Tigercat H250D PROCESSOR OPERATOR'S MANUAL - PDF DOWNLOAD

H250D PROCESSOR

OPERATOR'S MANUAL

SERIAL NUMBER 250H3001 – 250H3500

ISSUE 1.0, APRIL 2021 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat H250D Processor TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v MACHINE IDENTIFICATION AND SERIAL NUMBERS..................................................................................... vi STANDARDS FOR MACHINE OPERATOR PROTECTIVE STRUCTURES.....................................................vii NON-APPROVED FIELD PRODUCT CHANGES.............................................................................................viii REGULATORY INFORMATION.......................................................................................................................... ix WARRANTY – EPA............................................................................................................................................... x SAFETY...............................................................................................................................................................1 CONTROLS AND OPERATION...........................................................................................................................2 LUBRICATION AND MAINTENANCE.................................................................................................................3

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

H250D Available Literature Operator's Manual, English (this manual).......................................................................................Part No. 66005AENG Service Manual English ..................................................................................................................Part No. 66006AENG Parts Catalog...................................................................................................................................Part No. 51068A Vehicle Moving and Transporting Instructions.................................................................................Part No. 47882AMUL Engine Operation and Maintenance Manual N67 T2......................................................................Part No. 45045AMUL Engine Operation and Maintenance Manual N67 T4f.....................................................................Part No. 42939AMUL iii

iv

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

Tigercat H250D Processor INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the H250D Processor.

Serial numbers: H250D: 250H3001–250H3500 The H250D Processor is designed for at-the-stump processing or roadside processing applications as well as thinning, selective felling and clear felling applications in plantations and natural stands.

The operator's manual will assist the operator with the techniques of proper and safe operation of the H250D Processor. There is also important information regarding the safe operation of the attachment. The service manual contains safety and servicing procedures and a preventive maintenance schedule to assist in repair and to ensure optimum machine performance.

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

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

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

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.

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

All product or company names that may be mentioned in this publication are trade names, trademarks or registered trademarks of their respective owners.

Tigercat Industries Inc.

v

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

Introduction

Tigercat H250D Processor

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

200124

Engine Identification Label Location

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

200121

Machine Serial Number Plate Location– Cab

Engine Date of Manufacture:_______________________

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

200123

Engine Serial Number Plate Location 200122

Machine Serial Number Stamp Location– Upper Frame

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

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

Engine Serial Number:___________________________

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

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

Tigercat H250D Processor

Introduction

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

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

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

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

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

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

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

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

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

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

Tigercat Industries Inc.

vii

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

Introduction

Tigercat H250D Processor

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

It is Tigercat policy that no changes are to be made to its products including deletions or additions other than a Tigercat approved option fitted in the factory approved manner.

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

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

Authorization by any other person is unacceptable.

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

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

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

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

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

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

Tigercat Industries Inc.

viii

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

Tigercat H250D Processor

Introduction

REGULATORY INFORMATION The machine is equipped with standard or optional equipment that is capable of emitting radio frequency fields.

Bluetooth and Wi-Fi exposure limits are significantly less than the maximum permitted for public use.

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

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

Contains FCC ID: VPYLB1CL or NCMOCG2101

IQAN-G11 (Bluetooth)

Contains FCC ID: VPYLBZY

Radio (Bluetooth)

Contains FCC ID: OPDJHD36A

Radio (Bluetooth)

Contains FCC ID: OPDJHD1635BT

Radio (Bluetooth)

Contains FCC ID: OPDJHD3630BT

EXTERNAL: Inmarsat Modem (Satellite)

Contains FCC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains FCC ID: Q639603N

Transmitter (Light fob, not part of the machine)

Contains FCC ID: K4E939T4G

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

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

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

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

Contains IC ID: 772C – LB1CL or NCMOCG2101

IQAN-G11 (Bluetooth)

Contains IC ID: VPYLBZY

EXTERNAL: Inmarsat Modem (Satellite)

Contains IC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains IC ID: Q639603N

Transmitter (Light fob, not part of the machine) Contains IC ID: 23770-K939T4GNUQ These devices comply with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

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

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

Introduction

Tigercat H250D Processor

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

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

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

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

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

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

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

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

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

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

• PCV valve • Oil fill cap

x

Tigercat H250D Processor

Introduction

Exhaust after treatment Devices (if applicable)

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

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

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

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

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

• Items replaced due to customer demand.

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

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

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

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

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

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

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

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

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

• Unauthorized modification or updating machines without a warrantable failure.

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

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

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

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

5363-5378-E 0420

xi

Introduction

Tigercat H250D Processor

xii

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

Tigercat H250D Processor SECTION 1 – SAFETY Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 1

ISSUE 1.0, APRIL 2021

A

AVOID INJURY FROM BACKOVER ACCIDENTS................................................................................................... 1.9

B

BATTERY DISCONNECT SWITCH......................................................................................................................... 1.14 BATTERY SAFETY...................................................................................................................................................... 1.8

C

CAB EXITS................................................................................................................................................................. 1.11 PILOT INTERLOCK SWITCH – LEFT ARMREST................................................................................................ 1.11 COOLING SYSTEM.................................................................................................................................................. 1.15

D

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

E

EXHAUST FUMES.................................................................................................................................................... 1.16

F

FIRE PREVENTION.................................................................................................................................................. 1.26 AFTER A MACHINE FIRE...................................................................................................................................... 1.28 DRY CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.29 FIRE PREVENTION GUIDELINES....................................................................................................................... 1.26 HOW TO PREPARE FOR A MACHINE FIRE....................................................................................................... 1.27 IN CASE OF A MACHINE FIRE............................................................................................................................. 1.27 WET CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.29 FLUID INJECTION INJURY...................................................................................................................................... 1.21

G

GENERAL SAFETY PRECAUTIONS........................................................................................................................ 1.4 GREASE INJECTION INJURY................................................................................................................................. 1.22

H

HAZARD ZONE................................................................................................................................................... 1.4, 1.5

L

LIGHTNING SAFETY AWARENESS....................................................................................................................... 1.23 LIGHTNING SAFETY............................................................................................................................................. 1.23 WHAT IS A LIGHTNING STRIKE?........................................................................................................................ 1.23 LOOSE CLOTHING HAZARD.................................................................................................................................. 1.16

N

NOTICE LABELS....................................................................................................................................................... 1.38

O

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

P

PARKING THE MACHINE......................................................................................................................................... 1.13 PILOT INTERLOCK SWITCH – LEFT ARMREST.................................................................................................... 1.11 PROCESSING........................................................................................................................................................... 1.19 PROTECTIVE CLOTHING.......................................................................................................................................... 1.4

S

SAFETY HAZARDS OPERATING............................................................................................................................................................. 1.8 VITON SEALS.......................................................................................................................................................... 1.7

Safety

Tigercat H250D Processor

SAFETY LABELS...................................................................................................................................................... 1.30 SAFETY PRECAUTIONS GENERAL................................................................................................................................................................. 1.4 SERVICING............................................................................................................................................................ 1.14 SAFETY SIGNAL WORDS.......................................................................................................................................... 1.3 SAFETY SYMBOLS..................................................................................................................................................... 1.3 SERVICING SAFETY PRECAUTIONS.................................................................................................................... 1.14 W

WELDING, PRIOR TO............................................................................................................................................... 1.17 WORKING WITH OIL.................................................................................................................................................. 1.7

1.2

Tigercat H250D Processor

Safety

SAFETY SYMBOLS

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

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

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

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

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

1.3

Safety

Tigercat H250D Processor

GENERAL SAFETY PRECAUTIONS

WARNING

WARNING 24 VOLT ELECTRICAL SYSTEM Safety is a prime responsibility of all.

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

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

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

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

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

HAZARD ZONE

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

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

• 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.

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

1.4

Tigercat H250D Processor

Safety

The following diagram illustrates the HAZARD ZONE. All personnel must be kept clear of this zone while the processing head is operating.

150 M (500 FT)

150 M (500 FT)

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

150 M (500 FT)

WARNING 150 M (500 FT)

822D-117

Hazard Zone

• All personnel should be made AWARE of the HAZARD ZONE and be kept clear of this zone and it should be considered off limits to all individuals while the machine is operating.

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

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

• When approaching an operating machine on foot, stay at least 150 m (500 ft) away until the operator recognizes your presence. All processing equipment must be shut down before advancing to the machine.

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

NOTE: Raising the left armrest will stop machine functions. Opening the cab door will not stop machine functions.

Do not walk on angled steel or irregular shaped surfaces.

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

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

• Do not jump off the machine at any time.

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

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

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

• Do not use the machine foot controls as steps.

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.

1.5

Safety

Tigercat H250D Processor

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

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

• Wash machine completely at every major service.

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

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

• Check windows and door guards for damage.

• Check protective windows for cracks. A damaged window has reduced strength to stop flying objects.

All damaged windows must be replaced with original equipment.

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

• 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 machine at all times.

1.6

Tigercat H250D Processor

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.

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

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

• Visually inspect any seals or gaskets which have suffered from heat damage. They will appear black and sticky. If these are found, DO NOT TOUCH!

• Don't put oily rags in your pockets.

• Change oil soiled clothing as soon as possible.

• 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.

• 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.

• 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 H250D Processor

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

• Do not carry passengers either in the cab or anywhere else on the machine. The machine is provided and approved with seating for the operator only.

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

Contact with hot surfaces may cause injury.

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

• When moving the machine, there must be enough clearance 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.

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

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

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

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

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

• 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.

• 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 H250D Processor

Safety AVOID INJURY FROM BACKOVER ACCIDENTS

CAUTION

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

• Be alert for bystanders moving into the work area.

Use the horn to warn bystanders before moving the machine.

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.

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

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

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

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

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

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

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

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

• Before servicing the machine, turn OFF the battery disconnect switch and remove the negative (−) battery terminal cable (to the starter motor) from the battery.

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

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

Serious burns or an explosion can result.

1.9

Safety

Tigercat H250D Processor

OPERATING SAFETY PRECAUTIONS

FOR TIER 4F MACHINES ONLY

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

41581AUNI R0

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

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

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

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.

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

• Sound the machine horn before starting the machine.

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

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

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

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

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

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.

1.10

Tigercat H250D Processor CAB EXITS

Safety PILOT INTERLOCK SWITCH – LEFT ARMREST

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

A

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

LEFT SIDE DOOR This is the main point of entry used under normal operating conditions to enter or leave the cab. This door is not equipped with a safety interlock switch and if left open will not deactivate the pilot system. The left armrest is equipped with a safety interlock switch that prevents machine operation when the armrest is raised. Refer to PILOT INTERLOCK SWITCH – LEFT ARMREST in THIS SECTION for more details. Turn OFF the engine and raise the left armrest before using the side door exit.

234-089

A Pilot Interlock Switch in OFF Position – Left Armrest UP

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

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

IMPORTANT! Machine operators must be thoroughly familiar with these exits and their use.

A 200411

All operators should practice using all the cab exits to become familiar with escape procedures in the dark, when the machine is rolled over, or other possible emergencies.

IMPORTANT! Unlock the cab door before operating the machine. Test the latches from the inside and the outside to verify the door can be opened in case of emergency. Keep the door unlocked while operating the machine.

For additional information, refer to EMERGENCY EXITS in SECTION 3.

C

B

Check all exits regularly to verify they are operational and will function properly in an emergency.

200501

200469

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

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

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

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

1.11

Safety

Tigercat H250D Processor CAUTION WARNING

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

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

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

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

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

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

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

• Do not use the boom to service other equipment.

WARNING

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

• Use only prearranged and approved signalling practices.

• Do not modify the boom system.

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

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

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

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

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

It is the duty of the operator to ensure that no person approach the machine while in use.

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

• Secure loose items in the cab.

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

• 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.

• Do not work alone. Regularly inform other crew members of your intentions, location and length of time to perform duties.

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

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

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

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

1.12

Tigercat H250D Processor

Safety

PARKING THE MACHINE

A

B

201033

201034

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

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

Before leaving the cab for any reason, lower the attachment onto the ground.

Perform the following steps when parking the machine:

Battery Disconnect Switch – Front Engine Compartment

A OFF Position (Switch Open) B ON Position (Switch Closed)

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

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

A

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

B

The aftertreatment system and its related components are applicable to Tier 4f machines only. Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

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.

D

C

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

Improperly secured doors or panels pose a serious danger to pedestrians and other vehicles.

200175

A B C D

Parking the Boom

Hoist Cylinder Lowered Stick Cylinder Extended Attachment in Parked Position Tilt Locks in Position on Both Sides

1. Park on level ground with the attachment tilted forward and locked in position with the wheel arms open and the knife arms closed.

2. Apply the swing brake.

3. Turn OFF the engine.

4. Remove the ignition key.

1.13

Safety

Tigercat H250D Processor

SERVICING SAFETY PRECAUTIONS

LOCKOUT TAGOUT

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

C

D

B

A

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

M00068

A B C D

• Install a DO NOT START ENGINE sign on the control 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

201033

201034

Battery Disconnect Switch – ON Position Battery Disconnect Switch – OFF Position Lockout Hasp Padlock

• 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.

• 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).

Battery Disconnect Switch – Front Engine Compartment

A OFF Position (Switch Open) B ON Position (Switch Closed)

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

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

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

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

1.14

Tigercat H250D Processor

Safety

WARNING

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

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

• Lower the attachment to the ground, turn OFF the engine and relieve trapped pressure from pilot system and brake accumulators before performing work on components, or disconnecting any hoses.

For information on relieving pressure, refer to PARKING THE MACHINE in THIS SECTION.

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

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

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

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.

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

• 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.

• Fluid leaks, under pressure, may not be visible.

When searching for leaks, wear work gloves and use a wrench or piece of wood to move hydraulic hoses.

Do not grab hold of hydraulic hoses. Wear safety goggles for eye protection.

1.15

Safety

Tigercat H250D Processor WARNING Follow the instructions and safety warnings provided by the attachment manufacturer before approaching the attachment to make adjustments.

WARNING

• 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.

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

• 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.

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

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

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

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

• When performing required hydraulic checks and blade speed adjustments, install the saw blade guard. Refer to the ATTACHMENT MANUFACTURER'S DOCUMENTATION.

• 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.

1.16

Tigercat H250D Processor

Safety

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.

A

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.

234B-278

4. Turn OFF the battery disconnect switch.

5. Open the rear access door and disconnect the negative battery cable from the negative battery terminal. Refer to BATTERY BOOSTING in SECTION 2.

A XA2-A1 Module Multi-pin connector

8. Disconnect the multi-pin connector from the XA2-A1 expansion module (mounted on same plate as the XA2-A0 but in engine compartment).

The following steps protect the sensitive electronics on the machine:

A

234-108

A XC21-A2 Expansion Module A

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

630E-259

A ECU Multi-pin Connectors

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

A

A 234E-271

A XA2-A0 Module Multi-pin Connector

7. Disconnect the multi-pin connector from XA2-A0 expansion module (under platform in valve compartment).

A Computer Cover Fasteners – One Top (not shown)/Two Bottom

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

1.17

Safety

Tigercat H250D Processor

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

A

B

250D-064

A NOx Sensor (Obscured) B NH3 Sensor

11. Disconnect both the NH3 and the outlet NOx sensors mounted on a bracket next to the radiator on the left side of the engine compartment.

A

250D-066

A Inlet NOx Sensor Connector

12. Disconnect the inlet NOx sensor mounted above the vacuum pump at the back of the hydraulic oil tank.

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 switch.

1.18

Tigercat H250D Processor

Safety

PROCESSING

WARNING

GENERAL SAFETY PRECAUTIONS

If someone enters into the hazard zone, release trees from the processing head, place the processing head on the ground, and shut the pilot system off.

Improper operation, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any maintenance or repair of this product until you have read and understood the operation and repair information contained in the manuals provided by the processing head manufacturer.

• Lower the processing head to the ground and turn pilot system off when machine is not in use.

The following are general safety guidelines for processing attachments. Note the design, operation and maintenance of attachments varies among manufacturers. Follow the specific safety, maintenance and operating procedures provided by the processing head manufacturer.

• Fell trees in the direction they are leaning.

• Do not fell trees close to overhead power lines, vehicles, houses, roads/pathways, etc.

• Do not allow anyone within the hazard zone of 150 m (500 ft) from the machine during operation.

The operator of the machine and processing head must be properly trained in the operation of the equipment and its safety requirements.

OPERATING SAFETY PRECAUTIONS Felling trees with the processing head is very dangerous and must be done only by properly trained and experienced operators.

• Do not fell trees when there are personnel on the ground within the 150 m (500 ft) hazard zone.

• Do not fell trees in the direction of the operator’s cab.

WARNING Avoid the risk of chain shot. Do not operate the processing head so the saw bar is directly in line with the cab or any personnel!

PRIOR TO STARTING OPERATION

WARNING

• Do not process trees with the saw guide (bar) aligned with the operator’s cab. The hydraulically driven saw chain reaches high speeds and is an extreme hazard if the chain breaks.

The processing head may release held trees when the left armrest is moved to the raised position (the pilot system is turned OFF). Do not exit the cab with a tree suspended in the processing head.

• Operate so the chip discharge area of the processing head is not directed at people, livestock, houses, buildings, roads or other machines.

• Be particularly observant with the zone in line with the chain saw.

• Verify that no personnel is near the machine where the risk of personal injury is present.

WARNING

• Verify that no personnel is in the line of the chain saw when starting or operating the processing head. The hydraulically driven saw chain reaches high speeds and is an extreme hazard if the chain breaks.

• Regularly inspect, check and maintain the saw guide (bar), the saw chain and sprocket, ensuring that all components are secure and not damaged as detailed in the processing head operator’s manual.

• THROWN OBJECTS HAZARD. • KEEP CLEAR AS HIGH SPEED EJECTION OF CHAIN SAW PARTS CAN CAUSE SERIOUS INJURY OR DEATH.

• Verify that all safety equipment upgrades available from the processing head manufacturer have been installed.

• NEVER POSITION HEAD SO THAT CHAIN SAW BARS ARE IN LINE WITH ANY BYSTANDERS, OTHER MACHINES OR CAB.

• Before starting each shift, test ALL functions of the machine and processing head to verify they are in proper working order.

29921A R1

1.19

Safety

Tigercat H250D Processor

SERVICING SAFETY PRECAUTIONS

• Do not change the pressure settings of any hydraulic valves or make structural modifications to the processing head without obtaining authorized instructions from the processing head manufacturer.

Before beginning any service work on the processing head, place the machine on level ground, place the processing head on the ground and properly support the boom.

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

• Do not use the boom to service other equipment.

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

• Do not modify the boom system.

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

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

A

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

B 200130

Parking the Boom

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

A Stick Boom Positioned with Tip of Boom Pointed Down B Tip of Stick Boom Fully Supported

Stop the machine engine and turn the battery disconnect switch to the OFF position. Install any safety chains or locking parts required by the processing head manufacturer. Ensure that any accumulators on the processing head are completely relieved of hydraulic pressure. Follow the specific safety, maintenance, and operating procedures provided in the ATTACHMENT MANUFACTURER'S DOCUMENTATION.

• Do not use this machine to clear a logging deck on a new tract of timber when the rest of the equipment and operators are also moving in. Pre-plan to clear decks in advance before other equipment arrives.

• Do not work alone. Regularly inform other crew members of your intentions, location and length of time to perform duties.

• Stop the attachment before leaving the cutting area.

• Do not place any part of your body between the drive wheel arms or delimbing arms. This area is a crush zone. Keep clear to avoid personal injury or death.

• Do not place any part of your body near the drive wheels. Avoid the risk of entanglement in moving parts. Keep clear to avoid personal injury or death.

• Do not place any part of your body in front of the saw guide (bar). Avoid the risk of dismemberment.

Keep clear to avoid personal injury or death.

• When working in the area of the drive wheel arms, delimbing arms, or drive wheels and when changing the saw guide (bar) or saw chain the machine must be completely shut down, with the battery disconnect switch to the OFF position.

1.20

Tigercat H250D Processor

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

Hydraulic and diesel fuel systems on forestry machines operate at very high pressures, often 207 bar (3000 psi) and above. If a loose connection or a defect in a hose occurs, a fine, high velocity stream of fluid will result.

Even for systems pressurized to as little as 7 bar (100 psi), this fluid stream can penetrate human skin as if it were a hypodermic needle.

Safety IN THE EVENT OF ANY SUSPECTED FLUID INJECTION INJURY • REPORT THE INJURY TO YOUR SUPERVISOR IMMEDIATELY. • SEEK PROFESSIONAL MEDICAL ATTENTION IMMEDIATELY. The best defence against suffering the effects of fluid injection is to prevent the accident from occurring in the first place.

SEARCHING FOR POSSIBLE FLUID LEAKS: • Do not search for leaks with your bare hands. Wear thick protective gloves.

• Wear safety goggles for eye protection.

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

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation. There is a danger that you will tend to ignore this, thinking that it will get better with time. Most often, it does not! Within a very short time the wound may begin to throb painfully, indicating that tissue damage has already begun.

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

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

• Place the end of a long piece of wood in the suspected path of any fluid stream. Do not use any part of your body.

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

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

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

WHEN PERFORMING ANY SERVICE WORK • Stop the engine and relieve all diesel fuel or hydraulic pressure before disconnecting any lines or otherwise working on the system.

• Do not grab any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

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

• Do not use any hoses that you suspect could be defective.

1.21

Safety

Tigercat H250D Processor

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

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

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

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

Prior to using a high pressure pneumatic grease gun, perform the following: • All operators of high pressure pneumatic grease guns MUST be trained in the hazards of its operations and the treatment for such injuries.

• Do not operate a high pressure pneumatic grease gun unless you have been trained in the proper operation and are aware of all safety precautions of such a tool.

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

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

• Install protective shrouds on all grease gun nozzles as safety devices.

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

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

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

1.22

Tigercat H250D Processor

Safety

LIGHTNING SAFETY AWARENESS

LIGHTNING SAFETY

WHAT IS A LIGHTNING STRIKE?

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

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

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

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

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

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

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

• 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.

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

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

Thunder always accompanies lightning. When lightning occurs, the air through which it travels is instantaneously heated to a temperature more than 28,000°C (50,000°F).

The air expands rapidly due to this heating, then quickly contracts as it cools. It is this contracting shock wave that we hear as thunder.

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

• 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.

1.23

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 H250D Processor 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 fiberglass 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 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.

• 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.

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.

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

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

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

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

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

• Avoid entering any small enclosures or shelters.

IF YOU CAN, GET INSIDE:

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

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

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

IF INSIDE A BUILDING: • Don’t watch the lightning storm from open windows or doorways. Stay in inner rooms.

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

• 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.

1.24

Tigercat H250D Processor

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

1.25

Safety

Tigercat H250D Processor

FIRE PREVENTION

• 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.

• 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.

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.

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.

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.

• 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.

• 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 .

• 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 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.

• 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.

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

• 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.

• 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.

• 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.

• 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.

• 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.

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

1.26

Tigercat H250D Processor

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

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

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

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

HOW TO PREPARE FOR A MACHINE FIRE

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

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

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

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

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

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

• Verify the correct types of fire extinguishers are available at the work site. Most fires involving mobile forestry equipment will be Class A or B. Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A. • Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics,

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.

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

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.

• Class C fires apply to energized electrical equipment.

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

Before deciding to fight the fire, be certain that:

• 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.

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.

• 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.

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

1.27

Safety

Tigercat H250D Processor

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: 1. Determine the cause of the fire.

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.

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).

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

Break the plastic seal as the pin is pulled.

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.

1.28

Tigercat H250D Processor

Safety

DRY CHEMICAL CLEANUP PROCEDURES

WET CHEMICAL CLEANUP PROCEDURES

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

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

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

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

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

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

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

Wipe all surfaces with a damp cloth.

