stains.

Do not leave foreign bodies on the engine.

Use suitable, safe containers for used oil.

When completing a repair, make suitable provisions to stop the engine taking in air if, after start-up, an uncontrolled increase in engine speed were to occur.

ACCIDENT PREVENTION

Always wear heavy-duty footwear and overalls.

Never wear loose, flapping garments, rings, bracelets and/or necklaces in the vicinity of engines or moving parts.

Always wear protective gloves and goggles when: • filling up batteries with acid solution • refuelling with inhibitors or antifreeze • replacing or topping up lubricant (hot engine oil may cause burns and scalds. Only carry out these operations when the oil has dropped to a temperature of below 50°C (122°F).

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Tigercat MAINTENANCE SCHEDULE

Regular maintenance

Frequency

Visual engine check Daily Check for water in the fuel filter or pre-filter

Daily

Frequency

Replacement of engine oil and filter

250 hours

Replacement of pre-filter

250 hours (1)

Replacement of fuel filter

250 hours (1)

Replacement of crankcase ventilation filter (if equipped)

500 hours

Frequency

Check and adjustment of valve lash

2400 hours

1) Tigercat recommends using Tigercat approved Fuel Filters. Using a fuel filter that does not meet the manufacturer’s filtration and water separating requirements can severely impact fuel system life and reliability.

The maintenance intervals indicated below take into account the typical working factors for various types of engine use; the most suitable interval for maintenance operations for the various applications will be indicated by the maintenance staff, according to the way and working conditions in which the engine is used.

Planned maintenance

Special maintenance

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Tigercat FLUID CAPACITIES

WARNING

Parts to be supplied

Do not carry out maintenance operations when the electric power supply is turned on: always check to ensure that the appliances are properly grounded.

During diagnosis and maintenance operations, make sure that your hands and feet are dry, and whenever possible use insulating stands.

Cooling circuit (1) Lubrication circuit (2) total capacity (3) Periodic changing: oil sump at minimum level oil sump at maximum level Fuel tank (4)

litres

Gallons

refer to machine manual 28

7.4

19 24

5 6.3

model dependant

(*) The amounts indicated relate to the standard configuration of the engine only.

(1) Use a mixture of water and 60% Antifreeze even during the summer months. Antifreeze must comply with international specifications ASTM D-6210.

(2) Engine oil must be CJ-4 certified. The viscosity level of oil to be used depending on surrounding temperatures in given in the table provided in the appendix. Oil consumption is considered acceptable until it reaches a maximum of 0.5% of fuel consumption (3) The amounts indicated refer to initial filling, and include filling the engine, sump and filter.

(4) Engines are designed and warranted for optimum operation with mixtures of diesel and biodiesel up to 7%. No fuel additive are required. Any use of fuel additive must be approved by Tigercat.

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Tigercat LUBRICATION CIRCUIT DIAGRAM

3

2

5 6

Dropping oil Pressure oil 4

Oil introduction CUR-015

21

1

Tigercat Remove the Oil Dipstick and ensure that the oil level is between the “MIN” and “MAX” lines.

Lubrication circuit The Lubrication circuit consists of the following components (see previous page);

MIN

Rotary oil pump (1), housed in the rear of the crankcase,

operated by the straight toothed gear on the crankshaft tang.

MAX

If the oil level is low,

Water/oil heat exchanger (2), housed in the side of the engine block.

Fill the engine with clean oil. (See the Oil Viscosity Chart in the back on this manual.)

Oil overpressure valve (3), built in to the oil pump.

Oil pressure regulation valve (4), located on the left hand

Check the level on the dipstick periodically while filling, do not fill past the “MAX” fill line.

side of the crankcase.

By-pass valve (5) for excluding the filter if blocked, built into

Start the engine and let run for 2 to 3 minutes then shut off the engine.

Oil filter cartridge (6).

Check the oil level on the dipstick. (Once the oil has filled the new filter, it may be necessary to top up to reach the “MAX” line on the dipstick.)

the filter mount.

OIL LEVEL CHECK

Use only the recommended oil for your climate. See oil viscosity chart in this manual.