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

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

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

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

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

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

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

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

NOTICE

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

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

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

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

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

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

1.29

Safety

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

Tigercat H250D Processor READ OPERATOR'S MANUAL AND USE THE SEAT BELT AT ALL TIMES

OPERATOR'S MANUAL LOCATION

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

This label gives two messages.

The centre panel notifies the operator to read the operator’s manual before operating the machine. Pay close attention to warnings and hazard identifications.

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

The bottom panel notifies the operator the operator's seat is equipped with lap belt. Use this restraint systems at all times when operating the machine. Do not attempt to move or operate the machine until the seat belt is fastened properly.

1.30

Tigercat H250D Processor

Safety

EMERGENCY EXIT, HAND TIGHTEN ONLY

This label indicates the right side window can also be used as an emergency exit.

The label also indicates the right side window screen knobs are to be hand tightened only to allow for easy exit.

FIRST AID KIT

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

Ensure all exit locations are functioning properly.

Refer to CAB EXITS in THIS SECTION. Refer to EMERGENCY EXITS in SECTION 3.

1.31

Safety

Tigercat H250D Processor

KEEP CLEAR

NO RIDERS

43424BUNI R0

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

Keep clear of an operating machine.

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

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

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

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

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

No riders inside or outside the machine. Do not carry passengers either in the cab or anywhere else on the machine. The machine seating accommodation is for one operator only. Persons riding on the outside of the machine are subject to hazards such as falling off the machine, crush hazards, thrown object hazards and many other hazards which could result in death or serious injury.

If any person attempts to climb onto the machine during operation, Stop the machine immediately. Do not operate the machine until other personnel are a safe distance away from the machine.

1.32

Tigercat H250D Processor

Safety

ENTANGLEMENT HAZARD

ELECTROCUTION HAZARD

36779BUNI R0

This label warns of an entanglement hazard (rotating parts) zone.

Do not place hands or fingers in this area. Rotating parts such as pulleys, belts and drives can cause entanglement of body parts resulting in serious injury.

This label warns of a potential electrocution hazard.

Contact with electric lines will result in death or serious injury!

Keep hands and fingers clear of rotating belt, drive or pulley! Before performing any service work on these parts or in this area, shut engine off and wait for rotating parts to come to a complete stop.

Before beginning work in any area study the area thoroughly and become familiar with any potential hazards especially electrocution hazards from electric lines.

Do not move any part of the machine or load within 3 m (10 ft) plus two times line insulator length of any electric lines!

1.33

Safety

Tigercat H250D Processor

SLIPPERY SURFACE WHEN WET

CRUSH HAZARD

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

This label warns of a downward force crush zone caused by swinging or falling logs.

Approaching personnel are subject to crush injuries by falling or swinging logs which could result in death or serious injury.

Do not start the machine until other personnel are a safe distance away from the machine.

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 workers and all other personnel. It is the duty of the operator to not allow personnel to approach the machine while in use, the risk zone is 150 m (500 ft).

Do not attempt to service or work on the machine until the load is removed from the attachment, the machine is in the parked position and the engine is turned OFF.

1.34

Tigercat H250D Processor

Safety

CRUSH HAZARD

CRUSH HAZARD

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

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

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

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

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

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

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

1.35

Safety

Tigercat H250D Processor

EXPLOSION HAZARD

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

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

1.36

Tigercat H250D Processor FIRE PREVENTION

This label describes essential fire prevention measures: Read, understand, and follow the fire prevention guidelines in this manual.

Safety CHECK DAILY

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

FIRE EXTINGUISHER ACCESS PORT

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.

This label appears at each fire extinguisher access port.

1.37

Safety

Tigercat H250D Processor

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

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

ENGINE IDLE (TIER 4F MACHINES ONLY)

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

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

1.38

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

Tigercat H250D Processor SECTION 2 – CONTROLS AND OPERATION Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 2

ISSUE 1.0, APRIL 2021

A

AIR CONDITIONING CONTROLS........................................................................................................................... 2.18 AIR VENTS, CAB....................................................................................................................................................... 2.21 ALARM....................................................................................................................................................................... 2.19 ALARM LIGHT........................................................................................................................................................... 2.19 ANTI-STALL............................................................................................................................................................... 2.91 ATTACHMENT, INSTRUCTIONS AND PRECAUTIONS........................................................................................ 2.99 AUDIO SYSTEM........................................................................................................................................................ 2.18 AUTO IDLE DOWN.................................................................................................................................................... 2.13 AUXILIARY POWER SUPPLY, 12 V......................................................................................................................... 2.17

B

BATTERIES................................................................................................................................................................ 2.23 BATTERY BOOSTING.............................................................................................................................................. 2.85 BATTERY DISCONNECT SWITCH......................................................................................................................... 2.23

C

CAB CONTROLS CONTROL PANEL – LEFT ARMREST................................................................................................................... 2.12 CONTROL PANEL – RIGHT ARMREST................................................................................................................ 2.14 FOOT CONTROLS................................................................................................................................................. 2.11 JOYSTICK CONTROLS......................................................................................................................................... 2.10 MAIN CONSOLE.................................................................................................................................................... 2.17 OVERHEAD CONSOLE – FRONT......................................................................................................................... 2.19 OVERHEAD CONSOLE – RIGHT.......................................................................................................................... 2.18 CAB TILT (OPTIONAL).............................................................................................................................................. 2.80 BOLT LOCKER....................................................................................................................................................... 2.84 CAB TILT PUMP..................................................................................................................................................... 2.80 TILTING PROCEDURE – ELECTRIC PUMP........................................................................................................ 2.81 TILTING PROCEDURE – HAND PUMP................................................................................................................ 2.82 CB RADIO.................................................................................................................................................................. 2.18 COLD WEATHER STARTING................................................................................................................................... 2.93 WARM UP IDLE SPEED ADJUSTMENT.............................................................................................................. 2.94 COMPUTER MAIN SCREEN....................................................................................................................................................... 2.28 MAIN MENU............................................................................................................................................................ 2.37 ADJUST MENU................................................................................................................................................... 2.37 ENGINE............................................................................................................................................................ 2.39 FAN................................................................................................................................................................... 2.40 MACHINE PARAMETERS............................................................................................................................... 2.38 INFO MENU......................................................................................................................................................... 2.48 LOGS................................................................................................................................................................ 2.49 MODULES........................................................................................................................................................ 2.49 MEASURE MENU............................................................................................................................................... 2.43 PREFERENCES MENU...................................................................................................................................... 2.44 BACKLIGHT ADJUSTMENT........................................................................................................................... 2.44 DATE/TIME ADJUSTMENT............................................................................................................................. 2.45 DISPLAY ADJUSTMENT................................................................................................................................. 2.44 LANGUAGE ADJUSTMENT............................................................................................................................ 2.47 SCREEN SAVER ADJUSTMENT................................................................................................................... 2.45 ADJUSTMENT MENU............................................................................................................................................ 2.33 HYDRAULIC OIL GRADE SELECTION............................................................................................................ 2.33

Controls and Operation

Tigercat H250D Processor

COMPUTER CONTROL SYSTEM........................................................................................................................ 2.27 DISPLAY.................................................................................................................................................................. 2.17 ENGINE MENU....................................................................................................................................................... 2.29 ANTI-STALL......................................................................................................................................................... 2.32 COLD IDLE FUNCTION..................................................................................................................................... 2.32 ENGINE FUNCTIONS........................................................................................................................................ 2.30 UNITS OF MEASURE......................................................................................................................................... 2.32 HYDRAULIC OIL RETURN FILTERS BYPASSED.............................................................................................. 2.28 INFORMATION MENU........................................................................................................................................... 2.34 FUEL INFORMATION......................................................................................................................................... 2.34 TELEMATICS INFORMATION........................................................................................................................... 2.36 UNITS OF MEASURE......................................................................................................................................... 2.35 MESSAGES............................................................................................................................................................ 2.50 MESSAGES – ALERT............................................................................................................................................. 2.66 CHARGE FILTER BYPASSED........................................................................................................................... 2.69 DIESEL EXHAUST FLUID LEVEL..................................................................................................................... 2.78 DIESEL EXHAUST FLUID QUALITY................................................................................................................. 2.76 ENGINE AIR INTAKE FILTER RESTRICTED................................................................................................... 2.67 ENGINE COOLANT TEMPERATURE HIGH – SPN: 62755.............................................................................. 2.74 ENGINE FAULT CODE MESSAGES................................................................................................................. 2.74 ENGINE IDLE AUTOMATICALLY INCREASED............................................................................................... 2.74 ENGINE TORQUE DERATE ACTIVE – SPN: 64911.......................................................................................... 2.75 ENGINE VOLTAGE HIGH – SPN: 4449 OR 4961.............................................................................................. 2.75 ENGINE VOLTAGE LOW – SPN: 8801 OR 9313............................................................................................... 2.75 FUEL LEVEL LOW.............................................................................................................................................. 2.69 HARDWARE FAILURE – CURRENT OUTPUT.................................................................................................. 2.72 HARDWARE FAILURE – DIGITAL INPUT.......................................................................................................... 2.72 HARDWARE FAILURE – DIGITAL OUTPUT...................................................................................................... 2.72 HARDWARE FAILURE – VOLTAGE INPUT....................................................................................................... 2.72 HARDWARE FAULT – MD3 (COMPUTER)........................................................................................................ 2.71 HARDWARE FAULT – XA2-A0............................................................................................................................ 2.71 HARDWARE FAULT – XA2-A1............................................................................................................................ 2.71 HARDWARE FAULT – XC21................................................................................................................................ 2.71 HOIST BOOM LIMIT SENSOR.......................................................................................................................... 2.70 HYDRAULIC OIL FILTER RESTRICTED.......................................................................................................... 2.68 JOYSTICK AXIS FAULT..................................................................................................................................... 2.70 MACHINE VOLTAGE HIGH................................................................................................................................ 2.69 MACHINE VOLTAGE LOW................................................................................................................................. 2.69 MAIN FUEL FILTER CLOGGED........................................................................................................................ 2.68 MODULE HIGH SUPPLY VOLTAGE – ALERT................................................................................................... 2.73 MODULE HIGH TEMPERATURE...................................................................................................................... 2.73 MODULE LOW SUPPLY VOLTAGE.................................................................................................................. 2.73 STICK BOOM LIMIT SENSOR........................................................................................................................... 2.70 WATER IN FUEL – SPN: 17429........................................................................................................................... 2.75 MESSAGES – CRITICAL........................................................................................................................................ 2.51 AFTERTREATMENT SYSTEM ENGINE IDLE TOO LONG............................................................................ 2.61 AFTERTREATMENT SYSTEM TECHNICAL FAILURE................................................................................... 2.59 BOOST PRESSURE LOW – ENGINE DERATE................................................................................................ 2.53 ENGINE COOLANT LEVEL LOW...................................................................................................................... 2.52 ENGINE COOLANT TEMPERATURE HIGH.................................................................................................... 2.58 ENGINE COOLANT TEMPERATURE HIGH – ENGINE DERATE................................................................... 2.52 ENGINE FAULT CODE MESSAGES – CRITICAL............................................................................................. 2.57 ENGINE LOCKED OUT...................................................................................................................................... 2.60 ENGINE OIL PRESSURE LOW......................................................................................................................... 2.58 ENGINE OIL PRESSURE LOW – ENGINE DERATE........................................................................................ 2.55 ENGINE OIL TEMPERATURE HIGH................................................................................................................. 2.57 2.2

Tigercat H250D Processor

Controls and Operation

ENGINE STARTS REMAINING UNTIL ENGINE LOCKOUT........................................................................... 2.60 HARDWARE FAULT – ENGINE.......................................................................................................................... 2.56 HARDWARE FAULT – MD3 (COMPUTER)........................................................................................................ 2.55 HARDWARE FAULT – XA2-A0............................................................................................................................ 2.56 HARDWARE FAULT – XA2-A1............................................................................................................................ 2.56 HARDWARE FAULT – XC21................................................................................................................................ 2.55 HYDRAULIC OIL LEVEL LOW........................................................................................................................... 2.54 HYDRAULIC OIL TEMPERATURE HIGH......................................................................................................... 2.54 MAIN FUEL FILTER CLOGGED – ENGINE DERATE....................................................................................... 2.53 MESSAGES – ERROR............................................................................................................................................ 2.62 COMPUTER MODULE BLANK SCREEN......................................................................................................... 2.64 CURRENT OUTPUT ERROR (COUT).............................................................................................................. 2.64 DIGITAL INPUT ERROR (DIN)........................................................................................................................... 2.64 DIGITAL OUTPUT ERROR (DOUT).................................................................................................................. 2.64 MODULE NO CONTACT ERROR...................................................................................................................... 2.65 MODULE VREF ERROR.................................................................................................................................... 2.63 VOLTAGE INPUT ERROR (VIN)........................................................................................................................ 2.64 E

EMERGENCY EXIT................................................................................................................................................... 2.20 RIGHT SIDE WINDOW.......................................................................................................................................... 2.20 EMERGENCY STOP SWITCH................................................................................................................................. 2.17 ENGINE COOLANT SHUT-OFF VALVE.............................................................................................................................. 2.22 RESTARTING AFTER ENGINE RUNS OUT OF FUEL....................................................................................... 2.96 SPEEDS.................................................................................................................................................................. 2.13 STARTING.............................................................................................................................................................. 2.92 STOPPING.............................................................................................................................................................. 2.96 ENGINE COOLANT HEATER CONTROL (OPTIONAL)......................................................................................... 2.19

F

FAN CONTROL SWITCH – VARIABLE-PITCH FAN (OPTIONAL)......................................................................... 2.16 FILTERS CAB FRESH AIR.................................................................................................................................................... 2.21 RECIRCULATING AIR – A/C UNIT........................................................................................................................ 2.21 FIRE EXTINGUISHER.............................................................................................................................................. 2.21 FIRST AID KIT STORAGE........................................................................................................................................ 2.21 FOOT CONTROLS.................................................................................................................................................... 2.11

H

HEAT AND AIR CONDITIONING CONTROLS........................................................................................................ 2.18 HEATER, ENGINE COOLANT (OPTIONAL)........................................................................................................... 2.19 HORN......................................................................................................................................................................... 2.17

I

IGNITION SWITCH.................................................................................................................................................... 2.17

J

JOYSTICK CONTROLS............................................................................................................................................ 2.10

L

LIGHTS ALARM.................................................................................................................................................................... 2.19 INTERIOR CAB...................................................................................................................................................... 2.18 SERVICE................................................................................................................................................................. 2.15 WORK...................................................................................................................................................................... 2.15 LOAD SENSING, OPERATING TIPS....................................................................................................................... 2.98

M

MACHINE PREPARATION....................................................................................................................................... 2.97 SYSTEM TEST AND WARM-UP........................................................................................................................... 2.97 MASTER ALARM....................................................................................................................................................... 2.19 MOBILE DEVICE HOLDER...................................................................................................................................... 2.17

O

2.3

Controls and Operation

Tigercat H250D Processor

OPERATING THE MACHINE................................................................................................................................... 2.87 PRESTART CHECKS............................................................................................................................................. 2.87 OPERATOR'S MANUAL CASE................................................................................................................................ 2.21 P

PICTOGRAMS............................................................................................................................................................. 2.5 PILOT INTERLOCK RESET SWITCH..................................................................................................................... 2.13

R

RADIOS AUDIO SYSTEM..................................................................................................................................................... 2.18 AUXILIARY IN PORT............................................................................................................................................. 2.17 CB RADIO............................................................................................................................................................... 2.18 REFUELLING............................................................................................................................................................. 2.86

S

SEAT, OPERATOR'S................................................................................................................................................. 2.24 ADJUSTMENTS..................................................................................................................................................... 2.24 CLIMATE CONTROL SWITCHES......................................................................................................................... 2.26 PROBLEMS AND CORRECTIVE ACTIONS........................................................................................................ 2.26 STARTING ENGINE.................................................................................................................................................. 2.92 COLD WEATHER STARTING............................................................................................................................... 2.93 STOPPING ENGINE................................................................................................................................................. 2.96 SWITCHES AIR CONDITIONER/HEATER............................................................................................................................... 2.18 DRIVE SPEED........................................................................................................................................................ 2.14 EMERGENCY STOP.............................................................................................................................................. 2.17 ENGINE SPEED..................................................................................................................................................... 2.13 FAN CONTROL – VARIABLE-PITCH FAN (OPTIONAL)...................................................................................... 2.16 FAN SPEED, A/C-HEATER.................................................................................................................................... 2.18 HORN...................................................................................................................................................................... 2.14 IGNITION KEY........................................................................................................................................................ 2.17 INTERIOR CAB LIGHT.......................................................................................................................................... 2.12 PILOT INTERLOCK RESET.................................................................................................................................. 2.13 SEAT CLIMATE CONTROL................................................................................................................................... 2.26 SERVICE LIGHT.................................................................................................................................................... 2.15 SWING BRAKE....................................................................................................................................................... 2.14 TEMPERATURE CONTROL, A/C-HEATER......................................................................................................... 2.18 TRACK RANGE...................................................................................................................................................... 2.14 VACUUM, HYDRAULIC OIL TANK....................................................................................................................... 2.12 WINDSHIELD WIPER/WASHER........................................................................................................................... 2.18 WORK LIGHTS....................................................................................................................................................... 2.15

T

TELEMATICS SYSTEM............................................................................................................................................ 2.20 TRACK DRIVE CONTROL PEDALS............................................................................................................................................... 2.11 TRACK OPERATION AND WEAR PREVENTION................................................................................................ 2.100 PROTECTING STEEL TRACKS......................................................................................................................... 2.100 TRAVELLING BOOM RAISED....................................................................................................................................................... 2.98

U

USB PORT, COMPUTER.......................................................................................................................................... 2.17

V

VACUUM SWITCHES, HYDRAULIC TANK............................................................................................................. 2.12

W

WINDOWS................................................................................................................................................................. 2.20 WINDSHIELD WASHER FLUID BOTTLE............................................................................................................... 2.22 WORK LIGHTS.......................................................................................................................................................... 2.15

2.4

Tigercat H250D Processor

Controls and Operation

PICTOGRAM DESCRIPTIONS Boom UP

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.

Boom IN

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

Boom OUT

The pictograms used on this machine are as follows: Check, Visually 12V, Auxiliary Power Outlet Cigarette Lighter, 24 V

24V, Auxiliary Power Outlet ACCEPT

P

Adjustment Menu

P

Control Lever Multiple Direction

Control Lever One Direction Control Lever Two Direction

Air Conditioner ON

CRITICAL ERROR Message Air Conditioner OFF CRITICAL Message Air Intake Pressure, BOOST

Diesel Exhaust Fluid (DEF) Tier 4f machines only

Air Source, Fresh Air

Defrost, Front Window

Alert Message Symbol

Drive Motor SPEED

Battery CONNECT

Drive Pressure, FORWARD

Battery DISCONNECT Drive Pressure, REVERSE Boom DOWN

Engine ANTI-STALL

2.5

Controls and Operation

Tigercat H250D Processor

Engine BOOST PRESSURE

Engine speed

Engine AIR INTAKE PRESSURE (Engine AIR FILTER RESTRICTED)

Engine TURBOCHARGER BOOST PRESSURE

Engine Charge Air TEMPERATURE

Engine WAIT TO START

Engine Coolant TEMPERATURE

Engine WARNING

Engine DIAGNOSTICS

Engine WARM UP

Engine Emission Filter

AUTO

Exhaust Flap Position

Engine Emission Filter OFF

or

Fan AUTO REVERSING/CLEANING

Engine Emission System TEMPERATURE

Fan Full ON

ENGINE MENU

Fan Reverse CLEAN

Engine Oil PRESSURE Fan SPEED Engine Oil TEMPERATURE Fan – Ventilation Blower Engine – PERCENTAGE OF LOAD Flow Adjustment Engine RUN

Fluid Level HIGH

Engine SPEED – RPM

Fluid Level LOW Foot Pedal Control

Engine START

Fuel CONSUMPTION RATE

Engine STOP

Fuel – DIESEL

2.6

Tigercat H250D Processor

Controls and Operation

Fuel Heater

Horn

Fuel Information

Hours – MACHINE

Fuel Reset and Trip Fuel Information

Hours – ENGINE

Fuel TEMPERATURE

Hydraulic Oil Tank

Fuel – WATER IN FUEL Hydraulic Oil Case Drain Fuel Level LOW Hydraulic Oil Grade Processor Head Hydraulic Oil Level Processor Head - TILT FLOAT

Hydraulic Oil Level LOW

Hydraulic Oil, RETURN

Processor Head - TILT DOWN

Hydraulic Oil Temperature Processor Head - TILT UP Hydraulic Oil Temperature HIGH Processor Head - ROTATE (CW)

Hydraulic System Pressure, LOAD SENSE Hydraulic Oil Tank Vacuum

Processor Head - ROTATE (CCW)

Imperial/Metric Toggle Symbol Head TILT FORWARD Information Menu Icon

Head TILT BACK

Information Message Symbol

2.7

Controls and Operation

Tigercat H250D Processor Speed SLOW or LOW

Instrument Bulb Test

Switch ON Joystick and Switches

Switch OFF Swing brake

Lights – WORK

Swing CLOCKWISE

Lights – ENGINE SERVICE

Swing COUNTERCLOCKWISE

Lights – REAR

Telematics

Oil Cooler BYPASS

Telematics, Connectivity Operator Telematics, Messages Sent/Recorded Park Brake Telematics, Latitude

No Park Brake

Telematics, Longitude

Pilot System ON (Reset)

Temperature

Pilot System OFF Remote Hydraulic Cylinder EXTEND

Track left FORWARD/REVERSE and TRAVEL

Remote Hydraulic Cylinder RETRACT

Track right FORWARD/REVERSE and TRAVEL

Saw CUT

Serial Number

Travel Speed

Speed CREEP or VERY SLOW Vacuum

Speed FAST or HIGH

2.8

Tigercat H250D Processor

Controls and Operation

Variable Speed Ventilation Blower Fan

Wheel Arms - CLOSE

Wheel Arms - OPEN

Windshield Washer

Wrist COUNTERCLOCKWISE

Wrist CLOCKWISE

2.9

Controls and Operation

Tigercat H250D Processor

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

JOYSTICK CONTROLS LEFT JOYSTICK

RIGHT JOYSTICK

880-012A 53570BUNI

STICK BOOM • Move the joystick back to move the boom IN toward the machine.

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

SWING

880-012A 53570BUNI

HOIST BOOM • Move the joystick back to raise the hoist boom UP. • Move the joystick forward to lower the hoist boom DOWN.

ATTACHMENT ROTATE Move the joystick right to rotate the attachment CW.

• Move the joystick right to SWING the upper structure to the RIGHT (CW).

Move the joystick left to rotate the attachment CCW.

• Move the joystick left to SWING the upper structure to the LEFT (CCW).

2.10

Tigercat H250D Processor

Controls and Operation

FOOT CONTROLS

A

A

C

B

200174

A Foot Rest B Left Track Drive Foot Pedal/Lever C Right Track Drive Foot Pedal/Lever

LEFT TRACK DRIVE

RIGHT TRACK DRIVE

Press the left track foot pedal with TOE or push forward on the lever to place the left track in FORWARD drive mode.

Press the right track foot pedal with TOE or push forward on the lever to place the right track in FORWARD drive mode.

Press the left track foot pedal with HEEL or pull back on the lever to place the left track in REVERSE drive mode.

Press the right track foot pedal with HEEL or pull back on the lever to place the right track in REVERSE drive mode.

2.11

Controls and Operation

Tigercat H250D Processor

CONTROL PANEL – LEFT ARMREST

A

B

C

D

200142

A Interior Cab Light Switch B Vacuum Switch – Hydraulic Oil Tank

The control panel is located in the left armrest on the seat.

C Pilot Interlock Reset Switch D Engine Speed Switch

VACUUM SWITCH – ENGINE COMPARTMENT

The following machine functions are controlled by switches located on this control panel:

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

A

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

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

T250D-148

A Vacuum Switch – Engine Compartment

This switch is located in the front engine compartment.

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

2.12

Tigercat H250D Processor

Controls and Operation

PILOT INTERLOCK RESET SWITCH

ENGINE SPEED SWITCH

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

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

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

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

B

A 200501

200469

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

MAINTAINING CORRECT ENGINE SPEED

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

CAUTION

It is most important the speed of the engine be correct at all times: • LOW: 1000 rpm (No Load) • HIGH: 2100 rpm max. (No Load). Factory default is 2000 rpm NOTE: At start-up the engine speed defaults to LOW.

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

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

The above speeds are with the hydraulic oil and engine oil at normal operating temperatures and no functions activated. These values are preset into the engine ECU and cannot be adjusted without the proper electronic programming software equipment.

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

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

Refer to COMPUTER – MAIN MENU – ADJUST MENU – MACHINE PARAMETERS in THIS SECTION to adjust the idle down wait time.

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

Refer to COLD WEATHER STARTING in THIS SECTION.

2.13

Controls and Operation

Tigercat H250D Processor

CONTROL PANEL – RIGHT ARMREST

D

E

F

A

B

C

G

200143

A B C D

Horn Switch Track Range Switch Track Drive Mode Switch Service Light Switch

E Swing Brake Switch F Work Lights Switch G Fan Control Switch Location – Variable-pitch Fan (Optional)

HORN SWITCH

TRACK DRIVE MODE SWITCH

Press this rocker switch to sound the horn.

Placing this switch in the DOWN position will apply the park brake and prevent the machine from being accidentally driven while the attachment is being operated.

TRACK RANGE SWITCH This is a two-position maintained switch with track drive low and track drive high options. Refer to TRAVEL SPEED CONTROL in THIS SECTION. Track Drive High Track Drive Low The LOW position provides the slowest travel speed with maximum torque or driving force. The HIGH position provides a faster travel speed range, but with a lower driving force.

Place this switch in the LOW position when maneuvering around the processing area.

Place this switch in the UP position to drive the machine.

SWING BRAKE SWITCH This is a two position ON/OFF switch. Placing this switch in the ON position will apply the swing brake and prevent the upper structure from turning. The brake is also engaged when the pilot system is turned OFF (left armrest in raised position). As an added safety precaution, apply the brake with this switch before leaving the cab. The swing brake is a spring apply, hydraulic release, multi-disc brake.

Only use the HIGH position with the machine on flat solid ground. Use a flat bed trailer to transport the machine over greater distances.

2.14

Tigercat H250D Processor

Controls and Operation

SERVICE LIGHT SWITCH

WORK LIGHTS SWITCH

This switch controls the service light located in the front engine compartment.

This switch controls the work lights located on the front of the cab, the stick boom and the left side of the upper structure.

SERVICE LIGHT

WORK LIGHTS A

201114

B

A 201115

201117

A Service Light

Front Engine Compartment

C

201116

A Work Lights – Front B Work Light – Left Side C Work Lights – Stick Boom

2.15

Controls and Operation

Tigercat H250D Processor

FAN CONTROL SWITCH – VARIABLE-PITCH FAN (OPTIONAL) A B C

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

FULL ON POSITION 724G-011

A Full ON B Auto C Clean (Purge)

A

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

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

AUTO POSITION

A

2000123

A Fan Icon – Full On Position

When the switch is in the FULL ON position, the computer control system is overridden and the fan will run at FULL air flow (blades pitched to 100%), for cooling regardless of charge air, engine coolant or hydraulic oil temperatures. Normally the fan control switch is placed in the AUTO position for optimal cooling. The FULL ON position is intended for use in the event of a temporary failure of the control system.

CLEAN POSITION

2000087

A Fan Icon – Auto Position

AUTO is the normal operating position for the fan control switch. When the switch is in the AUTO position, the fan will operate completely in an automatic mode. The computer control system will automatically control the fan pitch to minimize system energy losses and improve performance based on the temperature of the charge air, engine coolant and hydraulic oil. The computer system automatically adjusts fan air flow to the minimum required level to maintain optimal operating conditions.

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

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

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

A 2000122

A Fan Icon – Clean Position

Momentarily pressing the switch to the CLEAN position will manually start the automatic clean cycle, reversing the flow of air (there is no need to hold the switch down).

The pitch of the fan blades is changed and the direction of airflow through the engine enclosure is reversed. This change in airflow blows debris from the machines engine enclosure to eliminate potential overheating and poor machine performance caused by overheating. Ensure there are no personnel standing directly to the sides of the machine when performing this operation, as dust and debris will fly out.

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

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

2.16

Tigercat H250D Processor

Controls and Operation

MAIN CONSOLE

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

MOBILE DEVICE HOLDER

A

An adjustable mobile device holder.

AUXILIARY POWER SUPPLY – 12 V

B

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

EMERGENCY STOP SWITCH

C

Press the emergency stop switch down, to immediately turn OFF the engine and hydraulic systems.

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

D

IGNITION SWITCH E

A B

F

C G

234B-013

A B C D E F G

Computer Display USB Port– Computer Radio Auxiliary IN Port (Behind Computer Display) Mobile Device Holder Auxiliary Power Supply – 12 V Emergency Stop Switch Ignition Switch

800590

A Stop Position B Run Position C Start Position

This is a three-position switch labelled STOP/RUN/ START:

COMPUTER DISPLAY

• STOP Position – All electrical power fed through the ignition switch is turned OFF.

The computer and display module is the operator's principal interface with the machine's electronic control system. Refer to COMPUTER in THIS SECTION for more details.

• RUN Position – The battery is connected to all functions. Used for normal machine operation.

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

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

2.17

• START Position – Turning the switch to this position starts the engine by connecting the batteries to the start relay. The switch will return to the RUN position when released.

Controls and Operation

Tigercat H250D Processor

OVERHEAD CONSOLE – RIGHT A

B

C

HEAT AND AIR CONDITIONING CONTROLS

D

A

B

C

234B-011

A B C D

CB Radio Interior Cab Light Audio System Windshield Wiper/Washer Switch

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

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

AUDIO SYSTEM Refer to the manufacturer's manual for operation instructions.

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

234B-011

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

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

FAN SPEED ROTARY SWITCH This is a rotary, four-position switch for the fan speed.

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

AIR CONDITIONER (A/C) SWITCH This is a 2-position ON/OFF power switch.

Turn the dial a setting further clockwise to set the wiper to low speed. Turn the dial a setting further clockwise to set the wiper to high speed. To slow or turn OFF the wiper, turn the dial counterclockwise until the desired setting is reached.

To operate the washer function, press and hold the dial.

This function sprays washer fluid on the windshield.

2.18

Tigercat H250D Processor

Controls and Operation

OVERHEAD CONSOLE – FRONT

B

A

ENGINE COOLANT HEATER CONTROL (OPTIONAL) A

F

E

E

D

B

C

2000013

A Alarm Light B Master Alarm C Engine Coolant Heater Control (Optional)

C LS855D-015

A B C D E F

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

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

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

ON/OFF Button LCD Screen Micro USB Service Port Selection Button Status Indicator Light(s) Rotary Knob

This heater heats and circulates the engine coolant through the engine, the hydraulic tank, and the cab.

There is a solenoid valve controlling the flow of coolant to the hydraulic tank heater. This solenoid valve is controlled directly by the heater control. The programming of the heater control in the cab will determine when the heater is ON and when it will turn OFF. Consult the manufacturer's instruction manual for additional information.

IMPORTANT! During warm weather when the engine coolant heater is not in use operate the heater for a period of 20 minutes monthly. This will circulate engine coolant to all components of the heater system.

NOTICE Open the engine coolant shut-off valve before operating the coolant heater. Damage to the engine coolant heater pump may result if the valve is closed.

Refer to ENGINE – COOLANT SHUT-OFF VALVE in THIS SECTION for more information.

2.19

Controls and Operation

TELEMATICS SYSTEM

Tigercat H250D Processor

WINDOWS

A

234B-351

A Sliding Window Handle

The right window and cab door window are sliding windows. To open, push on the handle and slide the window. To close, slide the window firmly until it stops and latch the handle to the frame.

800118

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

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

B

Refer to TELEMATICS SYSTEM in SECTION 6 for additional information.

EMERGENCY EXIT RIGHT SIDE WINDOW

A

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

1. Turn OFF the engine before using this exit.

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

201066

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

The right window can be equipped with an optional exterior screen to provide protection from branches during transport. The screen is held closed with hand knobs on the inside and outside of the cab. Removing one only hand knob (not both) will open the window screen.

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

2.20

Tigercat H250D Processor

Controls and Operation

CAB AIR FILTERS

FIRE EXTINGUISHER A

A

B

234-093

A Air Conditioner Recirculation Filter B Cab Fresh Air Filter

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

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

CAB AIR VENTS

234-095

A Check Fire Extinguisher

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

Check the extinguisher daily to verify that it is charged.

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

FIRST AID KIT STORAGE A

B

A

234-094

A Air Vents

2000015

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

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

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

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

2.21

Controls and Operation

Tigercat H250D Processor

ENGINE COOLANT SHUT-OFF VALVE

WINDSHIELD WASHER FLUID BOTTLE

A

A

B

200554

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

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

234B-352

A Windshield Washer Fluid Bottle

In cold climates, fill with an anti-freeze washer fluid.

To avoid scratching the windshield, Do not operate wipers on a dry windshield. The bottle is located in the compartment on the front-left corner of the machine.

The engine coolant shut-off valve is accessed through the engine compartment front access door.

2.22

Tigercat H250D Processor

Controls and Operation

BATTERY DISCONNECT SWITCH

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

A

If the batteries require boosting, refer to BATTERY BOOSTING in THIS SECTION. If the batteries need charging, refer to BATTERY CARE in SECTION 3.

200554

A Battery Disconnect Switch – Front Engine Compartment

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

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

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

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

2.23

Controls and Operation

Tigercat H250D Processor

OPERATOR’S SEAT – AIR RIDE

A

A

B

B D

E

C

C

E

D

G

F

N

H

M

H

L

I

I

K J 2000413

A B C D E F G

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

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

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

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

H I J K L M N

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

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

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

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

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

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

2.24

Tigercat H250D Processor

Controls and Operation

LUMBAR ADJUSTMENT

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

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

FORE AND AFT ADJUSTMENT

A

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

B

UP, DOWN AND ANGLE ADJUSTMENT Loosen the armrest up/down/angle adjustment wing-bolt handle to allow the armrest to slide up and down or to adjust the angle of the armrest.

C

WIDTH ADJUSTMENT

2000415

Right Side of Seat

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

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

A

BACK ANGLE ADJUSTMENT

B

A 2000416

Underside of Armrest

B

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

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

C 2000414

Left Side of Seat

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

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

2.25

Controls and Operation

Tigercat H250D Processor

SEAT CLIMATE CONTROL SWITCHES A

To operate the heated seat function: 1. Turn the ignition key to the RUN position.

B

2. Place the heater/ventilation switch in the H position.

3. Select heat level at the low-medium-high switch.

To operate the seat ventilation function: 1. Turn the ignition key to the RUN position.

2. Place the heater/ventilation switch in the V position.

3. Selection the fan speed at the low-medium-high switch.

PROBLEMS AND CORRECTIVE ACTIONS 803793

RIDE IS TOO STIFF/SEAT TENDS TO PUSH OR THROW OPERATOR FORWARD

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

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

The seat heater operates when the ignition switch is in the ON position.

A

H B

V C 801354

Heater/Ventilation Switch

RIDES TOO SOFT OR BOTTOMS OUT AND PINCHES OPERATOR The air ride control valve has under pressurized the seat air suspension ride adjustment. Insufficient pressure exaggerates the knee-action movement of the seat.

This usually happens because the operator is trying to lower the seat by decreasing the amount of air pressure instead of using the height adjustment lever.

SEAT TOO HIGH/SEAT TOO LOW

A Heated Seat B Seat Ventilation C Climate Control Off

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

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

A

III II I

The air ride control valve has over pressurized the seat air suspension. This typically happens because the operator is trying to use the air suspension to adjust the ride height rather than using the height adjustment lever to raise the seat.

B

There are several things which can cause improper seat height. Adjust the seat to the desired position. If the proper height cannot be reached using one of the height adjustment settings, it may be necessary to install the seat on a higher base.

OPERATOR’S LEGS FALLING ASLEEP The seat is adjusted too high and the air ride control valve has under pressurized the seat air suspension ride adjustment, resulting in the operator sitting too low into the seat.

C 801355

A High B Medium C Low

Low-Medium-High Switch

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

2.26

Tigercat H250D Processor

Controls and Operation

COMPUTER CONTROL SYSTEM

A

B

C

F

G

H

I

E

D

250D-079

A B C D E

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

F G H I

F1 Button F2 Button F3 Button F4 Button

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

• OK button

A

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

• Menu button Displays the Main menu. It is not programmable.

• BACK button

234B-013

A Computer Display

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

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

• UP and DOWN arrow buttons Navigation buttons that are used to scroll through selections on a menu page.

2.27

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

• F1 – F4 function buttons Programmed buttons that are configured by program software to bring up a display screen, bring up an adjustment group or act as an input.

Controls and Operation

Tigercat H250D Processor

COMPUTER DISPLAY MAIN SCREEN A

B

C

D

E

Q

F

I

G

J

K

L H

M

N

O

P

200769

A B C D E F G H I

Pilot System Reset – ON/OFF Anti-Stall – ON/OFF Cold Idle Function (Engine Warmup Status) Hydraulic Oil Return Filter Bypass * Engine Air Intake Filter Restriction Time of Day Engine Speed – rpm Engine Coolant Temperature Gauge *** Fuel Level Gauge **

J K L M N O P Q

DEF Level Indicator Hydraulic Oil Temperature Gauge Hydraulic Oil Grade Engine Menu – Press F1 To Select Adjustment Menu – Press F2 to Select Information Menu – Press F3 to Select Computer Messages – Press F4 To Select Fan Indicator – AUTO/FULL ON/CLEAN – Variable-pitch Fan (Optional)

* HYDRAULIC OIL RETURN FILTER BYPASS

** FUEL LEVEL GAUGE SYMBOL

GREY – Hydraulic oil is not bypassing return filters.

YELLOW– Fuel level is low.

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

*** TEMPERATURE GAUGE SYMBOL

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

WHITE– Temperature range is NORMAL.

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

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

2.28

Tigercat H250D Processor

Controls and Operation

ENGINE MENU

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

200162

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

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

200163

2.29

Controls and Operation

Tigercat H250D Processor

ENGINE FUNCTIONS

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

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

• Plugged charge air cooler.

Do not continue to operate the machine.

Refer to CLEANING COOLER PACKAGE in SECTION 3 and COMPUTER – MESSAGES in THIS SECTION. ENGINE COOLANT TEMPERATURE

200163

This display indicates the current engine coolant temperature.

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

• Plugged radiator.

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

B

C

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

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

2.30

Tigercat H250D Processor

Controls and Operation ENGINE OIL PRESSURE

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

This display indicates engine oil pressure.

If temperature rises above the recommended temperature a message is sent to the computer display and an alarm will sound. Check for the following:

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

• Plugged cooler package access door screen.

• Plugged radiator.

Refer to COMPUTER – MESSAGES in THIS SECTION. ENGINE LOAD

Do not continue to operate machine.

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

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

ENGINE HOURS

FUEL TEMPERATURE

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

This display indicates the fuel temperature.

ENGINE SPEED – RPM

VOLTAGE

This display indicates engine speed in rpm.

IMPORTANT! 24 VOLT ELECTRICAL SYSTEM This display indicates engine voltage levels.

Normal operating range for the electrical system is between 20 V and 30 V. If the engine voltage goes outside the normal range a message is sent to the computer display and an alarm will sound. Refer to COMPUTER – MESSAGES in THIS SECTION.

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

A reading in excess of 30 V indicates a possible faulty voltage regulator.

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

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

FUEL RATE (INSTANTANEOUS)

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

2.31

This display indicates the current rate of fuel consumption.

Controls and Operation

Tigercat H250D Processor

COLD IDLE FUNCTION

UNITS OF MEASURE A

200163

A Cold Idle Function Indicator

Press the F1 button to toggle the cold idle function ON or OFF. The cold idle function indicator will illuminate YELLOW on the computer display when the cold idle function is turned ON.

200163

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

Press the back button to return to the Main screen.

ANTI-STALL

250D-081

Press the F2 button to access the Anti-Stall ON/OFF selection.

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

Press the back button to return to the Main screen.

2.32

Tigercat H250D Processor

Controls and Operation

ADJUSTMENT MENU

HYDRAULIC OIL GRADE SELECTION

200135

200162

Press the F2 button to select the Oil Grade menu.

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

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

Press the OK button to confirm the selection.

Press the back button to return to the Main screen.

200134

The adjustment selections are: Hydraulic Oil Grade Adjustments – select F2

2.33

Controls and Operation INFORMATION MENU

Tigercat H250D Processor FUEL INFORMATION

201275

200162

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

Press the F2 button to reset the total fuel and trip fuel information functions.

201275

The INFORMATION mode menu displays the following information: Serial Number Machine Hours – h Hydraulic Oil Temp – °C or °F Hydraulic Oil Pressure, Load Sense Total Fuel Information Trip Fuel Information

2.34

Tigercat H250D Processor

Controls and Operation

UNITS OF MEASURE

201275

Press the F3 button to access the additional information screen.

201276

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

Press the F3 button to return to the Information menu.

Press the back button to return to the Main screen.

2.35

Controls and Operation

Tigercat H250D Processor

TELEMATICS INFORMATION

201283 201275

Press the F3 button to access the additional information screen.

Machines equipped with LogOn™ (no satellite antenna) will display this screen.

201276

Press the F2 button to show the Telematics information.

This tag is provided in the cab on machines equipped with LogOn™ to instruct the user how to set up the system.

To activate LogOn™: 1. Using a wireless device (laptop computer, tablet, phone), connect to the LogOn machine serial number (example: LogOn – 250H3001).

201284

2. Using a web browser, navigate to the IP address on the tag to obtain the LogOn User's Manual.

Machines equipped with RemoteLog™ and the satellite antenna will display this screen.

2.36

Tigercat H250D Processor

Controls and Operation

MAIN MENU

ADJUST MENU 200161

200162

Press the Menu button to go to the Main menu page.

200161

From the Main menu press the F1 button to access the Adjust menu.

201277

The Main menu page displays the following selections:

The following menu items can be selected:

• Adjust – Select F1

• Machine Parameters

• Measure – Select F2

• Engine

• Preferences – Select F3

• Fan (If equipped with optional variable-pitch fan)

• Info– Select F4

• Engine Operations

To return to the Main screen press the back button.

This menu is an alternate method of accessing the adjustment menu to make machine adjustments. Refer to COMPUTER– ADJUSTMENT MENU in THIS SECTION for details.

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

2.37

Controls and Operation

Tigercat H250D Processor

MACHINE PARAMETERS

IDLE DOWN WAIT TIME 200138

201277

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

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

Press the OK button to make the selection.

Press the OK button to make adjustments.

200139

200138

In the Machine Parameters menu the following items can be selected: • Anti-Stall • Oil Grade • Idle Down Wait Time ANTI-STALL Refer to COMPUTER – ENGINE MENU – ANTI STALL in THIS SECTION for setting instructions.

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

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

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

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

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

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

2.38

Tigercat H250D Processor

Controls and Operation

ENGINE

COLD IDLE SPEED 201289

Press the UP or DOWN arrow buttons to select Engine.

Press the OK button to make the selection.

200766

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

Press the OK button to make adjustments.

200148

The Cold Idle Speed can be adjusted from 950 to 1400 rpm.

Press the UP or DOWN arrow buttons to change the value.

Press the OK button to set the value.

2.39

Controls and Operation

Tigercat H250D Processor FAN

MAX ENGINE SPEED

201290

200767

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

Press the OK button to make adjustments.

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

200768

The Max Engine Speed can be adjusted from 1600 to 2100 rpm.

Press the UP or DOWN arrow buttons to change the value.

Press the OK button to set the value.

2.40

Tigercat H250D Processor

Controls and Operation

FAN AUTO CLEAN

FAN CLEAN FREQUENCY 2000140

2000142

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

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

Press the OK button to make adjustments.

Press the OK button to make adjustments.

2000141

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

2000143

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

The factory default setting is every 30 minutes.

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

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

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

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

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

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

2.41

Controls and Operation

Tigercat H250D Processor

FAN CLEAN DURATION

2000145 2000144

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

Press the OK button to make adjustments.

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

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

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

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

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

2.42

Tigercat H250D Processor

Controls and Operation

MEASURE MENU

201278 200161

This menu is used by Tigercat service technicians.

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

Press the F2 button to access the Measure menu.

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

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

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

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

2.43

Controls and Operation

Tigercat H250D Processor

PREFERENCES MENU

DISPLAY ADJUSTMENT 200166

200161

Press the F3 button to access the Preferences menu.

200164

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

BACKLIGHT ADJUSTMENT 200167

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

Press the F2 button to select the Backlight adjustment.

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

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

Press the OK button to set the value.

2.44

Tigercat H250D Processor

Controls and Operation

SCREEN SAVER ADJUSTMENT

DATE/TIME ADJUSTMENT 200168

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

200169

200152

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

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

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

Press the back button to return to the Preferences menu.

2.45

Controls and Operation

Tigercat H250D Processor

DATE ADJUSTMENT

200155 200153

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

When the month has been confirmed the day is highlighted.

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

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

Press the OK button to confirm day selected.

Press the OK button to confirm year selected.

200152 200154

When the year has been confirmed the month is highlighted.

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

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

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

Press the OK button to confirm month selected.

2.46

Tigercat H250D Processor

Controls and Operation LANGUAGE ADJUSTMENT

TIME ADJUSTMENT 200156

Hour is automatically highlighted.

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

Press the OK button to confirm hour selected.

200157

2000137

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

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

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

Press the back button to return to the Main menu.

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

When the hour has been confirmed the minute is highlighted.

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

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

Press the back button to return to the Preferences menu.

2.47

Controls and Operation

Tigercat H250D Processor

INFO MENU

201279 200161

The following menu items can be selected.

Press the F4 button to access the Info menu.

• Modules – Select F1 • Logs – Select F3 The Machine ID information will be displayed on the screen.

2.48

Tigercat H250D Processor

Controls and Operation

MODULES

LOGS 200159

Press F1 to select the Modules menu. This menu provides information on the following machine modules: • MD3 (Computer)

200165

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

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

• Valve Side • Tigercat/FPT NEF (Engine ECU)

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

• Cab Input Module

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

• Engine Side • Telematics

201280 200160

Shown above the MD3 module has been selected.

Specific information for the computer is displayed on the screen.

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

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

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

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

Press the BACK button to return to the Info screen or press the F1 button to return to the Main menu.

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

2.49

Controls and Operation

Tigercat H250D Processor

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

NOTE: The computer control system will automatically perform a bulb test at engine start up to verify that master alarm and alarm light are functioning. Refer to STARTING ENGINE in THIS SECTION. There are different types of messages and alarms. They appear on the screen as a block message.

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

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

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

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

2.50

Tigercat H250D Processor

Controls and Operation

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

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

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

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

A list of Critical Messages is as follows: • Engine Coolant Level Low • Engine Coolant Temperature High – Engine Derate

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

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message.

In this instance the machine should only be operated long enough to make the machine safe, then STOP machine operation and turn OFF the engine before serious machine damage can occur!