IMPORTANT! Checking the oil level should be done only with the engine stopped and at operating temperature.

When topping up, don’t mix oils having different viscosities.

Park the machine on level ground so that the engine is in the normal operating position.

Failure to follow these rules may void your warranty.

Wait approximately 10 minutes after shutting off the engine to allow the oil to drain into the oil pan.

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Tigercat Replacement of engine oil and filter

Whenever you replace the engine oil, it is also necessary to replace the oil filter.

The engine oil and filters should be changed at regular intervals. See the Planned Maintenance chart for frequency of oil and filter changes.

Start engine and run until warm.

Shut off engine.

Remove the plug at the bottom of the filter housing.

Unscrew the filter cartridge housing a few turns using a 1-7/8 inch wrench and allow any remaining oil to drain from the housing.

Place an oil collection container under the oil pan, directly beneath the oil drain plug. (Ensure that the container will hold approx. 24 litres / 6 ½ gallons)

Remove the filter housing and replace the filter element, making sure that it is properly seated in the housing.

Tabs on the top of the element should align with notches in the housing.

Unscrew the oil drain plug, take out the oil level dipstick and remove the fill cap to ease the down flow of the engine oil.

DO NOT PRE-FILL THE NEW FILTER. Install the new filter housing by turning it manually until the o-ring is in contact with the filter head.

Once the oil has been drained, replace the drain plug.

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Tigercat Further tighten to a torque of approx. 48 lbf-ft (65 Nm).

Install the drain plug in the bottom of the filter housing.

Fill the engine with clean oil. (See the Oil Viscosity Chart in the back on this manual.)

Check the level on the dipstick periodically while filling, do not fill past the “MAX” fill line.

MIN

Lubrication circuit warning A message will be displayed, warning light will flash and alarm will sound when engine oil pressure falls below 10 psi (0.7 bar).

Stop the engine when this alarm is activated. Check engine oil levels.

Refer to STARTING AND STOPPING THE ENGINE for more information.

MAX

See the Oil viscosity grade in relation to ambient temperature chart in the back of this manual.

Start the engine and let run for 2 to 3 minutes, then shut off engine. Check the oil level on the dipstick. (Once the oil has filled the new filter, it may be necessary to top up to reach the “MAX” line on the dipstick.)

Use only the recommended oil for your climate. See Oil Viscosity Chart in this manual.

When topping up, do not mix oils having different viscosities.

See FLUID CAPACITIES in this manual for oil specifications.

WARNING Used motor oil is a pollutant and can be harmful.

In case of contact with the skin, wash with soap and water.

Protect properly skin and eyes: operate according to safety rules.

Dispose of the used oil properly. See DISPOSAL OF WASTE in this manual.

Failure to follow these rules may void your warranty.

24

Tigercat Air intake and exhaust gas circuits

Electrical starter system

Air Filter

Periodically check, particularly during the winter, to ensure that the batteries are clean and in full working order. If battery replacement is necessary, be sure that the replacement battery has the same capacity and specifications as the one being replaced.

Inspect the cleanliness of the air intake circuit on a regular basis. See the machine operator’s manual for maintenance procedures and filter replacement intervals.

RUNNING IN

Turbocharger

Thanks to modern engine construction technology, no particular break in procedure is required. However, it is recommended that, for the first 50 hours, you do not use the engine at high power for long periods.

The turbocharger should be inspected regularly for signs of damage. Failure of the turbocharger during engine operation, could result in serious engine and after treatment damage.

CAUTION Do not attempt to start engine by shorting across starter terminals, as personal injury could occur.

Start engine only from operator’s seat.

25

Tigercat ELECTRICAL COMPONENT LOCATIONS ELECTRICAL COMPONENTS A. Fuel temperature sensor B. Camshaft timing sensor C. Starter motor D. EDC electronic control unit E. A/C compressor F. Oil temperature/pressure sensor G. Air temperature/pressure sensor H. Alternator I. Resistor for engine preheating L. Connector on engine head for electro-injectors M. Water temperature sensor N. Flywheel engine speed sensors O. Fuel control valve on high pressure pump Sensor connector

Chassis connector D

Chassis connector

Sensor connector

26

Tigercat Fuel System diagram COMMON RAIL

PRESSURE SENSOR

FUEL FILTER INJECTOR HEAT EXCHANGER

FUEL PUMP

FUEL /WATER SEPARATOR

27

Tigercat Fuel circuit

Low temperature diesel

Avoid using the engine with only a small reserve of fuel in the fuel tank; this encourages the formation of condensation and makes it more likely you will suck up dirt or air, resulting in engine stoppage.