• Main Fuel Filter Clogged – Engine Derate • Boost Pressure Low - Engine Derate • Hydraulic Oil Level Low • Hydraulic Oil Temperature High • Engine Oil Pressure Low – Engine Derate • Hardware Fault – MD3 (Computer) • Hardware Fault – XC21 • Hardware Fault – XA2-A0 • Hardware Fault – XA2-A1

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

• Hardware Fault – Engine • Engine Fault Code Messages – Critical • Engine Oil Pressure Low • Engine Coolant Temperature High • Engine Oil Temperature High • Aftertreatment System Technical Failure * • Engine Restarts Remaining Until Engine Lockout * • Engine Locked Out * • Aftertreatment System Engine Idle Too Long * * NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

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

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

2.51

Controls and Operation ENGINE COOLANT LEVEL LOW

Tigercat H250D Processor ENGINE COOLANT TEMPERATURE HIGH – ENGINE DERATE

Engine Coolant

Engine Coolant

Level Low.

This message will be displayed, alarm light will flash and alarm will sound when the coolant level drops below a safe operating level. The sensor is located in the surge tank.

If the light comes on when the engine is running, turn OFF the engine immediately and correct the fault. With engine running, top up radiator using correct solution of coolant.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3.

Temperature high - Engine Derate

This message will be displayed, alarm light will flash and alarm will sound when an engine derate is activated due to high engine coolant temperature. This message may be accompanied by Engine Fault Code Messages related to coolant temperature.

This message results in the following derate sequence: When coolant temperature rises to 107°C (225°F) for more than 5 seconds the critical symbol will flash.

When coolant temperature rises to 110°C (230°F) for more than 5 seconds this message will be shown and the engine will immediately begin to derate at 50 rpm/s to a set creep speed allowing the operator to safely stop the machine. Do not continue to operate machine.

Safely stop the machine, set engine speed at LOW and turn the A/C off. If the engine coolant temperature reading does not return to normal operating levels turn the engine OFF and perform further cooling system checks. Refer to COMPUTER– MESSAGES– CRITICAL – ENGINE COOLANT TEMPERATURE HIGH in THIS SECTION for recommended corrective action.

If engine coolant temperature does not return to normal operating levels contact dealer for service.

When coolant temperatures fall below 106°C (223°F) for more than 5 seconds this message will be turned off and the engine will automatically ramp up engine speed at 50 rpm/s to full operating speed.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be activated as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERT– ENGINE TORQUE DERATE ACTIVE.

2.52

Tigercat H250D Processor

Controls and Operation

MAIN FUEL FILTER CLOGGED – ENGINE DERATE

BOOST PRESSURE LOW – ENGINE DERATE

Engine Boost Pressure

Main Fuel Filter

Boost Pressure Low - Engine Derate

Clogged - Engine Derate

This message will be displayed, alarm light will flash and alarm will sound when an engine derate is activated due to a clogged main fuel filter. This message may be accompanied by Engine Fault Code Messages.

When a main fuel filter clog is detected a message will be displayed to alert the operator.

This message results in the following derate sequence: • When a fuel filter clog continues for more than 5 minutes this message will be shown and engine speed will immediately begin to derate at 5% per second to a set creep speed allowing the operator to safely stop the machine.

Change engine fuel filter as soon as possible to correct. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine fuel filter replacement instructions. If the problem continues contact dealer for service.

This message will be displayed, alarm light will flash and alarm will sound when an engine derate is activated due to turbocharger boost pressure being insufficient for engine load.

When low boost pressure is detected a message will be displayed to alert the operator.

This message results in the following derate sequence: • When low boost pressure is detected for more than 5 seconds the critical symbol will flash.

• Engine speed will immediately begin to derate at 5% per second to a set creep speed allowing the operator to safely stop the machine.

IMPORTANT! Do not continue to operate machine.

Safely stop the machine, set engine speed at LOW and turn OFF the engine. Contact dealer for service.

• When a fuel filter clog condition is no longer detected for more than 5 seconds this message will be turned off and engine speed will automatically ramp up at 5% per second to full operating speed.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be activated as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERT– ENGINE TORQUE DERATE ACTIVE in THIS SECTION.

2.53

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be activated as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERT– ENGINE TORQUE DERATE ACTIVE in THIS SECTION.

Controls and Operation HYDRAULIC OIL LEVEL LOW

Tigercat H250D Processor HYDRAULIC OIL TEMPERATURE HIGH

Hydraulic Oil

Hydraulic Oil

Level Low.

Temperature High.

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

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

When this alarm is activated turn OFF the engine and look for signs of broken hoses or other leaks. Repair leaks and refill the hydraulic oil tank to FULL mark on the hydraulic oil level sight gauge. Restart engine and inspect for leaks.

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

If the temperature rises above the recommended operating range for the type of hydraulic oil in use check the following: • Plugged cooler package access door screen.

• Malfunction in the hydraulic system.

• High loads on the hydraulic system.

• Malfunction of the cooling fan .

• Low hydraulic oil level.

• Correct Hydraulic Oil Grade Selection.

If hydraulic oil temperature rises above the recommended operating range, do not continue to operate the machine.

This alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main screen, together with the HYDRAULIC OIL OPERATING RANGE chart in SECTION 3 to prevent damage to the hydraulic system.

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

Operating outside the recommended operating range shortens hydraulic component life.

Refer to COMPUTER – ADJUSTMENT MENU – HYDRAULIC OIL GRADE SELECTION in THIS SECTION for hydraulic oil grade selection settings information.

Refer to APPROVED HYDRAULIC OILS in SECTION 3 for hydraulic oil operating range information.

Refer to COMPUTER – MAIN SCREEN in THIS SECTION for hydraulic oil temperature gauge

2.54

Tigercat H250D Processor

Controls and Operation

ENGINE OIL PRESSURE LOW – ENGINE DERATE

HARDWARE FAULT – MD3 (COMPUTER)

Hardware Fault – MD3

Engine Oil Pressure

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

Oil Pressure Low – Engine Derate

This message will be displayed, alarm light will flash and alarm will sound when and engine derate is activated due to low engine oil pressure. This message may be accompanied by Engine Fault Code Messages related to engine oil pressure.

This message results in the following derate sequence: When engine oil pressure readings fall below 1.2 bar (17 psi) for more than 5 seconds this message will be shown and engine speed will immediately begin to derate at 5% per second to a set creep speed allowing the operator to safely stop the machine. Do not continue to operate machine.

Safely stop the machine and turn OFF the engine. Refer to COMPUTER– MESSAGES– CRITICAL – ENGINE OIL PRESSURE LOW in THIS SECTION for recommended corrective action. If the problem continues contact dealer for service.

When engine oil pressure readings rise above 1.4 bar (20 psi) for more than 5 seconds this message will be turned off and engine speed will automatically ramp up at 5% per second to full operating speed.

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

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON. A VREF error is an example of the type of hardware fault which will be the original active fault which activates this message.

HARDWARE FAULT – XC21

Hardware Fault – XC21-A2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the XC21 expansion module (cab) has been hidden.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be activated as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERT– ENGINE TORQUE DERATE ACTIVE.

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON. A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which activates this message.

2.55

Controls and Operation HARDWARE FAULT – XA2-A0

Tigercat H250D Processor HARDWARE FAULT – ENGINE

Hardware Fault – XA2-A0

Hardware Fault – Engine

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

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

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the XA2-A0 expansion module has been hidden.

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON. A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which activates this message.

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

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON. No contact error is an example of the type of hardware fault which may be the original active fault which activates this message.

HARDWARE FAULT – XA2-A1

Hardware Fault – XA2-A1 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the XA2-A1 expansion module has been hidden.

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON. A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which activates this message.

2.56

Tigercat H250D Processor

Controls and Operation

ENGINE OIL TEMPERATURE HIGH

ENGINE FAULT CODE MESSAGES – CRITICAL

SPN: 7123 1 of 1

SPN: 4645 1 of 1

Engine oil temperature high.

Contact dealer.

This message will be displayed, alarm light will flash and alarm will sound when engine oil temperature exceeds recommended engine temperature.

Check the cooler package and fan for proper operation and run a clean cycle if the machine is equipped with a variable-pitch fan. It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures. Refer to CLEANING COOLER PACKAGE in SECTION 3.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for code information.

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

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

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

NOTE: Some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN code and contact service for more information.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for specific information regarding the engine and aftertreatment system.

NOTE: Contact your Tigercat dealer to obtain an Engine Fault Codes chart. An up to date copy should be kept in the manual box (in the cab). The chart is updated regularly by the engine manufacturer, so it is important to check periodically with the Tigercat dealer to ensure that you have a current copy of the Engine Fault Codes chart.

2.57

Controls and Operation ENGINE OIL PRESSURE LOW – SPN: 9939

Tigercat H250D Processor ENGINE COOLANT TEMPERATURE HIGH – SPN: 63011

SPN: 9939 1 of 1

SPN: 63011 1 of 1

Engine Oil Pressure Low.

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

Turn OFF the engine when this alarm is activated. Check engine oil level.

Refer to STARTING ENGINE in THIS SECTION for more information.

Engine coolant temperature high.

This message will be displayed, alarm light will flash and alarm will sound when engine temperature exceeds recommended engine temperature.

When this alarm is activated check for: • Plugged cooler package access door screen.

• Plugged radiator.

• Malfunction of the cooling fan.

Refer to CLEANING COOLER PACKAGE in SECTION 3.

WARNING

Do not remove the radiator cap when the engine is hot, release of pressurized coolant can cause serious burns.

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

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

2.58

Tigercat H250D Processor

Controls and Operation 2. The engine continues to operate at 75% of rated torque for approximately 65 minutes.

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

3. Engine torque reduces to 35% of rated torque over the next 40 minutes.

4. The engine continues to operate at 35% of rated torque for approximately 50 minutes.

AFTERTREATMENT SYSTEM TECHNICAL FAILURE

5. Engine torque reduces to minimum value as engine speed reduces to LOW over the next 30 minutes.

Some less severe technical faults can be fixed after the engine has been fully derated to LOW.

Aftertreatment System

More severe technical faults will result in an engine lockout when engine speed has derated to LOW and there have been 3 restarts. Once locked out the engine will only operate at LOW speed. The original cause(s) of the lockout must be corrected before the engine can be reset. Contact dealer to reset engine lockout for normal operation.

Technical failure severe. Engine lockout may occur after full torque derate and 3 engine restarts.

Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE LOCKED OUT and COMPUTER – MESSAGES– CRITICAL – ENGINE RESTARTS REMAINING UNTIL ENGINE LOCKOUT in THIS SECTION.

This message will be displayed, alarm light will flash and alarm will sound when an aftertreatment technical fault is detected. Take immediate action to avoid affecting engine performance and damage to the diesel oxidation catalyst /selective catalytic reduction (DOC/SCR) aftertreatment system components.

Identify the cause of the technical failure and take action to correct the problem.

TheEngine following engine derate sequence occurs derate – technical failure and tampering immediately after the Aftertreatment System– Technical failure severe message:

Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

1. Engine torque reduces to 75% of rated torque over the next 25 minutes.

100%

MIN

C

.

80%

≈ 25

90%

A

B

70%

≈ 65 MIN.

0M

50%

I N.

TORQUE

≈4

60%

40%

D

30%

≈ 50 MIN.

≈ 30

20%

MIN .

10% 0%

E

F

0

60

1000010

180

120

MINUTES

240

300

A Critical Message: Aftertreatment System– Technical Failure Severe.

Engine torque begins to reduce.

D

Engine torque reduced to 35% after 40 minutes.

B Engine torque reduced to 75% after 25 minutes.

C Engine torque begins to reduce further after 65 minutes.

E F

Engine torque begins to reduce further after 50 minutes.

Engine speed reduced to LOW after 30 minutes.

2.59

Controls and Operation ENGINE STARTS REMAINING UNTIL ENGINE LOCKOUT

Tigercat H250D Processor ENGINE LOCKED OUT

Engine

Engine

Engine locked out. Engine derate to 0% Torque and 850 rpm. Contact Dealer.

3 restarts remaining until engine lockout.

This message will be displayed, alarm warning light will flash and alarm will sound to inform the operator of the number of restarts available before the engine is locked out.

Note that an engine is locked out after several other critical aftertreatment system messages regarding the cause of the problem and this message regarding the number of restarts until engine lockout.

Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE LOCKED OUT in THIS SECTION.

This message will be displayed, alarm warning light will flash and alarm will sound when an engine is locked out by the computer system to prevent further damage to the engine and aftertreatment system.

Note that an engine is locked out after several other critical aftertreatment system messages regarding the cause of the problem and additional messages regarding the number of restarts until engine lockout.

Once locked out the engine will only operate at 850 rpm.

The original cause(s) of the lockout must be corrected before the engine can be reset. Contact dealer to reset engine lockout for normal operation.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL. Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE RESTARTS REMAINING UNTIL ENGINE LOCKOUT in THIS SECTION.

2.60

Tigercat H250D Processor

Controls and Operation

AFTERTREATMENT SYSTEM ENGINE IDLE TOO LONG

Aftertreatment System Engine idle too long. Shutdown engine to prevent damage to emission control system.

This message will be displayed, alarm light will flash and alarm will sound when this engine has idled for more than one hour. Shutdown engine to prevent damage to the emission control system.

IMPORTANT! Engine should not idle longer than one hour.

Damage to the emission control system will result.

When this machine idles for an extended period excess hydrocarbon buildup is created in the SCR aftertreatment system. Burn off of excess hydrocarbon at full load immediately after a long idle period will generate excess heat which will cause damage to emission control system components. It will take 45 minutes at 40% load (or an SCR exhaust outlet temperature of 320°C (608°F) to burn off the hydrocarbon that accumulates during a long idle.

2.61

Controls and Operation

Tigercat H250D Processor

ERROR MESSAGES (RED) Error messages advise the operator that a machine fault is about to occur or a system fault has occurred.

Error messages are computer system generated and are generally activated by computer system error and fault related conditions.

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

Error messages are activated when a fault such as an electrical connection is broken/disconnected. Most error messages are due to computer system hardware or connection faults.

A list of some types of ERROR MESSAGES is as follows:

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

Voltage Input Error (VIN)

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

Current Output Error (COUT)

In some instances the machine requires immediate action to correct the problem which requires the operator to stop machine operation, shut the engine off and service the machine to correct the problem.

Module VREF Error Digital Input Error (DIN) Digital Output Error (DOUT) Module No Contact Error NOTE: Not all error messages are shown.

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message.

In this instance the machine should only be operated long enough to move the machine to a safe location then stop machine operation and shut the engine off before serious machine damage can occur!

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

Error messages flash the critical symbol or the alert above the F4 button when active messages are hidden depending on the type of error message. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

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

2.62

Tigercat H250D Processor

Controls and Operation

MODULE VREF ERROR The module VREF message will be displayed to indicate a problem related to the 5V reference signal coming from the module.

MD3

The module is identified on the display screen.

VREF error

This message indicates a problem with a sensor, connecting wires or the 5V reference signal itself.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen.

Refer to COMPUTER – MESSAGES – ALERT and COMPUTER – MESSAGES– CRITICAL in THIS SECTION. XC21 VREF error

XA2-A0 VREF error

XA2-A1 VREF error

2.63

Controls and Operation VOLTAGE INPUT ERROR (VIN)

Air Intake Sensor VIN Low error

Tigercat H250D Processor CURRENT OUTPUT ERROR (COUT) Current output error messages will be displayed to indicate a problem with a current output signal from a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal destination and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

Voltage input error messages will be displayed to indicate a problem with a voltage input signal to a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal source and the text indicates the type of error.

Once acknowledged these message will be replaced with a hardware failure message for the corresponding module when active faults recalled to the screen. Refer to COMPUTER– MESSAGES– ALERT– HARDWARE FAILURE in THIS SECTION.

COMPUTER MODULE BLANK SCREEN

An example of a voltage input error message is shown above.

DIGITAL INPUT ERROR (DIN) Digital input error messages will be displayed to indicate a problem with a digital input signal to a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal source and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

DIGITAL OUTPUT ERROR (DOUT) Digital output error messages will be displayed to indicate a problem with a digital output signal from a computer system module.

The computer module is the central unit in the computer control system, which works as both a master and a display unit. Faults or failure in this unit will affect all other computer components.

Likely causes are:

The module and pin number are identified on the display screen.

• Power – Fuse (Computer)

The heading identifies the signal destination and the text indicates the type of error.

• LCD display settings too light to read

• Ground • Faulty computer

The display is similar to the voltage input error message shown above.

2.64

Tigercat H250D Processor

Controls and Operation

MODULE NO CONTACT ERROR The module no contact error message will be displayed to indicate a loss of communication with or power to a module. The module is identified on the display screen.

When a module loses contact all machine functions controlled by that module cease and all messages associated with that module are activated. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

Engine Side XA2-A1 No contact

NOTE: If the display has a loss of power or other malfunction the screen may go blank and all machine functions controlled by the computer system will be affected.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen.

Refer to COMPUTER – MESSAGES – ALERT and COMPUTER – MESSAGES– CRITICAL in THIS SECTION.

Valve Side XA2-A0 No contact

Cab Input Module XC21(0) No contact

Tigercat/FPT NEF No contact

2.65

Controls and Operation

Tigercat H250D Processor

ALERT MESSAGES (YELLOW) Alert messages advise the operator that machine operation will be compromised.

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

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

Service the machine to correct the problem at the earliest opportunity to prevent future damage to the machine.

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

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

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

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

There are two types of alert messages: 1. Alert programmed messages. The messages are generally initiated by machine function related conditions.

2. Alert computer system messages. These messages which are generally initiated by computer system errors and fault related conditions.

NOTE: Active hardware fault alert messages are acknowledged by pressing the F2 button (OK). To recall these messages turn ignition key switch OFF and ON. On screen messages will indicate to the operator that an active hardware fault has been hidden.

When an alert message is displayed, the audible alarm and warning light will sound and flash on and off three times alerting the operator of the message. The alert message remains on the screen until the operator hides it by pressing the F2 button (Hide).

2.66

Tigercat H250D Processor

Controls and Operation

INTERACTIVE ALERT MESSAGES

ENGINE AIR INTAKE FILTER RESTRICTED

A list of ALERT MESSAGES is as follows: • Engine Air Intake Filter Restricted • Hydraulic Oil Filter Restricted

Engine Air Filter

• Main Fuel Filter Clogged

Restricted. Service Machine.

• Fuel Level Low • Charge Filter Bypass • Machine Voltage High • Machine Voltage Low • Hoist Boom Limit Sensor Error • Stick Boom Limit Sensor Error

This message will be displayed when a signal is received from the restriction indicator sensor on the engine air cleaner.

• Joystick Axis Fault • Hardware Fault – Voltage Input • Hardware Fault – Digital Input • Hardware Fault – Digital Output • Hardware Fault – Current Output • Hardware Fault – MD3 (Computer) • Hardware Fault – Module XA2-A0

T250D-147

• Hardware Fault – Module XA2-A1

A

A Engine Air Intake Filter Restriction Icon – ON (Red)

• Hardware Fault – Module XC21

The engine air intake filter restriction icon on the computer display will also illuminate RED.

• Hardware Failure – Voltage Input • Hardware Failure – Digital Input

When this happens the engine air cleaner requires immediate service.

• Hardware Failure – Digital Output • Hardware Failure – Current Output

Refer to AIR INTAKE SYSTEM– AIR CLEANER in SECTION 3.

• Module High Temperature • Module High Supply Voltage • Module Low Supply Voltage • Engine Fault Code Messages – Alert • Engine Coolant Temperature High • Engine Torque Derate Active • Water in Fuel • Engine Voltage Low • Engine Voltage High • Diesel Exhaust Fluid Quality * • Diesel Exhaust Fluid Level – Below 10% * • Diesel Exhaust Fluid Level – Below 5% * • Diesel Exhaust Fluid Level – Empty * * NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

2.67

Controls and Operation HYDRAULIC OIL FILTER RESTRICTED

Tigercat H250D Processor MAIN FUEL FILTER CLOGGED

Hydraulic Oil Filter

Main Fuel Filter

Restricted. Service machine.

Clogged. Replace filter to prevent engine derate

This message will be displayed when an oil flow restriction in excess of 1.4 bar (20 psi) is encountered at the hydraulic oil return filters. If pressure continues to build up to 1.7 bar (25 psi) the bypass valve in the filter head opens allowing oil to bypass the filter elements and return to the hydraulic oil tank .

A

This message will be displayed when a main fuel filter clog is detected.

Replace engine fuel filter to prevent engine derate.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine fuel filter replacement instructions.

When a fuel filter clog continues for more than 5 minutes a critical message will be shown and the engine will immediately begin to derate. Refer to COMPUTER – MESSAGES– CRITICAL – MAIN FUEL FILTER CLOGGED– ENGINE DERATE in THIS SECTION.

T250D-133

A Hydraulic Oil Filter Restricted Icon – ON (Red)

The hydraulic oil filter restriction icon on the computer display will also illuminate RED. If this message appears, replace all four hydraulic oil return filters to prevent contamination to the hydraulic system which could lead to damage to hydraulic components.

Refer to FILTERS– HYDRAULIC OIL RETURN in SECTION 3.

2.68

Tigercat H250D Processor

Controls and Operation

FUEL LEVEL LOW

MACHINE VOLTAGE HIGH

Fuel

Machine Voltage

Level low.

High. Service machine to correct.

This message will be displayed when the fuel level falls below 5% of full.

This message will be displayed when machine voltage readings of greater than 30 volts are detected.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

A

MACHINE VOLTAGE LOW

200317

A Fuel Icon – Low (Yellow)

The fuel icon will also illuminate yellow when the fuel level is low.

Machine Voltage

Refer to REFUELLING PROCEDURE in SECTION 3.

Low. Service machine to correct.

CHARGE FILTER BYPASSED

Charge Filter Bypassed. Service machine to correct.

This message will be displayed when machine voltage readings of less than 20 volts are detected.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

This message will be displayed when an oil flow restriction in excess of 3.5 bar (50 psi) is encountered at the swing pump charge pressure filter and hydraulic oil is bypassing the filter.

Refer to FILTERS– SWING PUMP CHARGE PRESSURE in SECTION 3.

2.69

Controls and Operation HOIST BOOM LIMIT SENSOR

Tigercat H250D Processor JOYSTICK AXIS FAULT

Hoist Boom Limit Sensor

RH Joystick Y-Axis

Malfunction. Contact Dealer

Low Voltage

This message will be displayed when a malfunction occurs with this sensor.

The sensor helps cushion the hoist boom cylinder at minimum and maximum stroke.

When this alarm is activated contact Tigercat Dealer to repair or replace the sensor.

This message will be displayed when a fault has been detected in one of the voltage outputs from the joystick axis.

This message will indicate if the fault is in the left or right joystick and with the X or Y axis.

STICK BOOM LIMIT SENSOR

Stick Boom Limit Sensor Malfunction. Contact Dealer

This message will be displayed when a malfunction occurs with this sensor.

The sensor helps cushion the stick boom cylinder at minimum and maximum stroke.

When this alarm is activated contact Tigercat Dealer to repair or replace the sensor.

2.70

Tigercat H250D Processor

Controls and Operation

HARDWARE FAULT – MD3 (COMPUTER)

HARDWARE FAULT – XA2-A0

Hardware Fault – MD3

Hardware Fault – XA2-A0

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

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

This message will be displayed when an alert level active hardware fault related to the computer has been hidden.

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

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON.

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON.

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

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which activate this message.Hardware Fault – xA2-A1

HARDWARE FAULT – XC21 Hardware Fault – XA2-A1 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault – XC21 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

This message will be displayed when an alert level active hardware fault related to the XC21-A2 expansion module (cab) has been hidden.

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON. High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which activate this message.

2.71

This message will be displayed when an alert level active hardware fault related to the XA2-A1 expansion module has been hidden.

To recall the original active fault(s) the operator must turn the ignition key switch OFF and ON. High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which activate this message.

Controls and Operation HARDWARE FAILURE – VOLTAGE INPUT

Tigercat H250D Processor HARDWARE FAILURE – DIGITAL OUTPUT

Hardware Failure – VIN

Hardware Failure – DOUT

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

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

This message will be displayed when a voltage input error message has been hidden.

This message will be displayed when a digital output error message has been hidden.

To recall the original active fault(s) turn the ignition key OFF and ON.

To recall the original active fault(s) turn the ignition key OFF and ON.

HARDWARE FAILURE – DIGITAL INPUT

HARDWARE FAILURE – CURRENT OUTPUT

Hardware Failure – DIN

Hardware Failure – COUT

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

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

This message will be displayed when a digital input error message has been hidden.

This message will be displayed when a current output error message has been hidden.

To recall the original active fault(s) turn the ignition key OFF and ON.

To recall the original active fault(s) turn the ignition key OFF and ON.

2.72

Tigercat H250D Processor

Controls and Operation

MODULE HIGH TEMPERATURE

MODULE LOW SUPPLY VOLTAGE

XA2[0]@MD3[0]:A

XA2[0]@MD3[0]:A

Valve Side

Valve Side

High temperature Value 88°C

Low supply voltage

Module high temperature alert message will be displayed to indicate the computer control system has detected high temperature readings in a system module.

The module is identified on the display screen. The temperature reading value is also displayed.

Module low supply voltage alert message will be displayed to indicate the computer control system has detected low supply voltage readings in a system module.

The module is identified on the display screen.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES – ALERT – HARDWARE FAULT in THIS SECTION.

MODULE HIGH SUPPLY VOLTAGE XA2[0]@MD3[0]:A

Valve Side High supply voltage Value 35.80 V

Module high supply voltage alert message will be displayed to indicate the computer control system has detected high supply voltage readings in a system module.

The module is identified on the display screen. The voltage reading value is also displayed.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES – ALERT – HARDWARE FAULT in THIS SECTION.

2.73

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES – ALERT – HARDWARE FAULT in THIS SECTION.

Controls and Operation ENGINE FAULT CODE MESSAGES – ALERT

Tigercat H250D Processor ENGINE COOLANT TEMPERATURE HIGH – SPN: 62755

SPN: ##### 1 of 1

SPN: 62755

Contact service

Alert engine fault message(s) are displayed, the alarm light flashes and the alarm sounds when an alert engine fault message is received from the engine electronic control module.

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

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

NOTE: Some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN code and contact service for more information.

Engine coolant temperature high.

This message will be displayed, alarm light will flash and alarm will sound when engine temperature exceeds recommended engine temperature.

When this alarm is activated check for: • Plugged cooler package access door screen.

• Plugged radiator.

• Malfunction of the cooling fan.

Refer to CLEANING COOLER PACKAGE in SECTION 3.

Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE COOLANT TEMPERATURE HIGH in THIS SECTION.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for specific information regarding the engine.

2.74

Tigercat H250D Processor

Controls and Operation

ENGINE TORQUE DERATE ACTIVE– SPN:64911

ENGINE VOLTAGE LOW – SPN: 8801 OR 9313

SPN: 64911 1 of 1

SPN: 8801 1 of 1

Engine torque derate active.

Engine voltage low.

This message will be displayed, alarm light will flash and alarm will sound when the engine ECU has derated the engine. The code for a Torque Derate due to high NOx is shown above as an example.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for code information to identify the cause(s) of engine derating and more information regarding failure cause and repair.

WATER IN FUEL – SPN 17429

This message will be displayed when engine voltage readings of less than 20 V are detected.

When this alarm is activated investigate the cause immediately.

ENGINE VOLTAGE HIGH – SPN 4449 OR 4961

SPN: 4449 1 of 1 Engine voltage high.

SPN: 17429 1 of 1 Water in fuel.

This message will be displayed when engine voltage readings of greater than 30 V are detected.

This message will be displayed when water is detected in the fuel.

When this alarm is activated check the fuel filter/water separator.

2.75

When this alarm is activated investigate the cause immediately.

Controls and Operation THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY.

DIESEL EXHAUST FLUID QUALITY

Tigercat H250D Processor Refer to DIESEL EXHAUST FLUID TANK – DRAINING AND CLEANING in SECTION 3.

Refer to AFTERTREATMENT SYSTEM in SECTION 3 for information regarding the use of DEF and its function in the aftertreatment system.

SPN: 19402

SPN: 19658

DEF quality low.

DEF quality low.

This message will be displayed, alarm light will flash and alarm will sound when a diesel fluid quality problem is detected. Take immediate action to correct the problem to avoid affecting engine performance and damage to the aftertreatment system components.

This message results in the following derate and engine lockout sequence if no action is taken to correct the problem: 1. Beginning approximately 50 minutes after a DEF quality low message, engine speed ramps down to 1320 rpm and engine torque reduces to 35% of rated torque over the next 40 minutes.

2. After operating for two hours at derated engine speed and torque, engine speed reduces to LOW and engine torque reduces to its minimum value over the next 30 minutes.

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

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

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

A total of three restarts are allowed after any derate has started. Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE LOCKED OUT and COMPUTER – MESSAGES– CRITICAL – ENGINE RESTARTS REMAINING UNTIL ENGINE LOCKOUT in THIS SECTION. To correct the DEF quality problem, clean the area around the DEF tank then drain and refill the tank with clean DEF which meets ISO 22241 specifications.

Additional messages from the DENOX 2.2 Module will also be displayed. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for code information.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be displayed as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERT– ENGINE TORQUE DERATE ACTIVE.

2.76

T4f Engine derate – poor DEF quality

Tigercat H250D Processor

Controls and Operation

DIESEL EXHAUST FLUID QUALITY – ENGINE DERATE SEQUENCE 100%

B

A ≈ 50 MIN.

90% 80%

≈ 40

70%

TORQUE

M I N.

60% 50% 40%

D

30%

≈ 120 MIN.

C

≈ 30

20%

MIN

0%

.

10%

E

0

120

60

240

300

MINUTES

1000009

A Alert Message: Poor DEF quality detected.

B Engine torque begins to reduce.

C Engine torque reduced to 35% after 40 minutes.

180

D Engine torque begins to reduce further after 120 minutes.

E Engine speed reduced to LOW after 30 minutes.

2.77

Controls and Operation DIESEL EXHAUST FLUID LEVEL There are three levels of diesel exhaust fluid level messages generated by the DENOX 2.2 Module.

DIESEL EXHAUST FLUID LEVEL BELOW 10%

Tigercat H250D Processor Fill the DEF tank and restart the engine to clear the message.

Refer to DIESEL EXHAUST FLUID TANK – FILLING in SECTION 3.

DIESEL EXHAUST FLUID LEVEL EMPTY

SPN: 61839 1 of 1

SPN: 64191 1 of 1

DEF Level below 10%.

This message will be displayed, alarm light will flash and alarm will sound when a diesel exhaust fluid level below 10% is detected. Take immediate action to correct DEF levels to avoid affecting engine performance and damage to the aftertreatment system components.

The engine will continue to operate normally for approximately one hour after this message is displayed.

Fill the DEF tank and restart the engine to clear the message.

Refer to DIESEL EXHAUST FLUID TANK – FILLING in SECTION 3.

DIESEL EXHAUST FLUID LEVEL BELOW 5%

SPN: 62095 1 of 1 DEF Level below 5%.

DEF tank empty.

This message will be displayed, alarm light will flash and alarm will sound when diesel exhaust fluid level empty is detected. Take immediate action to correct DEF levels to avoid affecting engine performance and damage to the aftertreatment system components.

Beginning immediately after a DEF tank empty message, engine speed reduces to LOW and engine torque reduces to its minimum value over the next 30 minutes.

Fill the DEF tank and restart the engine to clear the message.

Refer to DIESEL EXHAUST FLUID TANK – FILLING in SECTION 3.

NOTE: An ENGINE TORQUE DERATE ACTIVE message will also be displayed as the engine begins to derate. Refer to COMPUTER – MESSAGES– ALERT– ENGINE TORQUE DERATE ACTIVE.

This message will be displayed, alarm light will flash and alarm will sound when a diesel exhaust fluid level below 5% is detected. Take immediate action to correct DEF levels to avoid affecting engine performance and damage to the aftertreatment system components.

Beginning immediately after a DEF Level below 5% message, engine speed ramps down to 1320 rpm and engine torque reduces to 35% of rated torque over the next 40 minutes.

2.78

T4f Engine derate – low DEF level

Tigercat H250D Processor

Controls and Operation

DIESEL EXHAUST FLUID LEVEL – ENGINE DERATE SEQUENCE 100% 90%

A

≈ 60 MIN.

B

80% 70% ≈ 40 MIN

60%

.

TORQUE

50% 40% ≈ 20 MIN.

30%

C

D 0M

≈3

20%

1000008

.

0%

IN

10% <10%

<5%

E

0

≈ 1.8% DEF LEVEL

A Alert Message: DEF Level Below 10%.

B Alert Message: DEF Level Below 5%. Engine torque begins to reduce.

C Engine torque reduced to 35% after 40 minutes.

2.79

D E

DEF tank empty. Engine speed begins to reduce to LOW. Engine speed reduced to LOW after 30 minutes.

Controls and Operation

Tigercat H250D Processor

CAB TILT

CAB TILT PUMP

Cab tilt is operated hydraulically by the cab tilt pump located in the riser below the cab. An electric pump and motor and self contained tank provide hydraulic power for the cab tilt hydraulic cylinder.

A B

A

C

201038

201235

Left Side of Riser– Cover Plate Hidden for Clarity

A Manual Override B Fill Cap C Pump Tank

DEXRON III ATF hydraulic oil is used as the hydraulic oil for the cab tilt hydraulic system. Remove the fill cap on top of the tank to add oil. System capacity is 3.75 L (1 US gal). Tank capacity is 0.9 L (30 oz).

B

NOTE: Check oil level and add oil to tank with cab in the tilt DOWN position.

Place a drain pan under the tank and operate the cab tilt DOWN and UP with the fill cap off to verify the system is not over filled after topping up the tank. Wipe up any spilled oil and install the fill cap.

201236

A Cab in the Backward (UP) Position B Cab in the Forward (DOWN) Position

The cab can also be tilted manually with the hydraulic hand pump. Refer to CAB TILT – TILTING PROCEDURE – HAND PUMP in THIS SECTION.

2.80

Tigercat H250D Processor

Controls and Operation

CAB TILTING PROCEDURE – ELECTRIC PUMP

WARNING

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

Check that no personnel are in front of the cab before tilting.

2. Remove all loose items from inside the cab.

3. Close and latch the cab door.

A

B

201037

A Retaining Bolts B Bolt Locker

4. Remove the retaining bolts at the rear of cab riser and place in the bolt locker. Refer to CAB TILT– BOLT LOCKER in THIS SECTION. Doors on the riser provide access to the bolts.

7. Using the cab tilt pump key switch, turn the key counterclockwise to tilt the cab forward (DOWN) until the tilt cylinder stops.

A

NOTE: Do not leave the cab partially tilted. It should be either fully forward or fully upright.

8. Using the cab tilt pump key switch, turn the key clockwise to tilt the cab (UP) back to its upright operating position.

9. Reinstall the retaining bolts at the rear of the cab riser frame and torque to 925 – 1016 N-m (681 – 750 lbf-ft).

250D-004

WARNING Failure to install the retaining bolts will render the machine unsafe.

250D-004

A Cab Tilt Pump Key Switch

5. Insert key in cab tilt pump key switch on electrical box in engine compartment.

6. Check there are no obstacles in front of the cab that would prevent the cab from tilting.

2.81

Controls and Operation

Tigercat H250D Processor

CAB TILTING PROCEDURE – HAND PUMP 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove all loose items from inside the cab.

3. Close and latch the cab door.

A

B

201037

A Retaining bolts B Bolt Locker

4. Remove the retaining bolts at the rear of cab riser and place in the bolt locker. Refer to CAB TILT– BOLT LOCKER in THIS SECTION. Doors on the riser provide access to the bolts.

A

A T234B-017

A Cab Tilt Hand Pump

5. The cab tilt hand pump handle is stored on the inside of the front access door. Insert the handle into the hand pump located in the engine compartment.

6. Check there are no obstacles in front of the cab that would prevent the cab from tilting.

T234B-017

A Hand Pump Valve

7. Turn the hand pump valve all the way clockwise.

Operate the hand pump to tilt the cab forward (DOWN) until the tilt cylinder stops.

NOTE: Do not leave the cab partially tilted. It should be either fully forward or fully upright.

WARNING Check that no personnel are in front of the cab before tilting.

2.82

Tigercat H250D Processor

Controls and Operation

A

201038

A Cab Tilt Pump Manual Override

8. Turn the manual override on the electric pump solenoid valve and operate the hand pump to tilt the cab (UP) back to the upright operating position.

9. Reinstall the retaining bolts at the rear of the cab riser frame and torque to 925 – 1016 N-m (681 – 750 lbf-ft).

WARNING Failure to install the retaining bolts will render the machine unsafe.

10. Turn the manual override on the electric pump solenoid back to the original position.

2.83

Controls and Operation

Tigercat H250D Processor

BOLT LOCKER

A B

C B 880D-049

A Bolt Locker Gate B Cable Tie

Prior to tilting the cab for maintenance or transporting, remove the cab riser mounting bolts and store in the locker. The bolt locker is located on the floor of the cab riser. Lift the bolt locker gate and place the retaining bolts upside down in the locker. Close the bolt locker gate.

A

When transporting the machine, secure the bolt locker gate with a cable tie.

200178

A Bolt Locker B Bolt Locker Gate C Retaining bolts

B

C

A

200179

A Bolt Locker B Bolt Locker Gate C Retaining bolts

2.84

Tigercat H250D Processor

Controls and Operation

BATTERY BOOSTING NOTICE A

This machine has a 24 V starting system. Only use the same voltage when boosting with an auxiliary battery. Using a higher or lower voltage will cause serious damage to the electrical system. Only a compatible (same) voltage is permissible.

A

B

B

200176

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

6. Connect the clamp of the red jumper cable to the positive (+) terminal of the dead battery.

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

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

200177

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

9. Connect the other clamp of the black jumper cable to the negative ( – ) terminal of the dead battery.

The batteries are located in the rear of the engine compartment.

10. Start the engine with the good battery.

BATTERY BOOSTER CABLE WITH CLAMPS

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

11. Start the engine with the dead battery.

1. Situate the boosting source as close to the machine as possible without touching.

IMPORTANT

13. Disconnect the clamp of the black jumper cable from the negative (-) terminal of the good battery.

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

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

24 VOLT ELECTRICAL SYSTEM 2. Make sure the machine with the good battery uses a 24 V system.

3. Turn OFF the ignition of both machines.

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

5. Remove the protective covers from the battery terminals.

2.85

16. Replace the protective covers on the battery terminals.

If the batteries require charging, refer to BATTERY CARE in SECTION 3.

Controls and Operation

REFUELLING WARNING

Tigercat H250D Processor THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F MACHINES ONLY.

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

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.

2.86

Tigercat H250D Processor

Controls and Operation

OPERATING THE MACHINE The appropriate lubrication and maintenance schedule must been performed prior to operating the machine.

Refer to SCHEDULED MAINTENANCE in SECTION 3.

A

Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL supplied with the machine.

B

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

PRESTART CHECKS 1. Unlock cab door.

234B-001

A Fuel Level Gauge B DEF Level Indicator

4. Turn the ignition key to the RUN position to check fuel and DEF levels on the computer display Main screen. Fill fuel and DEF to the required levels.

Refer to REFUELLING PROCEDURE and DIESEL EXHAUST FLUID TANK – FILLING in SECTION 3.

A

NOTE: The DEF level indicator is applicable to Tier 4f machines only.

234-106

A Ignition Switch-STOP Position

2. Set the ignition key to the STOP position.

A

A

B

234B-107

A Hydraulic Oil Level Sight Gauge B Low Level Sending Unit

5. Check the hydraulic oil level. The sight gauge is viewable through the engine compartment front access door.

234-095

A Portable Fire Extinguisher

3. Check portable fire extinguisher for sufficient charge.

2.87

The level should be between the HIGH and LOW marks on the level gauge with all cylinders fully retracted. Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – FILLING in SECTION 3.

Controls and Operation

Tigercat H250D Processor

A A

T250D-033

T250D-123

A Engine Air Precleaner – Top of Engine Compartment

A Engine Oil Level Dipstick

6. Check the engine oil level. Dipstick is located in the front engine compartment.

The level of the oil must be between the ADD and FULL marks on the dipstick. Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL.

9. Check the air intake precleaner. Remove any blockages or obstructions. Refer to AIR INTAKE SYSTEM– ENGINE AIR PRECLEANER in SECTION 3.

A

A

B 234B-354

A Swing Drive Gearbox Oil Bottle

7. Check swing drive gearbox oil level. The bottle is located under a cover to the left of the main boom.

Half fill bottle with recommended oil as specified in SECTION 3.

A

T250D-116

A Air Intake Filter Restriction Indicator B Air Cleaner Unloader Valve

10. Check the air filter restriction indicator. Service to the air filter is required when the restriction indicator shows RED. Refer to AIR INTAKE SYSTEM– AIR FILTER RESTRICTION INDICATOR in SECTION 3.

T234B-021

A Windshield Washer Bottle

8. Check windshield washer fluid level. The bottle is located under a cover to the left of the main boom.

2.88

Tigercat H250D Processor

Controls and Operation

A B

C D

A 701086

201061

Front of Engine Compartment

A B C D

A Fuel Filter/Water Separator Drain Plug

11. Check the fuel filter/water separator and drain any accumulated water into a bowl and clean up any spills. Refer to FILTERS– FUEL FILTER/WATER SEPARATOR in SECTION 3.

Engine Coolant Surge Tank Cover Engine Coolant Surge Tank Engine Coolant Fill Cap Engine Coolant Level Sight Glass

13. Check the engine coolant level in the surge tank. Fill as required. Coolant level must be visible in the sight glass.

NOTE: A low level sensor warns the operator if the coolant level falls below an acceptable level.

WARNING B A

Do not remove the engine coolant fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

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

2000025

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

A Serpentine Belt (Fan not shown) B A/C Compressor Belt

12. Check tension and condition of all engine belts.

Refer to AIR CONDITIONING SYSTEM– ENGINE BELTS in SECTION 3 for adjustment details.

2.89

Controls and Operation

D

B

Tigercat H250D Processor

C

A

200545

A B C D

Charge Air Cooler Radiator A/C Condenser Hydraulic Oil Cooler

14. Clean the cooler package if required. Refer to CLEANING COOLER PACKAGE in SECTION 3.

A

B

E

C C

830-02

A B C D E

D

20. If cab has been tilted, verify that it is secured to the frame with the retaining bolts. Refer to CAB TILT in THIS SECTION.

Cracking Bent Worn Edge Broken Edge Worn Holes

15. Inspect track shoes for wear, bends, breaks, or cracks.

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

17. Fasten all doors, covers and access panels securely.

18. Check all exits.

19. Inspect all windows daily and immediately after any impacts. Refer to WINDOWS– INSPECTION AND MAINTENANCE in SECTION 3.

2.90

Tigercat H250D Processor

Controls and Operation

ANTI-STALL Selecting Anti Stall ON turns on an electronic load control system which automatically prevents overloading of the engine when several high load functions are in use at the same time. Turn Anti Stall ON during normal machine operation and OFF only when performing service checks on the machine.

If engine stalling occurs, check: • That Anti Stall function is ON. • For a malfunction of the Anti-stall system.

200162

1. Press the F1 button from the computer display Main screen to select the Engine menu.

250D-081

2. Press the F2 button to access the Anti Stall ON/OFF selection.

3. Press the UP or DOWN arrow buttons to turn Anti Stall ON or OFF. 4. Press the OK button to confirm the selection.

2.91

Controls and Operation

Tigercat H250D Processor

STARTING THE ENGINE

1. Complete all prestart checks before starting the engine. Refer to OPERATING THE MACHINE – PRESTART CHECKS in THIS SECTION. 2. Clear personnel from the area before starting the engine.

3. Sound the horn to warn personnel of machine startup.

CAUTION Start the engine from the operator's seat only.

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

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.

A

NOTICE 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.

234E-022

A WAIT TO START Icon

4. Turn the ignition key to the RUN position. The Wait To Start icon appears on the computer display during the pre-heat phase. Grid heating elements situated in the engine air intake manifold warm the intake air when starting the engine. Do not start the engine until the Wait to Start icon disappears from the display.

NOTE: Depending on the ambient tempreature, the WAIT TO START icon may not appear on the display.

NOTE: The computer tests the alarm and alarm light when the key is turned to the RUN position.

5. Turn the ignition key to the START position to crank the engine.

6. When the engine starts, release the ignition key to the RUN position.

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

7. Set engine speed at LOW. Wait three to five minutes before operating with a load.

8. 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 to the STOP position and repeat steps 2 – 8.

2.92

Tigercat H250D Processor

Controls and Operation

COLD WEATHER STARTING

5. Activate the pilot system and turn ON the saw.

• The hydraulic filter bypass icon must be OFF.

WARNING

• Observe the saw blade speed has stabilized.

• Operate the saw for approximately five minutes to warm up the spindle bearings.

Do not use ether! The engine is equipped with an electrical starting aid. Use of ether may cause an explosion and severe injury.

6. Turn OFF the saw.

7. Increase the engine speed to 1300 rpm and begin slow boom movements.

IMPORTANT! Cold start-ups can result in pump failure. Refer to APPROVED HYDRAULIC OILS in SECTION 3 for recommended oil viscosity and temperature ranges.

• The hydraulic filter bypass icon must be OFF.

NOTE: Cold temperatures require the use of an engine block heater and a hydraulic oil heater. Preheating of hydraulic oil is recommended as standard procedure in cold weather.

1. Follow the STARTING ENGINE instructions for this COLD WEATHER STARTING procedure, paying attention to the WAIT TO START icon on the computer display.

This message will be ON during the key RUN engine preheat time. The engine must not be started until this message turns OFF automatically.

NOTE: If at any time during the warming procedure, the hydraulic filter bypass message comes on, return the engine speed to LOW. 2. During the engine warm-up period constantly monitor the engine coolant temperature and the engine oil pressure. Turn OFF the engine if any pressure or temperature does not meet the specification.

3. Continue with MACHINE PREPARATION – SYSTEM TEST AND WARM-UP in THIS SECTION.

• Operate the boom to raise the attachment off the ground.

• Operate the stick boom slowly IN and OUT. 8. Swing the upper structure 360° to the left, then 360° to the right.

9. Operate the wrist tilting head to the left, then to the right.

NOTE: Avoid going to the end of stroke during wrist operation.

10. Place the track range switch in the LOW position and drive the machine forward pressing the foot pedals very gradually. Do not exceed ½ pedal position.

11. Watch the hydraulic oil temperature; it must reach 10°C (50°F) before any work may begin.

12. Increase the engine speed to 1500 rpm, and begin driving to the work area in LOW travel speed. Do not fully press the foot pedals until the hydraulic oil reaches 32°C (90°F). Processing may begin but work very slowly. The machine functions will seem to operate much slower until the systems are warmed up. Avoid operating the boom functions quickly until the hydraulic oil is above 32°C (90°F). Work the machine for thirty minutes at 1500 rpm.

13. When the hydraulic oil reaches 32°C (90°F) and the machine has been operated for 30 minutes, it is safe to increase engine speed to HIGH.

4. Start the engine and keep speed at LOW. • Do not activate the pilot system.

• The Hydraulic Oil Return Filter Bypass icon must be OFF before proceeding to the next step.

• The engine coolant temperature must reach 60°C (140°F) before proceeding to the next step.

• The hydraulic oil temperature must reach −7°C (20°F) before proceeding to the next step.

• Check the cooling fan is turning before proceeding to next step.