D

The common rail injection system does not require air to be bled from the fuel circuit.

Fuel Level low A sending unit is installed and connected to the computer display on the instrument panel. This message will be displayed when the fuel level falls below 5% of full.

CAUTION Never loosen the high pressure fuel circuit connectors in any way.

Refer to FUEL TANK in MACHINE OPERATOR’S MANUAL for tank capacities.

RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL

REFUELLING

1. If the engine has run out of fuel the fuel line must be primed.

CAUTION When refuelling, always pay great care to ensure that no solid or liquid contaminants enter the fuel tank; you must also remember that smoking and open flames are prohibited when refuelling.

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

4. Bleed the system according to the MACHINE OPERATOR’S MANUAL.

IMPORTANT! Refuelling from drums or tanks may result in contamination of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.

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

28

Tigercat CHECK FOR WATER IN FUEL FILTER/WATER SEPARATOR

PRIMARY FUEL FILTER COMPONENTS TEMPERATURE SENSOR

The high risk of refuelling with fuel that is polluted by foreign bodies and water makes it advisable to carry out this control every time you refuel.

FILTER HEAD

Only proceed with the engine stopped.

FOR PROCEDURE ON CHECKING AND CHANGING THE SECONDARY FUEL FILTER/WATER SEPARATOR, PLEASE REFER TO YOUR MACHINE’S OPERATOR’S MANUAL. Note: The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel.

WARNING Drain fuel filter into a container and dispose of all fluids properly.

FILTER IMPORTANT !

Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced according to the MAINTENANCE SCHEDULE in this manual.

29

Tigercat Further tighten to a torque of approx. 25 lbf-ft (34 Nm) either by hand or with a filter wrench.

Replacement of fuel filter Place a container under the fuel filter and drain the fuel by loosening the drain plug.

WARNING

Unscrew the filter cartridge housing using a 2 inch wrench and remove the o-ring

During this operation don’t smoke or use open flames.

Avoid inhaling the vapors coming from the filter.

Replace the filter element, making sure that the o-ring is properly seated in it`s groove.

Inspection/replacement of CRANKCASE VENTILATION filter (IF EQUIPPED)

Clean the surface of the filter head in contact with the filter housing.

The crankcase ventilation filter is designed to collect and filter the lubricating oil vapors.

Only proceed with the engine stopped and at a low temperature, to avoid the risk of burning.

Apply a thin layer of oil to the filter housing o-ring.

Install the new filter housing by turning it manually until the o-ring is in contact with the filter head. Do not prefill the new filter.

Breather cover

filter element

fuel filter housing

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Tigercat Remove the 3 bolts which fasten the breather to the engine and remove the assembly.

Remove the timing gear cover (1) by removing the 6 bolts (2). Once the cover is removed, you will have access to the centrifugal filter (3).

Breather

Clean the surface of the crankcase ventilation housing, as well as it’s location on the engine by removing any oil residue or impurities.

Inspect the diaphragm located inside the breather cover for any cracks or tears from usage.

Re-install the breather, including the seal, to the engine using the 3 lock screws.

Unscrew the 3 bolts and remove the centrifugal filter Install the new centrifugal filter and replace the 3 bolts holding it to the tune wheel.

Re-install the timing cover.

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Tigercat Replacement of alternator belt

Take note of the serpentine belt path. Remove worn belt.

Before installing the new belt, inspect the tensioner for damage and ensure that it rotates freely.

Place the new belt on the pulleys and guide rollers in the same path as the old belt.

2

Release the tensioner to apply tension to the new belt.

Refer to machine manual for proper belt routing.

1

All belts should be inspected periodically for signs of incision, cracks, excessive wear in grooves, and signs of end or surface grinding.