NOTE: At a starting temperature of −18°C (0°F), it will take approximately thirty minutes to complete the above step.

2.93

Controls and Operation

Tigercat H250D Processor

WARM UP IDLE SPEED ADJUSTMENT

2000074

The COLD IDLE function is provided to adjust engine idle speed to assist in warming the engine and cab temperature in cold weather conditions.

TURN ON COLD IDLE FUNCTION

4. Press the F1 button to access the Adjust menu.

200764

200162

1. From the Main screen press the F1 button to select the Engine menu.

A

5. Press the UP or DOWN arrow buttons to select Engine.

6. Press the OK button to make the selection.

200163

A Cold Idle Function Indicator

2. Press the F1 button to turn the cold idle function ON. The cold idle function icon at the top of the screen will illuminate when the machine warm up function is ON. 3. Press the Menu button to go to the Main menu.

2.94

Tigercat H250D Processor

Controls and Operation 200147

TURN OFF COLD IDLE FUNCTION 1. Press the BACK button as required to return to the Main screen.

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

8. Press the OK button to make adjustments.

234B-047

200162

2. Press the F1 button to select the Engine menu.

A

200173

9. The Cold Idle Speed can be adjusted from 950 to 1400 rpm.

A Cold Idle Function Indicator

10. Press the UP or DOWN arrow buttons to change the value.

11. Press the OK button to set the value.

2.95

3. When engine and cab have warmed to the desired temperature, press the F1 button to turn the cold idle function OFF. The cold idle function icon at the top of the screen will turn grey when the machine warm up function is OFF.

Controls and Operation

ENGINE, RESTARTING AFTER ENGINE RUNS OUT OF FUEL

1. Fill the fuel tank completely.

2. Bleed the system according to the procedures in the ENGINE OPERATION AND MAINTENANCE MANUAL.

WARNING Do not use ether! The engine is equipped with an electrical starting aid. Use of ether may cause an explosion and severe injury.

3. Crank the engine until it starts. If it fails to start after 20 seconds, stop and wait for two minutes before trying again.

IMPORTANT! To prevent damage to the starter, do not engage the starter motor for more than 15 – 20 seconds. Wait two minutes between each attempt to start the engine. If the engine fails to start, refer to ENGINE OPERATION AND MAINTENANCE MANUAL.

Tigercat H250D Processor

STOPPING ENGINE

IMPORTANT! Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components. Follow the stopping procedure outlined below to allow the engine to cool. The important benefits are: • Extended life of engine, cooling and exhaust systems.

• Reduced risk of post shutdown fires.

• Interior of machine cools significantly reducing risk of touching hot surfaces.

1. Turn the attachment OFF and rest it firmly on the ground before leaving the processing area.

2. Apply the swing brake.

3. Reduce engine speed to LOW, deactivate the pilot system by raising the left armrest and let the engine run at LOW speed for approximately three minutes (minimum) to allow dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

Do not increase engine speed before turning it OFF. 4. Place all controls in neutral positions and turn OFF all accessories and functions.

5. Turn OFF the engine.

6. Remove the ignition key.

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

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

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

8. Perform EVERY 8 HOURS maintenance at the end of the shift (greasing, clean engine compartment, etc.). This allows the machine time to cool down while under the watchful eye of the operator.

2.96

Tigercat H250D Processor

Controls and Operation

MACHINE PREPARATION

9. With the head raised slightly off the ground:

SYSTEM TEST AND WARM-UP

a. Operate the accumulation and clamp arms and check for proper operation.

Prior to commencing any processing operations follow steps 1 – 15 to accomplish the following:

b. Tilt the head forward and back and check for proper operation. c.

• Warm up the hydraulic system.

• Test all systems for proper operation.

• Inspect for hydraulic oil leaks.

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

1. Perform OPERATING THE MACHINE – PRESTART CHECKS, STARTING ENGINE and SETTING THE MACHINE procedures in THIS SECTION. 2. Sound the horn to warn personnel of machine startup.

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

Operate the swing in both directions to ensure proper operation.

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

11. Observe all boom operations. If any operations are not operating as they should, take the necessary steps to correct the problem.

12. Turn ON the saw. Refer to ATTACHMENT MANUFACTURER’S DOCUMENTATION and check the attachment for proper operation according to manufacturer’s instructions.

13. Turn OFF the attachment and rest it on the ground.

14. Set the swing brake to the ON position.

15. Set engine speed at LOW. 16. Exit cab and visually inspect machine for leaks or other machine damage. Ensure that machine is in proper working order and is in safe condition before continuing operation.

WARNING B

A

C

2000013

A Alarm Light B Master Alarm C Engine Coolant Heater Control Panel (Optional)

4. Controller display alarm light must indicate normal operating conditions.

Do not use your bare hand to check for fluid leaks.

5. Check that all personnel are clear of the machine.

6. Lower the left armrest and press the pilot interlock reset switch.

7. Set engine speed to warm-up position (1400 rpm).

NOTE: The computer has a warm-up mode function which limits engine speed and applies the anti-stall during cold starts.

8. Slowly raise and lower the stick boom and the hoist boom, and check for proper operation.

2.97

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.

Controls and Operation

TRAVELLING – BOOM RAISED

1. Select the appropriate drive range.

Place the track range switch in the low position.

When travelling in low, the machine moves slower but with increased drive force. Select low when operating on sloped terrain.

When travelling with the track range switch in high position, the machine moves faster but with less drive force. Select high when travelling over longer distances when the terrain permits.

Do not travel continuously for longer than ten minutes. Take five minute breaks to help prevent track drive gearbox overheating.

For a more detailed description of drive range refer to SWITCHES– TRACK DRIVE in THIS SECTION. 2. Turn off the swing brake switch.

3. Set engine speed at HIGH. 4. Operate the foot pedal controls to maneuver the machine. Refer to FOOT CONTROLS in THIS SECTION.

Tigercat H250D Processor

OPERATING TIPS – LOAD SENSING When operating the controls on a machine equipped with a hydraulic load sensing system, it is instructive to consider how the system works.

If the operator moves a lever or pedal 20% of its total travel, the system provides the necessary pressure (up to maximum capacity if needed) to meet this speed requirement. If the operator moves the control further in an attempt to accelerate the movement, the machine likely overshoots the desired speed. It is best to use the minimum necessary lever/pedal action.

Loading sensing systems respond to sudden or abrupt control movements with amplified actuator responses. If, for example, a boom seems to be jerky or unsteady, it is helpful to move the controls more gently.

Jerky actuator responses may also indicate the margin pressure setting is too high. Changing the margin pressure to a lower setting may help to calm the actuator responses.

Conversely, if the actuators seem to respond too slowly to the controls, it may be helpful to increase the margin pressure setting.

Refer to SET MARGIN PRESSURE in SECTION 4 of the SERVICE MANUAL. Refer to SET FLOW (FUNCTION SPEED) RATE in the appropriate BOOM FUNCTIONS, SWING or TRACK DRIVE sections of the SERVICE MANUAL.

2.98

Tigercat H250D Processor

Controls and Operation

ATTACHMENT OPERATING INSTRUCTIONS AND SAFETY PRECAUTIONS

1. Perform processing on sloped terrain in LOW driving range. Refer to SWITCHES – TRACK DRIVE in THIS SECTION. 2. Refer to the GENERAL SAFETY PRECAUTIONS and the OPERATING SAFETY PRECAUTIONS in SECTION 1.

3. Read and understand the operating and safety instructions in the ATTACHMENT MANUFACTURER'S DOCUMENTATION for the attachment installed on this machine.

2.99

Controls and Operation

TRACK OPERATION AND WEAR PREVENTION NOTE: The following illustrations are presented for illustrative purposes only and may not necessarily depict your machine or model.

Tigercat H250D Processor 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. Pay attention to the way you're turning and changing directions whenever possible to ensure even wear.

Make gradual turns instead of counter-rotations:

R7150L2-7

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:

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.

In the event a counter rotation is required some operators will carefully push the boom and attachment down against a suitable obstacle and lift the forward or rear sections of the track off the ground. The operator will then counter rotate the tracks while swinging the upper structure. This will disengage most of the track length from the ground during the counter rotation resulting in less site damage and potentially less track wear. This is a complex manoeuvrer and should only be completed by fully trained and experienced operators working in stable ground conditions.

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: 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.

Watch your speed: There are times when a job requires higher speed operation, but the fact is, wear accelerates as speed increases. Links, rollers and idlers are particularly vulnerable. Keep them working longer by controlling your speed.

870C-TRACK1A

Work up or down a slope whenever possible: Working across a slope can shorten undercarriage component life, so try to structure the job with minimal cross-slope activity.

Avoid unnecessary reverse operation: 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.

2.100

Tigercat H250D Processor

Controls and Operation Other factors: • Application refers to the type of work you do.

Bunching, 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.

845C TRACK1A

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: Avoid machine travel over distances of 1 km (0.60 mi) 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 hr).

If it is absolutely necessary to drive the machine over an extended distance, observe the following essential precautions: 1. Travel with the boom and attachment tucked in as close to the machine as safety permits. This travel position distributes the load most evenly across all rollers.

2. Stop the machine frequently.

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

4. 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.

2.101

• 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 steeltrack 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 number-one '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.

To reduce and prevent track chain joint seizing, move the machine at least once per week, in order to articulate each joint. Avoid long stops in wet environments, for example wet soil or in water.

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.

Controls and Operation

Tigercat H250D Processor

2.102

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

Tigercat H250D Processor SECTION 3 – LUBRICATION AND MAINTENANCE Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 3 A

ISSUE 1.0, APRIL 2021

ACCESS DOORS AND COVERS............................................................................................................................ 3.19 COOLER PACKAGE.............................................................................................................................................. 3.96 FRONT ACCESS DOOR........................................................................................................................................ 3.21 LEFT SIDE ACCESS DOOR................................................................................................................................. 3.21 REAR ACCESS DOOR.......................................................................................................................................... 3.21 SAFETY STOP....................................................................................................................................................... 3.21 AFTERTREATMENT SYSTEM................................................................................................................................. 3.67 APPROVED ANTI-SEIZE PASTES FOR SENSORS.......................................................................................... 3.91 CATALYTIC CONVERTER.................................................................................................................................... 3.87 DEF (DIESEL EXHAUST FLUID).......................................................................................................................... 3.76 DEF SUPPLY LINES, HEATED............................................................................................................................. 3.78 DEF SUPPLY MODULE......................................................................................................................................... 3.80 DENOX 2.2 DOSING SYSTEM............................................................................................................................. 3.79 DIESEL EXHAUST FLUID (DEF).......................................................................................................................... 3.76 DIESEL OXIDATION CATALYST (DOC)............................................................................................................... 3.80 DOSING MODULE (DEF INJECTOR).................................................................................................................. 3.86 EXHAUST FLAP..................................................................................................................................................... 3.79 HEATER VALVE..................................................................................................................................................... 3.78 HUMIDITY SENSOR.............................................................................................................................................. 3.88 MIXER TUBE.......................................................................................................................................................... 3.86 NH3 SENSOR......................................................................................................................................................... 3.89 NOX SENSOR........................................................................................................................................................ 3.90 SYSTEM COMPONENTS,..................................................................................................................................... 3.68 TANK, DIESEL EXHAUST FLUID...................................................................................................................... 3.71 TEMPERATURE SENSORS................................................................................................................................. 3.88 AIR CONDITIONING SYSTEM................................................................................................................................ 3.49 CAB AIR FILTERS.................................................................................................................................................. 3.52 COMPRESSOR...................................................................................................................................................... 3.49 CONDENSER......................................................................................................................................................... 3.49 ENGINE BELTS...................................................................................................................................................... 3.54 EVAPORATOR, HEATER CORE AND BLOWERS.............................................................................................. 3.51 EXPANSION VALVE............................................................................................................................................... 3.50 INSPECTION.......................................................................................................................................................... 3.53 RECEIVER-DRIER................................................................................................................................................. 3.50 AIR INTAKE SYSTEM............................................................................................................................................... 3.64 AIR CLEANER........................................................................................................................................................ 3.65 AIR CLEANER UNLOADER VALVE..................................................................................................................... 3.66 AIR FILTER RESTRICTION INDICATOR............................................................................................................. 3.66 AIR FILTER RESTRICTION SENSOR................................................................................................................. 3.66 AIR INTAKE TUBING AND JOINTS...................................................................................................................... 3.64 CHANGING FILTER ELEMENTS.......................................................................................................................... 3.65 ENGINE AIR PRECLEANER................................................................................................................................. 3.64 IMPROPER SERVICING....................................................................................................................................... 3.65 OVER SERVICING................................................................................................................................................. 3.65 ANTI-CORROSION SPRAY, REMOVAL................................................................................................................ 3.101 APPROVED HYDRAULIC OILS............................................................................................................................... 3.18

B

Lubrication and Maintenance

Tigercat H250D Processor

BATTERY CARE........................................................................................................................................................ 3.57 BELTS, ENGINE........................................................................................................................................................ 3.54 C

CARE OF POLYCARBONATE WINDOWS.............................................................................................................. 3.98 CARE OF THE MACHINE......................................................................................................................................... 3.94 CLEANING COOLER PACKAGE............................................................................................................................. 3.96 COMMERCIAL WOOD, WEIGHTS........................................................................................................................ 3.112

D

DIESEL EXHAUST FLUID (DEF) (TIER 4F MACHINES ONLY)............................................................................ 3.76 DISPOSAL.............................................................................................................................................................. 3.73 HANDLING AND STORAGE................................................................................................................................. 3.77 PROPER HANDLING PRACTICES...................................................................................................................... 3.77 DIESEL EXHAUST FLUID TANK............................................................................................................................. 3.71 DRAINING AND CLEANING................................................................................................................................. 3.72 FILLING................................................................................................................................................................... 3.75 FILL STRAINER, CLEANING................................................................................................................................ 3.74 SENDING UNIT/DEF QUALITY SENSOR........................................................................................................... 3.71

E

EMERGENCY EXITS.................................................................................................................................................. 3.9 EMERGENCY STOP SWITCH................................................................................................................................. 3.93 ENGINE COMPARTMENT........................................................................................................................................ 3.21 FRONT ACCESS DOOR........................................................................................................................................ 3.21 LEFT SIDE ACCESS DOOR................................................................................................................................. 3.21 REAR ACCESS DOOR.......................................................................................................................................... 3.21 ENGINE COOLANT ADDING................................................................................................................................................................... 3.26 DRAINING............................................................................................................................................................... 3.26 ENGINE COOLANT HEATER UNIT (OPTIONAL).................................................................................................. 3.41 COMPONENTS...................................................................................................................................................... 3.41 CONTROLS......................................................................................................................................................... 3.41 COOLANT HEATER UNIT.................................................................................................................................. 3.41 COOLANT PUMP................................................................................................................................................ 3.41 REMOTE FUEL TANK......................................................................................................................................... 3.42 ENGINE COOLANT HEATER UNIT PREVENTIVE MAINTENANCE................................................................ 3.43 ANNUAL MAINTENANCE.................................................................................................................................. 3.45 BIANNUAL MAINTENANCE............................................................................................................................... 3.44 DAILY MAINTENANCE....................................................................................................................................... 3.43 CONTROLS...................................................................................................................................................... 3.44 COOLANT PUMP............................................................................................................................................. 3.44 ENGINE COOLANT HEATER UNIT............................................................................................................... 3.44 MACHINE FUEL TANK.................................................................................................................................... 3.43 REMOTE FUEL TANK..................................................................................................................................... 3.43 LOCKOUT RESET PROCEDURE..................................................................................................................... 3.48 LOW VOLTAGE DISCONNECT ADJUSTMENT............................................................................................... 3.46 MONTHLY MAINTENANCE............................................................................................................................... 3.44 ENGINE DIAGNOSTICS CONNECTION................................................................................................................ 3.57

F

FILTERS ATTACHMENT CASE RETURN............................................................................................................................ 3.38 CAB AIR.................................................................................................................................................................. 3.52 DEF DOSING MODULE......................................................................................................................................... 3.81 ENGINE OIL............................................................................................................................................................ 3.58 FUEL........................................................................................................................................................................ 3.59 FUEL FILTER/WATER SEPARATOR.................................................................................................................... 3.60 HYDRAULIC OIL RETURN.................................................................................................................................... 3.34 PILOT PRESSURE................................................................................................................................................ 3.37 SWING PUMP CHARGE PRESSURE.................................................................................................................. 3.37 3.2

Tigercat H250D Processor

Lubrication and Maintenance

FIRE PREVENTION.................................................................................................................................................. 3.10 FIRE EXTINGUISHER........................................................................................................................................... 3.10 FLUID ANALYSIS PROGRAM.................................................................................................................................... 3.6 FLUID ANALYSIS KITS............................................................................................................................................ 3.6 FLUID SAMPLING PROGRAM.................................................................................................................................. 3.7 FLUID SAMPLE COLLECTION PROCEDURES................................................................................................... 3.7 FUEL HEATER........................................................................................................................................................... 3.61 FUEL, REFUELLING PROCEDURE........................................................................................................................ 3.63 FUEL TANK................................................................................................................................................................ 3.62 CAPACITY............................................................................................................................................................... 3.62 FUEL FILL CAP...................................................................................................................................................... 3.62 IN-TANK FUEL STRAINER.................................................................................................................................... 3.62 FUSES AND RELAYS CAB......................................................................................................................................................................... 3.55 ECU FUSE.............................................................................................................................................................. 3.57 ENGINE COMPARTMENT..................................................................................................................................... 3.56 G

GRAFFITI REMOVAL.............................................................................................................................................. 3.100

H

HORN......................................................................................................................................................................... 3.93 HYDRAULIC OIL OPERATING RANGE CHART.................................................................................................... 3.18 HYDRAULIC SYSTEM.............................................................................................................................................. 3.27 CASE DRAIN STRAINER...................................................................................................................................... 3.39 COMPONENTS...................................................................................................................................................... 3.28 FILTER RESTRICTION PRESSURE SWITCH.................................................................................................... 3.34 HYDRAULIC OIL RETURN FILTERS................................................................................................................... 3.34 FILTER CHANGE PROCEDURE....................................................................................................................... 3.36 HYDRAULIC OIL TANK.......................................................................................................................................... 3.29 ADDING OIL........................................................................................................................................................ 3.32 CLEAN OUT COVER.......................................................................................................................................... 3.31 DRAINING........................................................................................................................................................... 3.31 OIL LEVEL SIGHT GAUGE................................................................................................................................ 3.29 OIL LOW LEVEL SENDING UNIT...................................................................................................................... 3.29 OIL TEMPERATURE SENDING UNIT............................................................................................................... 3.29 RETURN DIFFUSER/STRAINERS.................................................................................................................... 3.40 VACUUM.............................................................................................................................................................. 3.30 REFILLING.............................................................................................................................................................. 3.33

N

NEW MACHINE MAINTENANCE FIRST 125 HOUR INSPECTION REPORT............................................................................................................ 3.5 INITIAL PRE-DELIVERY INSPECTION................................................................................................................. 3.5

P

PRESSURE AND SPEED SETTINGS................................................................................................................... 3.113 PRESSURE WASHING............................................................................................................................................. 3.94 PREVENTIVE MAINTENANCE SCHEDULE............................................................................................................ 3.5

R

REFILLING THE HYDRAULIC SYSTEM................................................................................................................. 3.33 REFUELLING PROCEDURE................................................................................................................................... 3.63 REMOTE FUEL TANK FILLING................................................................................................................................ 3.48 ROTARY MANIFOLD SEAL LUBRICATION............................................................................................................ 3.25

S

3.3

Lubrication and Maintenance

Tigercat H250D Processor

SCHEDULED MAINTENANCE GENERAL................................................................................................................................................................. 3.8 FREQUENTLY........................................................................................................................................................ 3.11 8 HOURS................................................................................................................................................................. 3.13 125 HOURS............................................................................................................................................................. 3.13 250 HOURS............................................................................................................................................................. 3.13 500 HOURS............................................................................................................................................................. 3.14 1000 HOURS........................................................................................................................................................... 3.14 2000 HOURS........................................................................................................................................................... 3.15 2 YEARS................................................................................................................................................................. 3.15 SEASONAL............................................................................................................................................................. 3.15 SERVICE AND LUBRICATION POINTS ROTARY MANIFOLD SEAL................................................................................................................................... 3.25 SWING BEARING.................................................................................................................................................. 3.25 SWING DRIVE GEARBOX LOWER BEARINGS................................................................................................. 3.24 SWING DRIVE GEARBOX UPPER GEARING.................................................................................................... 3.24 SWING PINION...................................................................................................................................................... 3.25 STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE................................................................ 3.92 STRAINERS CASE DRAIN.......................................................................................................................................................... 3.39 FUEL TANK............................................................................................................................................................. 3.62 HYDRAULIC OIL RETURN.................................................................................................................................... 3.40 T

TORQUE CHART, FLUID CONNECTIONS................................................................................................3.108 – 3.110 TORQUE CHART, GENERAL................................................................................................................................. 3.107 TORQUE CHART, SPECIFIC................................................................................................................................. 3.106 TRACK DRIVE GEARBOX....................................................................................................................................... 3.22 FILLING................................................................................................................................................................... 3.22 OIL DRAINING AND REPLACEMENT................................................................................................................. 3.23 TRACKS IMPORTANT TRACK DRIVE NOTES................................................................................................................. 3.102 MEASURING TRACK SAG.................................................................................................................................. 3.102 TRACK SAG ADJUSTMENT............................................................................................................................... 3.104 TRACK SHOE RETAINING BOLTS.................................................................................................................... 3.105 UNDERCARRIAGE BOLTS – TORQUING.......................................................................................................... 3.105

V

VACUUM SYSTEM, HYDRAULIC OIL TANK.......................................................................................................... 3.30

W

WINDOWS................................................................................................................................................................. 3.98 CARE OF POLYCARBONATE WINDOWS.......................................................................................................... 3.98 CAUTIONS........................................................................................................................................................ 3.100 CLEANING INSTRUCTIONS............................................................................................................................. 3.99 CONCEALING HAIRLINE SCRATCHES........................................................................................................ 3.100 FIRE PRECAUTIONS....................................................................................................................................... 3.100 GRAFFITI REMOVAL........................................................................................................................................ 3.100 INSPECTION AND MAINTENANCE................................................................................................................. 3.98 RESISTANCE TO CHEMICALS......................................................................................................................... 3.99 RESISTANCE TO WATER.................................................................................................................................. 3.99 WINDOW SCREENS (OPTIONAL)........................................................................................................................ 3.101

3.4

Tigercat H250D Processor

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE

WARNING

NEW MACHINE MAINTENANCE INITIAL PRE-DELIVERY INSPECTION Perform the initial pre-delivery inspection using Tigercat form numbers 5337 and 5347: PDI and 125 hour inspection report.

FIRST 125 HOUR INSPECTION AND SERVICE REPORT With the owner's mechanic present, perform an inspection and service according to the Tigercat form numbers 5337 and 5347: PDI AND 125 HOUR INSPECTION REPORT.

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 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 and boom pin retainers Check torque on swing bearing retaining bolts

SET TRACK SAG

Engine mounting bolts

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

Pump mounting bolts Track shoe bolts Track roller retaining bolts Track sprocket retaining bolts

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

Track drive gearbox mounting bolts Track drive motor mounting bolts Swing gearbox mounting bolts Swing motor mounting bolts Cab securing bolts Any other loose nut, bolt or fitting 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.

3.5

Lubrication and Maintenance

Tigercat H250D Processor

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 SAMPLE PROGRAM in THIS SECTION for sample valve and drain plug locations.

200 Series Location

First Sample

Follow-up Samples

Hydraulic Oil

125 hrs

Every 1000 hrs or 6 Months

Swing Drive Gearbox

125 hrs

Every Oil Change (500 hours or 3 Months)

Track Drive Gearboxes (if applicable)

125 hrs

Every 1000 hrs or 6 Months

Transmission (if applicable)

125 Driving hrs

Every Oil Change (500 hours or 3 Months)

Front & Rear Axles (if applicable)

125 Driving hrs

Every Oil Change (1000 hours)

3.6

Tigercat H250D Processor

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.

A

B 234E-200

A Hydraulic Oil Return Filters Restriction Indicator B Oil Sampling Connector

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

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

• 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.

• 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.

3.7

Lubrication and Maintenance

Tigercat H250D Processor

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.

• Lower the boom to the ground when leaving the cab, leaving the machine unattended or when performing servicing procedures.

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

• Clean up oil spills in engine enclosure immediately.

• Install door safety struts when working on the machine.

• Before welding on machine, disconnect all electrical connections and follow all servicing safety precautions as outlined in 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

3.8

Tigercat H250D Processor

Lubrication and Maintenance

CHECK EMERGENCY EXIT MONTHLY

WINDOW SCREEN – RIGHT SIDE (OPTIONAL)

SLIDING WINDOWS

A

B

A

201066

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

234B-351

A Right Cab Window Latch Handle

Turn inside and outside window screen hand knobs counter-clockwise to verify they can be opened by hand.

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

Turn knobs clockwise to tighten.

2. Close window firmly to verify the latch seats correctly.

IMPORTANT! Retighten window screen knobs hand-tight only to ensure quick exit in case of emergency.

3.9

Lubrication and Maintenance

FIRE PREVENTION

Tigercat H250D Processor 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, saw dust, 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.

234-095

A Charge Gauge

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

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

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

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

4. In case of fire, lower the attachment to the ground and turn OFF the engine before discharging the fire suppression system.

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

Refer to FIRE PREVENTION in SECTION 1 for additional information.

3.10

Tigercat H250D Processor

Lubrication and Maintenance

SCHEDULED MAINTENANCE

WARNING

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

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

• Visual engine check.

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

Hot fluids and hot machine surfaces can cause serious burns!

• Check for debris, snow and ice buildup on emergency exits and remove accumulation immediately.

• 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)!

3.11

Lubrication and Maintenance

Tigercat H250D Processor

EVERY 8 HOURS

**Lubricating cylinder pins and boom joints:

PERFORM

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

• FREQUENTLY maintenance.

• Drain fuel filter/water separator.

• Conduct an overall visual inspection.

CHECK • Engine coolant level.

• Engine oil level at dipstick.

• Hydraulic oil level.

• Swing gearbox oil level.

• Air intake precleaner.

• Air intake filter restriction indicator.

• Replace primary filter if indicator is in red zone.

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

• Air cleaner unloader valve.

• All engine air intake system components (including charge air cooler) rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

• For leakage around hydraulic components and flexible hoses.

200175

• For loose nuts, bolts and fittings.

• Condition and tension of belts.

• Visually check condition of tracks.

• Exhaust system and aftertreatment system for leaks.

• Fire extinguisher for sufficient charge.

2. Lower the hoist boom, extend the stick boom, tilt the attachment forward and lock in position with wheel arms open and knife arms closed.

3. While in this position lubricate all cylinder retaining pins and boom joints.

NOTE: This procedure will allow grease to flow to the normally loaded side of the pin/bearing surfaces.

CLEAN • Oil cooler, engine radiator, A/C condenser and charge air cooler.

• Remove potentially damaging limbs or sticks and all debris.

LUBRICATE • Swing bearing: 1-fitting – 4 shots while swinging.

• Swing pinion: 1-fitting – 10 shots while swinging.

• Rotary manifold: 1 fitting – 1 shot while swinging.

• Boom joint: 2-fittings – purge**.

IMPORTANT: Care must be taken to protect the boom hoses from snagging, kinking or bending when putting the machine in the service position. Replace any hose that has been kinked, bent, cut or is otherwise damaged.

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

• Boom knuckle: 2 fittings – purge**.

• Yoke pins: 2 fittings – purge**.

• Cylinders: boom, stick & hoist: 4-fittings total – purge**.

3.12

Tigercat H250D Processor

Lubrication and Maintenance

EVERY 125 HOURS

EVERY 250 HOURS

PERFORM

PERFORM

• FREQUENTLY maintenance.

• FREQUENTLY maintenance.

• 8 HOURS Maintenance.

• 8 HOURS Maintenance.

• 125 HOURS Maintenance.

CHECK • Hydraulic oil return filters restriction indicator on filter heads with engine running at high speed with oil flow.

• 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.

CHECK • Fire extinguisher and turn it to mix contents.

• Condition of engine serpentine belt.

REPLACE • Engine oil and filter. * • Engine fuel filter. *

• All hydraulic pressures.

• Fuel filter/water separator filter. *

• Hydraulic pumps and motor securing bolts.

• DEF dosing module filter (Tier 4f machines only).

• Torque tightening points as per new machine maintenance.

Refer to the SERVICE MANUAL for various oil change procedures.

CLEAN/REPLACE

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

• Recirculating air filter – A/C heater unit. * • Cab fresh air filter. *

VISUALLY INSPECT FOR DAMAGE TO

LUBRICATE

• Main boom, stick boom and cylinders.

• Swing gearbox lower bearing: 2-fittings – 5 shots each. **

• Track components and undercarriage frames.

• Swing bearing area.

NOTE: Do not use a power grease gun.

• Attachment.

** With gearbox at operating temperature slowly add 5 shots of lithium based EP2 grease to each side of the gearbox.

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 and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

3.13

NOTE: During cold weather applications the swing function must operate for several hours to achieve operating temperature.

IMPORTANT! Do not force grease, gearbox failure may result. Do not use winter grease. Grease should purge from gearbox pinion seal.

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

Lubrication and Maintenance

Tigercat H250D Processor

EVERY 500 HOURS

EVERY 1000 HOURS

PERFORM

PERFORM

• FREQUENTLY maintenance.

• FREQUENTLY maintenance.

• 8 HOURS Maintenance.

• 8 HOURS Maintenance.

• 125 HOURS Maintenance.

• 125 HOURS Maintenance.

• 250 HOURS Maintenance.

• 250 HOURS Maintenance.

CHECK • All hydraulic pressures.

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

• Torque on swing bearing and swing gearbox retaining bolts.

• Torque on track drive gearboxes and motor mounting bolts.

• 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.

• 500 HOURS Maintenance.

CHECK • In-tank fuel strainer.

DRAIN AND REFILL • Track drive gearboxes.

FILL • Track drive gearbox with both level plugs in line with the horizontal plane and above centre.

REPLACE • Engine serpentine belt.

• Air cleaner unloader valve.

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

DRAIN AND REFILL • Oil in swing gearbox – fill bottle to halfway mark.

REPLACE • Hydraulic oil return filters. * • Hydraulic oil pilot pressure filter. * • Swing pump charge pressure filter. * • Attachment case return filter. * • Recirculating air filter – A/C heater unit. * • Fresh air filter – cab. * • Engine crankcase ventilation filter (Tier 4f machines only). *

LUBRICATE • Door and cover hinges: 8 fittings – 1 shot.

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

3.14

Tigercat H250D Processor

Lubrication and Maintenance

EVERY 2000 HOURS

CHECK

• FREQUENTLY maintenance.

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

• 8 HOURS Maintenance.

• Air intake precleaner.

PERFORM

• 125 HOURS Maintenance.

REPLACE

• 250 HOURS Maintenance.

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

• 500 HOURS Maintenance.

• 1000 HOURS maintenance.

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

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

Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

NOTE: Refer to AIR INTAKE SYSTEM 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 – ADJUSTMENT MENU – HYDRAULIC OIL GRADE SELECTION in SECTION 2 or SECTION 6 of the SERVICE MANUAL, for selecting hydraulic oil type setting procedure.

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

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

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

3.15

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION 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 and ATTACHMENT MANUFACTURER'S DOCUMENTATION 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.

Lubrication and Maintenance

Tigercat H250D Processor

3.16

Tigercat H250D Processor

Lubrication and Maintenance

3.17

Lubrication and Maintenance

Tigercat H250D Processor

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

3.18

Tigercat H250D Processor

Lubrication and Maintenance

ACCESS DOORS AND COVERS A

I

H

B

C

G

F

D

E

201238

A B C D E F G H I

Left Side Door Cab Riser Access Door Engine Coolant Surge Tank Cover Engine Compartment Front Access Door Pump Compartment Access Door Swing Drive Gearbox Cover DEF Tank Fill Cover Toolbox Door Undercarriage Toolbox

Provides Access to: Cab Cab Tilt Pump Engine Coolant Fill Cap Fuel Filter/Water Separator, Engine ECU, Fuse and Relay Panel, Engine Oil Dipstick Hydraulic System Filters, Hydraulic System Pumps Swing Drive Gearbox Bottle, Windshield Washer Bottle DEF Tank Fill Cap Storage Storage

3.19

Lubrication and Maintenance

A

Tigercat H250D Processor

B

C

D

E

201239

A B C D E

Engine Compartment Rear Access Door Cooler Package Access Door Engine Coolant Surge Tank Cover Cab Riser Access Door Cab Window and Optional Screen – Right Side

Provides Access to: Engine Oil Filter, Aftertreatment System Components, Engine Belts, Batteries Cooler Package Engine Coolant Fill Cap Cab Riser Compartment, Cab Locking Bolts, Bolt Locker Emergency Exit

3.20

Tigercat H250D Processor

Lubrication and Maintenance

LEFT SIDE ACCESS DOOR

REAR ACCESS DOOR

201059

201240

To open the left side door unscrew the three retaining bolts and swing the door open.

To open the rear door lift the latch outwards and turn it 90° and swing the door open.

FRONT ACCESS DOOR

SAFETY STOP

A

201069

Rear Access Door Shown

A Door Safety Stop in Locked Position

The side and rear doors are equipped with a door safety stop. To brace the door open, lift the door safety stop out of its storage position in the door and place the safety stop bolt in the hole provided in the door ledge. Store the safety stop back in the door before closing.

201058

CAUTION

To open the front access door lift the latches outwards, turn them 90° and lift the panel up and out.

Install the door safety stop when opening the doors to perform service in the engine compartment and on the cooler package. If not used, the doors could close unexpectedly causing personal injury or component damage.

3.21

Lubrication and Maintenance

Tigercat H250D Processor

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'.

3.22

Tigercat H250D Processor

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. Dispose of waste oil according to local regulations.

7. Install plug 'A'.

3.23

Refer to SECTION 11 of the SERVICE MANUAL for further information.

Lubrication and Maintenance

SWING DRIVE LUBRICATION

Tigercat H250D Processor GEARBOX UPPER GEARING

GEARBOX LOWER BEARINGS

B

A

The cavity in the lower portion of the gearbox where the two lower bearings are housed is completely filled with grease.

A

234B-355

A Half Fill Bottle with Recommended Oil. B Connecting Hose to Gearbox

234B-352

A Lower Bearing Grease Fittings

Open the swing drive gearbox enclosure and locate the grease fittings. Using a hand grease gun and with the gearbox at operating temperature slowly add 5 shots of lithium based EP2 grease to each side of gearbox every 250 hours. Do not over grease.

NOTE: During cold weather applications the swing function must operate for several hours to achieve operating temperature. If machine is not warmed up, the lower seal can be damaged.

The swing gearbox upper gearing is filled with gear oil.

Check oil level in the bottle every eight hours. The oil bottle is located on the side of the swing drive gearbox enclosure. Oil level in the bottle must be kept at the half full mark at all times. Drain and replace swing drive gearbox upper bearing gear oil every 500 hours. Use 75W-90 or 80W-140 gear oil.

For lubrication schedule, refer to SCHEDULED MAINTENANCE in THIS SECTION. For additional information, refer to SECTION 15 of the SERVICE MANUAL.

IMPORTANT! Do not force grease, gearbox failure may result. Do not use a power grease gun to lubricate this machine. Use a hand grease gun only.

For lubrication schedule, refer to SCHEDULED MAINTENANCE in THIS SECTION. For additional information, refer to SECTION 15 of the SERVICE MANUAL.

3.24

Tigercat H250D Processor

Lubrication and Maintenance

ROTARY MANIFOLD SEAL LUBRICATION

SWING BEARING AND SWING PINION

C B A A B

200141

A Swing Bearing Grease Fitting B Swing Pinion Grease Fitting C Lubrication Label

200141

A Rotary Manifold Seal Grease Fitting B Lubrication Label

To lubricate the swing bearing, apply 4 shots of grease while swinging every eight hours to the middle grease fitting located between the foot pedals in the operator's cab.

To lubricate the rotary manifold, apply one shot of grease while swinging every eight hours to the top grease fitting located between the foot pedals in the operator's cab.

To lubricate the swing pinion (or teeth), apply 10 shots of grease every eight hours while swinging to the lower grease fitting located between the foot pedals in the operator's cab.

The grease fitting is clearly identified on the lubrication label.

NOTE: On some machines the rotary manifold does not require grease and this fitting will not be present.

The grease fittings are clearly identified on the lubrication label.

For lubrication schedule, refer to SCHEDULED MAINTENANCE in THIS SECTION.

For lubrication schedule, refer to SCHEDULED MAINTENANCE in THIS SECTION.

For additional information refer to SECTION 15 of the SERVICE MANUAL.

For additional information refer to SECTION 15 of the SERVICE MANUAL.

3.25

Lubrication and Maintenance

ADDING ENGINE COOLANT

Tigercat H250D Processor

DRAINING ENGINE COOLANT Refer to SCHEDULED MAINTENANCE or SERVICE AND LUBRICATION SCHEDULE in THIS SECTION for maintenance and service intervals.

To drain the engine coolant from the system: 1. Open the coolant shut-off valve, if not already open.

Refer to ENGINE COOLANT SHUT-OFF VALVE in SECTION 2.

A B

2. Open the engine coolant surge tank cover.

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

C

B C

D

A

B

201061

A B C D

Engine Coolant Surge Tank Cover Engine Coolant Surge Tank Engine Coolant Fill Cap Coolant Level Sight Glass

Engine coolant is added to the system through the engine coolant surge tank. The tank is located under the engine coolant surge tank cover located on top of the engine compartment. The coolant level sight glass is located on the side of the tank, inside the engine compartment.

NOTE: A proper solution of coolant antifreeze must be used when filling the surge tank.

WARNING

A 201072

A Coolant Drain Shut-off Valve B Coolant Drain Hose C Coolant Drain Hose Plug

4. Locate the coolant drain hose and remove the plug in the end of the hose.

5. Place the end of the drain hose into a suitably sized container.

6. Open the coolant drain shut-off valve.

7. Drain the engine coolant.

Do not remove the engine coolant fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

8. Close the coolant drain shut-off valve. Replace the plug in the hose and tighten the hose clamp.

9. Fill the cooling system. Refer to ENGINE COOLANT – ADDING in THIS SECTION.

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

10. Close the engine coolant shut-off valve if required.

Refer to ENGINE COOLANT SHUT-OFF VALVE in SECTION 2.

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

11. Replace the engine coolant fill cap.

12. Close the engine coolant surge tank cover.

3.26

Tigercat H250D Processor

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

Tigercat H250D Processor

HYDRAULIC SYSTEM COMPONENTS M

L

K

D

J

I

E

H

G

D

C

B

A

F

F

N

O

P

Q

R

S

T

201244

A B C D E F G H I J

Hydraulic Oil Tank Case Drain Strainer (Black) Dual Filter Head (Qty 2) Breather Hydraulic Oil Return Manifold Attachment Case Return Filter Hydraulic Oil Temperature Sending Unit Hydraulic Oil Tank Heater Location (Bottom of Tank, Optional) Water Absorbent Filter (Blue – Qty 1) Hydraulic Oil Return Filters (White – Qty 3)

K L M N O P Q R S T

3.28

Vacuum Switch Hydraulic Oil Level Sight Gauge and Low Level Sending Unit Hydraulic Oil Tank Vacuum Pump Pilot Pressure Filter Main Pump Swing Pump Cooling Pump Swing Pump Charge Pressure Filter Hydraulic Oil Return Diffuser/Strainers (Qty 2) Clean Out Cover (Rear of Machine)

Tigercat H250D Processor

Lubrication and Maintenance

HYDRAULIC OIL TANK

HYDRAULIC OIL LOW LEVEL SENDING UNIT A low level sending unit is installed in the tank. A message is sent to the computer display when the hydraulic oil tank level is low. The alarm light will flash and the alarm will also sound.

Refer to COMPUTER – MESSAGES– CRITICAL – HYDRAULIC OIL LEVEL LOW in SECTION 2.

A

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

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

HYDRAULIC OIL TEMPERATURE SENDING UNIT 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.

B

Refer to COMPUTER – MESSAGES– CRITICAL – HYDRAULIC OIL TEMPERATURE HIGH in SECTION 2.

234B-107

A Hydraulic Oil Level Sight Gauge B Hydraulic Oil Low Level Sending Unit

Located at the left rear of the upper structure, the hydraulic oil tank has a capacity of 250 L (66 US gal).

HYDRAULIC OIL LEVEL SIGHT GAUGE An oil level sight gauge, viewable through the front engine compartment indicates the HIGH and LOW levels of the hydraulic oil.

Maintain the hydraulic oil between the HIGH and LOW level marks on the gauge label. Check oil level with all cylinders fully retracted to obtain an accurate level reading. Overfilling the tank may cause excess oil to discharge from the breather vent.

3.29

Lubrication and Maintenance

Tigercat H250D Processor

HYDRAULIC OIL TANK VACUUM

SWITCH IN CAB – LEFT ARMREST A

B

B

A

E C

D 200170

F

234B-277

A B C D E F

Air Vent Check Valve Vacuum Sensing Switch Vacuum Pump Solenoid Valve Air Vent Breather Hydraulic Oil Tank

The purpose of the vacuum pump system is to hold the hydraulic oil in the tank when servicing pumps and other hydraulic components, minimizing any oil spill. When activated, a solenoid valve closes off the hydraulic oil tank breather air supply. The pump removes tank air to create a vacuum, which then holds the oil in the tank.

This system eliminates the need to drain the hydraulic oil tank before servicing the system.

NOTE: When the ignition key is in the RUN position, the vacuum pump system will not start. When the vacuum pump is on, the engine cannot be started.

IMPORTANT! Do not use the vacuum pump when changing hydraulic filters. Using the vacuum pump system while changing filters creates the risk of introducing much more air into the hydraulic system.

The vacuum system can be used when changing the case drain strainer.

NOTE: Depending on the type maintenance performed with the vacuum pump system ON, it will be necessary to bleed air from the hydraulic system. Refer to STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE in THIS SECTION.

A Vacuum Switch OFF Position B Vacuum Switch ON Position

Push the top of the switch to put it in the ON position to activate the vacuum pump.

NOTE: This switch will not function with the battery disconnect switch is in the OFF position.

SWITCH IN ENGINE COMPARTMENT

A

T250D-148

A Vacuum Switch

This switch is located in the front engine compartment.

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

Activating the pump will create a vacuum condition (9 in. Hg) in the hydraulic oil tank. The vacuum pump will automatically start and stop as necessary to maintain the tank vacuum. The vacuum switch will also lock out the start solenoid to prevent the engine from being started.

Relieve the vacuum in the tank by placing the vacuum switch in the OFF position.

NOTE: The engine will not start until the tank vacuum has been relieved.

Do not attempt to start the machine or turn the ignition key to the RUN position.

Do not leave machine unattended or overnight with the vacuum pump ON.

3.30

Tigercat H250D Processor

Lubrication and Maintenance

DRAINING

CLEAN OUT COVER

To drain the hydraulic oil tank:

The clean out cover is located on the rear of the hydraulic oil tank.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

Removing the clean out cover provides access into the hydraulic oil tank for cleaning, inspection and mounting of components.

IMPORTANT! Remove the clean out cover only when the hydraulic oil tank has been completely drained of hydraulic oil. Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – DRAINING in THIS SECTION. To remove the clean out cover: A

B

C

A

201113

Hydraulic Oil Tank – Bottom

A Environmental Drain Plug

2. Remove the dust cap from the environmental drain plug on the bottom of the tank.

3. Thread the drain hose onto the environmental drain plug.

NOTE: Once the drain hose seats itself, the valve will open and hydraulic oil will begin to drain through the hose.

201112

Hydraulic Oil Tank – Rear

A Clean Out Cover B O-ring C Fastener (Qty 10)

CAUTION Drain the hydraulic oil tank when the hydraulic oil temperature is below 38°C (100°F), but warm enough to be less viscous.

1. Remove the clean out cover fasteners.

2. Remove the clean out cover.

3. Remove the O-ring.

4. Drain the hydraulic oil into a suitable container.

NOTE: Dispose of the waste hydraulic oil according to local regulations.

5. Remove and store the drain hose.

6. Install the environmental drain plug dust cap.

3.31

NOTE: Install a new O-ring when reinstalling the clean out cover.

Lubrication and Maintenance

Tigercat H250D Processor

ADDING OIL

VACUUM

Prior to adding oil to the tank, determine and repair the source of the oil loss.

The vacuum can be used to add oil to the hydraulic oil tank.

HAND FILL PUMP

B

C

D

E

A

A

B

F

234E-280

A Oil Fill Shut-Off Valve B Hand Fill Pump

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

Remove hose clamp from end of suction hose, remove hose from stored position, thoroughly clean outside surface of suction hose and insert end into supply drum.

Open the oil fill shut off valve (ball valve located on top of the hand pump). Operate the pump by moving the handle back and forth at medium speed and a steady motion. The oil passes through the filters on the return lines of the hydraulic system. When the sight gauge reads between LOW and HIGH cease pumping and return handle to upright position. Close the oil fill shut off valve.

NOTE: Turning on the hydraulic oil tank vacuum pump will assist the filling procedure.

CAUTION

200044

A B C D E F

Vacuum Switch Hose Storage Coupler Return Filter Manifold Quick Connect Coupler Hose Container with Hydraulic Oil

1. Turn ON the vacuum switch to build up vacuum in the tank.

2. Place a container of hydraulic oil on the machine deck.

3. Insert the hose in the oil in the container.

4. Connect the hose to the quick connect coupler on the hydraulic oil return filter manifold.

5. Allow oil to empty from the container.

6. Disconnect the hose coupling from the return filter manifold.

7. Turn OFF the vacuum and clean any spilled oil.

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.

3.32

Tigercat H250D Processor

Lubrication and Maintenance

REFILLING THE HYDRAULIC SYSTEM When filters are replaced, there is a nominal amount of oil loss through leakage and oil contained in the filters.

This requires a hydraulic system top-up or refill.

Before refilling, check the computer to verify which oil type is selected. Use the same type and grade of oil to refill the system. This will allow the program to optimize the cooling and warning functions to best suit the oil type. Refer to COMPUTER– ADJUSTMENT MENU – HYDRAULIC OIL GRADE SELECTION in SECTION 2 for selecting hydraulic oil type setting procedure.

It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results.

Refer to HYDRAULIC 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 variable-pitch cooling fan (if equipped) for proper operation after hydraulic oil has been replaced.

3.33

Lubrication and Maintenance HYDRAULIC OIL RETURN FILTERS

FILTER RESTRICTION PRESSURE SWITCH A filter restriction pressure switch is installed at the inlet of one of the filter heads. When an oil pressure in excess of 1.4 bar (20 psi) is encountered at the inlet, this pressure switch closes and the Hydraulic Oil Return Filter Bypass icon illuminates RED on the computer display. The alarm will sound and the alarm light will flash continuously.

B

A

FILTER/DIFFUSER SERVICE NOTE: The return filters should be checked/changed when the Hydraulic Oil Return Filter Bypass icon displays RED on the computer display. If the icon continues to display RED after the filters have been changed, the diffuser/strainers attached to the base of the return tubes in the hydraulic tank should be examined for possible obstruction.