Drive belt tensioning is controlled by the automatic tensioner, therefore checking belt tension is not required.

WARNING With motor switched off (but still hot) the belt can operate without advance notice.

Wait for the motor to cool to avoid serious accidents.

Insert a 1/2” drive socket wrench into the belt tensioner Rotate the tensioner away from the belt to relieve tension.

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Tigercat After engine start and while engine is running, proceed with the following checks and controls:

WHEN PERFORMING ENGINE MAINTENANCE: 1. Do not disconnect the batteries with the engine running.

Check presence of any leakage from the fuel, cooling, and lubricating circuits.

2. Do not carry out arc welding operations in the vicinity of the engine without first removing electrical cables.

Verify absence of noise or unusual rattle while engine is working.

3. After each maintenance operation involving disconnection of the battery/batteries, make sure that the terminals have been properly locked onto the poles.

Verify, using the machine’s gauges/display, the correct pressure, temperature, and other parameters.

4. Do not use battery chargers to start the engine.

Visual check of fumes (colour of exhaust emissions)

5. Disconnect the battery/batteries when recharging.

Visual check of cooling liquid level, in the expansion tank.

6. Do not paint the appliances, components and electrical connectors equipping the engine.

IMPORTANT! Do not execute any operation which may change the ignition pump’s calibration.

The ignition pump’s calibration has been completed as part of the engine system test, based on its final use or destination.

7. Disconnect the battery/batteries before any electrical operations.

8. Contact the Manufacturer before installing electronic equipment on board (two-way radios and the like).

HOW TO PROCEED -

WARNING

Visual engine check

The motor oil reaches very high temperatures, always wear protective gloves.

Avoid direct contact of hot oil with your skin.

Before starting the engine, it is a good habit to perform a series of simple checks to ensure the engine will run properly, and to prevent problems from arising . Such checks are usually up to the machine’s operators

Level controls and check for any leakage from the fuel, cooling, and lubricating circuits.

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Tigercat

ENGINE MALFUNCTIONS

MOVING THE ENGINE Removing and re-installing the engine must only be carried out by qualified technicians from Service Centres.

The vehicle is equipped with a sophisticated onboard diagnostic system. This system monitors the performance of engine and emissions. If any of these systems require service, the computer display will show and store the diagnostic codes and other information to assist your authorized service technician in making repairs. Depending on the severity of the diagnostic codes a limitation of engine speed and performance can occur, contact your authorized Tigercat dealer for service as soon as possible.

When lifting the engine, only use the lifting lugs indicated in this manual in the section ENGINE TECHNICAL DATA Lifting must be carried out using a rocker arm that keeps the metal cables supporting the engine parallel, using all the lifting lugs provided simultaneously; the use of a single lifting lug only is not allowed. The engine lifting system must have a capacity and size suited to the weight and dimensions of the engine; check that there is no interference between the lifting system and the engine components. Do not lift the engine before removing the transmission members that are coupled to it.

CAUTION The engine electronic control unit can adopt safety strategies at any time during use of the machine, should conditions arise that are considered to put the engine at risk.

When conditions of this kind occur, proceed only if necessary and with the greatest possible care and attention.

DISPOSAL OF WASTE The hazardous materials listed below must be taken to specialized Collection Centres; the laws in force in various Countries foresee severe penalties for offenders: Starter batteries.

Used lubricants.

Mixtures of water and antifreeze Filters.

Additional cleaning materials (e.g. greasy or fuel-soaked

CAUTION Do not leave machines with the engine running, without first ensuring that the parking brake is on.

cloths).

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Tigercat engine oil chart

Engine Oil Ambient Temperature Limits 0W-40 CJ-4 10W-40 CJ-4 15W-40 CJ-4 -40°C -40°F

-30°C -22°F

-20°C -4°F

-10°C 14°F

0°C 32°F

10°C 50°F

20°C 68°F

30°C 86°F

40°C 104°F

50°C 122°F

- ENGINE BLOCK HEATER AND WEBASTO COOLANT HEATER REQUIRED IN THIS RANGE 35

Tigercat

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