D

C 200140

A B C D

Tigercat H250D Processor

Return Filter Manifold Filter Restriction Pressure Switch Hydraulic Oil Return Filters (White) – Quantity 2 Water Absorbing Return Filter (Blue) – Quantity 1

The return oil entering the hydraulic oil tank passes through four spin-on hydraulic oil filters mounted on two filter heads. One of the filters is a water absorbing (blue) filter which is in place to assist with the removal of unwanted moisture from the hydraulic oil.

Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – RETURN DIFFUSER/STRAINERS in THIS SECTION. IMPORTANT! Do not use these warnings as a substitute for changing the hydraulic oil return filters at regular intervals as per SCHEDULED MAINTENANCE in THIS SECTION. This information is assuming that operating conditions and running temperatures are normal.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION. There is a bypass valve, preset at 1.7 bar (25 psi), built into each filter head, which will open when the filters become restricted. Before the valve is activated a filter restriction pressure switch will cause the Hydraulic Oil Return Filter Bypass icon on the computer display to illuminate RED. Refer to HYDRAULIC SYSTEM – FILTER RESTRICTION PRESSURE SWITCH in THIS SECTION.

A T250D-133

A Hydraulic Oil Return Filter Bypass Icon

If the Hydraulic Oil Return Filter Bypass icon illuminates RED between scheduled maintenance intervals, stop the machine and change the return filters immediately.

NOTE: The Hydraulic Oil Return Filter Bypass icon will illuminate YELLOW when the hydraulic oil temperature is low and the filter restriction switch is activated. Allow the hydraulic oil to warm to operating temperature and the icon should change to GREY. Refer to MACHINE PREPARATION in SECTION 2.

3.34

Tigercat H250D Processor

Lubrication and Maintenance

RETURN FILTER RESTRICTION INDICATOR

B

A C D E

F

234E-200

A B C D E F

Filter Restriction Indicator From Oil Cooler From Main Valve and Processor Head From Main Valve and Processor Head From Hand Fill Pump From Cooling Pump

The IN side of the return filter heads are connected to a return manifold. A return filter restriction indicator is mounted on the manifold.

With the hydraulic oil at normal operating temperature, the engine speed at HIGH and with no machine functions operating, the return filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone, replace all four hydraulic oil return filters.

3.35

Lubrication and Maintenance

Tigercat H250D Processor

FILTER CHANGE PROCEDURE

 'O' RING GASKET

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

A

2. Open the left side engine compartment access door to access the return filters.

3. Wipe clean the area around the filters and filter head.

4. Wearing eye and face protection (in case of an oil spray), unscrew the old filter.

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 C FILTR_SEALS 2

A Filter Head B Gasket C Filter Element

a. Remove the used gasket and clean the gasket seat in the head.

7. The new Tigercat filter is supplied with two gaskets enclosed. Examine the filter head closely to determine which gasket to use and follow the instructions to ensure proper installation.

b. Apply clean oil to the new gasket surfaces. c.

 SQUARE SECTION GASKET

d. Screw on the new filter until the gasket makes contact.

A

e. Tighten the filter until the top edge makes metal to metal contact with the filter head (approximately 11⁄2 additional turns after gasket contact).

B C FILTR_SEALS 2

A Filter Head B Gasket C Filter Element

Install the new gasket on the inside lip of the filter.

8. Use the fill pump to raise the hydraulic oil level up to the FULL line, replacing oil lost during filter change.

Refer to HYDRAULIC SYSTEM–HYDRAULIC OIL TANK–ADDING OIL in THIS SECTION. 9. Clean up any spilled oil.

a. Remove the used gasket and clean the groove in the head.

10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

b. Apply clean oil to new gasket surfaces.

11. Run engine at LOW speed for at least five minutes to purge any remaining air from the filter system.

Then turn OFF the engine for 15 minutes to allow air bubbles in the hydraulic oil tank to rise.

c.

Install the new gasket into the groove in the filter head.

d. Screw on the new filter until the gasket makes contact.

12. Re-check hydraulic oil level and top-up as needed.

e. Tighten the filter an additional 3⁄4 turn.

3.36

Tigercat H250D Processor

Lubrication and Maintenance

SWING PUMP CHARGE PRESSURE FILTER

PILOT PRESSURE FILTER

A 200296

A

A Swing Pump Charge Pressure Filter Element

The swing pump charge pressure filter is located under the engine compartment on the left side.

Hydraulic oil from the swing pump charge passes through this filter before being used in the swing hydraulic circuit.

201273

A Pilot Pressure Filter Element

The pilot pressure filter is located under the engine compartment on the left side.

A single element filter head filters all pilot oil prior to entering the pilot system. The filter head has a built-in bypass valve with a 3.4 bar (50 psi) cracking pressure so that oil can bypass the filter if the element becomes restricted.

A

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION.

T250D-114

A Bypass Pressure Switch – Swing Pump Charge Pressure Filter

A bypass switch in the swing pump charge filter head sends a message to the computer display when an oil flow restriction in excess of 3.5 bar (50 psi) is encountered at the charge filter. This pressure build up opens the bypass valve in the filter head allowing oil to bypass the filter element and return to the hydraulic oil tank.

Refer to COMPUTER – MESSAGES– ALERT– CHARGE FILTER BYPASSED in SECTION 2.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION. 3.37

Lubrication and Maintenance ATTACHMENT CASE RETURN FILTER

Tigercat H250D Processor FILTER CHANGE PROCEDURE – SWING PUMP CHARGE, PILOT PRESSURE AND ATTACHMENT CASE RETURN 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

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

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

4. Wearing eye and face protection (in case of an oil spray), unscrew the old filter.

5. Dispose of old filter and any oil properly.

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

7. The new filter has an attached gasket, apply clean oil to the gasket surface.

8. Screw on the new filter until the gasket makes contact.

A

9. Tighten filter an additional 1⁄4 – 1⁄2 turn, by hand.

NOTE: Do not use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

201273

A Attachment Case Return Filter Element

The attachment case return filter is located under the engine compartment on the left side.

This filter receives case drain oil from the attachment motor. Oil from the filter returns directly to the case drain strainer.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION. Replace earlier if the back pressure indicator on the filter head is in the red.

10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

IMPORTANT! Contaminated hydraulic oil can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals, Refer to SCHEDULED MAINTENANCE in THIS SECTION.

3.38

Tigercat H250D Processor

Lubrication and Maintenance

CASE DRAIN STRAINER

A

200294

A Case Drain Strainer

The case drain strainer is located in the engine compartment behind the left side access door. 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.

3.39

Lubrication and Maintenance HYDRAULIC OIL RETURN DIFFUSER/ STRAINERS

Tigercat H250D Processor CHANGING OR CLEANING THE DIFFUSER/ STRAINERS This should only be performed in the event of a pump or motor catastrophic failure or hydraulic oil contamination.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Install a DO NOT START ENGINE sign on the operator's cab door and in the engine compartment.

3. Turn OFF and lock out the battery disconnect switch.

4. Drain the hydraulic oil tank into a suitable container.

Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – DRAINING in THIS SECTION. 5. Remove the cleanout cover and O-ring. Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – CLEAN OUT COVER in THIS SECTION for details.

IMPORTANT! Remove the clean out cover only after the hydraulic oil tank has been completely drained of hydraulic oil.

200573

B

A

6. Clean any debris from the bottom of the tank and wipe it clean.

A Diffuser/Strainers in Hydraulic Oil Tank B Clean Out Cover – Rear of Tank

There are three reusable diffusers/strainers on the return tubes inside the hydraulic oil tank. Inspecting, changing or cleaning the diffuser/strainers is only to be performed in the event of a catastrophic pump or motor failure or hydraulic oil contamination.

701097

Diffuser/Strainer Removal

7. Remove the hydraulic oil return diffuser/strainers using the hex on the end of diffuser.

8. Carefully clean the diffuser/strainers as they are easily damaged by rough handling.

9. Check for a buildup of foreign materials where the diffusers screw onto the pipes.

10. Re-install the diffuser/strainers.

NOTE: Repair any burrs created when removing the diffuser/strainers before reinstalling.

11. Reinstall the clean out cover with a new O-ring.

12. Refill the hydraulic tank and check for leaks.

Refer to HYDRAULIC OIL TANK – ADDING OIL and HYDRAULIC SYSTEM – REFILLING in THIS SECTION.

3.40

Tigercat H250D Processor

Lubrication and Maintenance

ENGINE COOLANT HEATER UNIT (OPTIONAL)

CONTROLS

COMPONENTS COOLANT HEATER UNIT

A 2000013

Overhead Console– Front

A Engine Coolant Heater Control Panel

C

The engine coolant heater control panel is located on the overhead console at the front of the cab.

B

Refer to ENGINE COOLANT HEATER CONTROL (OPTIONAL) in SECTION 2 for additional information and operating instructions.

A

200705

Engine Coolant Heater Unit

A Exhaust Port B Intake Port C Coolant Pump

The coolant heater unit is located below the hydraulic oil tank at the lower left rear of the upper structure.

The engine coolant heater uses circulating coolant to heat the hydraulic oil. Refer to ENGINE COOLANT HEATER UNIT (OPTIONAL) in SECTION 10 for additional information on the coolant heater.

COOLANT PUMP The coolant pump is located in front of the coolant heater unit.

The coolant pump circulates the coolant to heat the hydraulic oil. Refer to ENGINE COOLANT HEATER UNIT (OPTIONAL) in SECTION 10 for additional information on the coolant pump.

3.41

Lubrication and Maintenance

Tigercat H250D Processor

REMOTE FUEL TANK

The remote fuel tank may be filled with appropriate diesel fuel or kerosene. Tigercat recommends using kerosene as the primary fuel in especially cold conditions; kerosene has a lower gel point and burns cleaner than diesel.

Top up the fuel level on a daily basis to prevent condensation from forming inside the tank walls.

A

B

200710

Rear of Cab

D C

200706

A B C D

Fill Cap Sight Level Gauge Fuel Pump Fuel Filter

Remote Fuel Tank

The remote fuel tank is located on the outside rear of the cab.

The fuel pump and fuel filter are located on the left side of the upper structure, under the engine.

3.42

Tigercat H250D Processor

Lubrication and Maintenance

ENGINE COOLANT HEATER UNIT PREVENTIVE MAINTENANCE

REMOTE FUEL TANK

The following preventive maintenance schedule keeps the engine coolant heater unit in proper working order.

Refer to the manufacturer's operation manual for further information.

If the engine coolant heater unit draws fuel from a remote fuel tank: A

B

DAILY MAINTENANCE Complete the following preventive maintenance items once per day: MACHINE FUEL TANK If the engine coolant heater unit draws fuel directly from the machine fuel tank: E D C

200706

A

A B C D E

802243

A Vent Ports

Fuel Tank Fill Cap

Typical Remote Fuel Tank (Rear View)

Fill Cap Vent Fuel Pump Fuel Filter Fuel Line

Remove any debris, snow, or ice around the fill cap.

Remove any debris, snow, or ice around the fuel tank fill cap. Keep the vent ports clear to prevent a vacuum inside the fuel tank.

Inspect the tank vent line for free flow of air.

Inspect the fuel line and fittings for damage or leaks.

Refer to REMOTE FUEL TANK FILLING in THIS SECTION.

A

802246

A Venting Valve

Fuel Tank Fill Cap

Inspect the fuel tank fill cap venting valve for proper operation in freezing temperatures. If the valve may freeze while the machine is parked overnight, leave the cap loose to prevent a vacuum inside the fuel tank.

3.43

Lubrication and Maintenance ENGINE COOLANT HEATER UNIT

Tigercat H250D Processor CONTROLS Check the engine coolant heater timer/controller for correct operation. Perform the lockout reset procedure if necessary, and then resolve any faults. Refer to LOCKOUT RESET PROCEDURE in THIS SECTION. A

B

A

234B-011

A Cab Temperature Control Knob 200705

Typical Engine Coolant Heater Unit

A Exhaust Port B Intake Port

Remove debris, snow, or ice around the engine coolant heater unit air intake and exhaust ports.

ENGINE COOLANT PUMP

Set the cab temperature control knob to the full hot position before turning OFF the engine at end of shift to permit engine coolant circulation and to help prevent overheating faults.

MONTHLY MAINTENANCE Complete the following preventive maintenance items once per month: • Run the engine coolant heater unit for 20 minutes once per month from January through December, irrespective of weather conditions. Verify the engine coolant shut-off valves are open before operating the engine coolant heater unit. Refer to ENGINE COOLANT SHUT-OFF VALVES in SECTION 2 for further information.

BIANNUAL MAINTENANCE Complete the following preventive maintenance items once every six months: • Clean the exterior of the engine coolant heater unit.

Do not permit water to enter the unit.

802257

Engine Coolant Pump

Inspect the engine coolant pump for leaks. It is normal to observe a few drops upon startup in cold temperatures.

• Clean inside the bores of the engine coolant heater unit air intake and exhaust tubes.

• Inspect all engine coolant pump and all cooling system hoses, fittings, and valves for damage, cracks, or leaks.

3.44

Tigercat H250D Processor

Lubrication and Maintenance

ANNUAL MAINTENANCE Complete the following preventive maintenance items once each year:

A

B

802266

A Fuel Filter B Fuel Pump

• Change the fuel filter.

• Inspect fuel lines for leaks or damage.

• Verify that each hose clamp is properly tightened to prevent air from entering the fuel system.

• Inspect the electrical connections at the engine coolant heater unit for corrosion. Ensure that connectors fit together tightly and securely.

3.45

Lubrication and Maintenance

Tigercat H250D Processor

LOW VOLTAGE DISCONNECT ADJUSTMENT The low voltage disconnect (LVD) feature permits the operator to determine the battery voltage threshold at which the timer/controller shuts down the heater, or prevents it from starting.

If the battery voltage is equal to or lesser than the low voltage disconnect threshold, plus 0.1 V, the heater will not operate.

For example, if the operator selects a 24.5 V threshold, the engine coolant heater unit cannot start unless the battery voltage is at least 24.7 V. Before operating the engine coolant heater unit, verify the low voltage disconnect threshold is set to an appropriate value.

802289

4. Turn the rotary knob counterclockwise to the highlight options link.

For a 24 V system, the engine coolant heater unit operating range is 21 – 25.5 V and the recommended LVD value is 22 V. To check and/or set the low voltage disconnect threshold:

F

A B

C

802285

5. Press the selection button to enter the options page.

D E C 801597

A B C D E F

Engine Coolant Heater Timer/Controller

On/Off Button Display Status Indicator Lights Selection Button Micro USB Service Port Rotary Knob

802286

6. Turn the rotary knob to highlight the LVD link.

1. Turn ON the engine coolant heater unit.

2. Press the selection button to access the main menu.

3. Turn the rotary knob clockwise by two or three clicks.

3.46

Tigercat H250D Processor

Lubrication and Maintenance

802287

7. Press the selection button to enter the LVD threshold page.

802288

8. Turn the rotary knob to adjust the LVD threshold to 22 V. 9. Press the selection button three times to return to the main page and confirm the change.

3.47

Lubrication and Maintenance

Tigercat H250D Processor

LOCKOUT RESET PROCEDURE

REMOTE FUEL TANK FILLING

The electronic control unit monitors heater operation.

If the electronic control unit detects component errors and/or operational faults, it may shut down the engine coolant heater unit and lock out the timer/controller.

To fill the remote fuel tank:

The following errors or faults can activate a lockout: • no start/incorrect start • temperature sensor defect • overheating sensor interrupted (or short circuit) • overheating sensor installed incorrectly • ceramic glow pin interrupted (or short circuit) • fan motor overloaded or blocked (or short circuit) • fuel metering pump or circuit error • voltage drops or spikes exceeding 20 seconds • electronic control unit defect

804897

Remote Fuel Tank

• overheating

1. Remove the remote fuel tank fill cap.

To reset a lockout: 1. Turn ON the engine coolant heater unit.

A

B

804901

Engine Coolant Heater Unit

A Electronic Control Unit B Harness Receptacle

2. Disconnect the wiring harness from the receptacle at the bottom side of the electronic control unit.

3. Pause for 10 seconds.

4. Connect the wiring harness to the receptacle at the bottom side of the electronic control unit.

5. Turn OFF the engine coolant heater unit.

804898

2. Fill the remote fuel tank with appropriate fuel or kerosene.

3. Replace the remote fuel tank fill cap.

4. Rinse or wipe any spilled fuel from the remote fuel tank.

NOTE: Top up the fuel level on a daily basis to prevent condensation from forming inside the tank walls.

6. Turn ON the engine coolant heater unit.

7. Rectify the cause of the fault or error.

NOTE: Use the engine coolant heater unit manufacturer's PC diagnostic tool to read fault and error codes. Refer to the manufacturer's operation manual for further information.

3.48

Tigercat H250D Processor

Lubrication and Maintenance

AIR CONDITIONING SYSTEM

COMPONENTS

All service work must be performed by a certified A/C technician. Charge the system with R134a refrigerant only. Polyalkylene Glycol (PAG) oil should be present in the system and must be used on O-rings and fittings.

COMPRESSOR

A/C SYSTEM TOTAL CAPACITIES R134a Refrigerant

2.0 kg (4.5 lb)

PAG Oil Compressor shipping quantity (Shipping oil from vendor)

200 ml (6.76 oz)

Tigercat factory added oil

+ 59 ml (2 oz)

Total

= 259 ml (8.76 oz)

When replacing air conditioning system components, it is important to replace PAG oil that has been lost when parts are changed. The total amount of PAG oil added to compensate for replacement components should not exceed the total capacity.

When recharging the system, only add the quantity of oil reclaimed during the recovery process.

Low PAG oil levels can starve the compressor for oil and lead to compressor failure. Too much PAG oil can hurt the cooling performance.

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

NOTICE Before disconnecting any lines or removing the PAG oil plug, make sure the refrigerant has been removed from the A/C system by recovering it with the appropriate recovery equipment.

A B

201051

A A/C Compressor B A/C Compressor Belt

The compressor and charge ports are accessed through the rear engine compartment door.

The compressor draws in the low-pressure refrigerant vapour from the A/C system.

The compressor is powered by a separate drive belt connected to the engine crankshaft. When the A/C system is turned on, the compressor clutch engages and the compressor pumps refrigerant vapour under high pressure to the condenser.

CONDENSER The condenser is part of the cooler package.

Refer to CLEANING COOLER PACKAGE in THIS SECTION for the location of the condenser.

Refrigerant flows through the condenser tubing from top to bottom. The high internal pressure coupled with the large volume of air cooling the condenser as it passes over the condenser core produces a condition in which vapour refrigerant converts to liquid refrigerant (condensation). This change usually takes place in the bottom third portion of the condenser.

3.49

Lubrication and Maintenance

Tigercat H250D Processor

RECEIVER-DRIER C A B

200145

A Sight Glass (Indicates Condition of Charge) B High-Pressure Switch C Moisture Indicator (on top)

The receiver-drier is located in the lower engine compartment beside the front left engine mount. It is accessible from underneath the engine compartment.

EXPANSION VALVE The high pressure liquid refrigerant flows into the expansion valve and then passes through a variable orifice. The orifice limits the speed and therefore the flow of refrigerant causing the pressure of the refrigerant to drop. The refrigerant exits the expansion valve as a low pressure liquid.

Refer to AIR CONDITIONING SYSTEM– EVAPORATOR, HEATER CORE AND BLOWERS in THIS SECTION for the location of the expansion valve.

3.50

Tigercat H250D Processor

Lubrication and Maintenance

EVAPORATOR, HEATER CORE AND BLOWERS

B

Liquid refrigerant flows into the evaporator coil. As the blowers pull the warm cab air across the evaporator coil, heat is absorbed by the refrigerant. This results in cooling of the air as it passes across the evaporator coil.

When enough heat is absorbed by the refrigerant, the refrigerant changes to a low pressure vapour.

A

A 2000026

A A/C Heater Unit Access Cover B Thumb Screws

4. Remove the A/C heater unit access cover thumb screws and remove the access cover.

2000027

A

B

A

B

234-093

A A/C Heater Unit Cover Panel B A/C Heater Unit

The evaporator core, heater core and blowers are a part of the A/C heater unit located in the cab behind the A/C heater unit cover panel behind the operator's seat.

To inspect the evaporator and blowers do the following:

2000022

A B C D

D

C

Blower Heater Core Evaporator Core Expansion Valve

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

5. Inspect the evaporator core, heater core and blowers for dirt and debris. Remove if required.

2. Slide the operator's seat as far forward as possible and adjust the seat backrest as far forward as possible.

6. Install the A/C heater unit access cover and fasteners.

3. Remove the six socket head capscrews fastening the A/C heater unit cover panel and remove the panel.

3.51

Lubrication and Maintenance CAB AIR FILTERS

Tigercat H250D Processor FRESH AIR FILTER – CAB

Inspect and clean the cab air filters every 125 hours.

Replace the filters regardless of condition every 500 hours.

A

B A

B

2000029

B

A

234-093

A Recirculating Air Filter B Fresh Air Filter – Cab

RECIRCULATING AIR FILTER – A/C HEATER UNIT B

2000030

C

A Fresh Air Filter – Cab B Filter Securing Plate C Wing Nut

2000028

A

A Recirculating Air Filter B Thumb Screws

The filter is located at the base of the A/C heater unit.

Remove the two thumb screws on the filter box cover to access the filter.

To inspect, clean or replace the A/C recirculation filter: 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove the two thumb screws on the A/C heater unit access panel.

3. Remove the filter and housing.

This filter is located adjacent to the AC heater unit, behind the left side door.

To inspect, clean or replace the cab fresh air filter: 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove the wing nut and washer at the bottom of the filter securing plate.

3. Lower the filter securing plate to clear the retaining tabs from the holder.

4. Slide the filter out.

5. Inspect, clean or replace the filter.

6. Hold the filter in position and install the filter securing plate.

IMPORTANT! Install the filter with the air flow arrows facing into the cab.

4. Inspect, clean or replace the filter.

5. Install the filter and housing on the A/C heater unit access panel.

6. Install the thumb screws and tighten.

7. Install the wing nut and washer and tighten.

3.52

Tigercat H250D Processor

Lubrication and Maintenance

INSPECTION

C

Perform the following inspection along with the 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION.

D

1. Check A/C recirculating and cab fresh air filter in the operator cab. Refer to AIR CONDITIONING SYSTEM– CAB AIR FILTERS in THIS SECTION. 2. Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING COOLER PACKAGE in THIS SECTION.

B

CAUTION A

If using pressurized water or compressed air for cleaning, use at 2 bar (30 psi) or less.

900035

Use personal protective equipment (safety glasses) to guard against flying debris.

A B C D

3. Check the evaporator core, located inside the A/C heater unit, for dirt and debris. Also check the inside of the A/C heater unit. Clean as required.

Receiver-Drier (Top View)

Binary Switch Sight Glass Moisture Indicator High Pressure Relief Valve

10. Inspect the sight glass on the receiver-drier with the A/C ON. A constant stream of bubbles indicates the system is low on refrigerant and requires charging *.

4. With the engine stopped, check the air conditioner compressor belt tension and condition.

Refer to AIR CONDITIONING SYSTEM– RECEIVER-DRIER in THIS SECTION.

Refer to AIR CONDITIONING SYSTEM– ENGINE BELTS in THIS SECTION.

11. Check the color in the moisture indicator: BLUE is OK; PINK indicates desiccant material in drier is saturated with moisture.

5. Check all A/C hoses for kinks.

6. Run the air conditioning system for three to five minutes.

In the latter situation: a. Replace the receiver-drier. b. Evacuate the system. c.

Recharge the system with both refrigerant and PAG oil *.

*Indicates these repairs must only be carried out by a certified A/C technician.

A B

For additional SERVICE information refer to the Tigercat A/C SERVICE MANUAL part number 18795A, available from Tigercat parts department.

The air conditioner circuit uses a binary switch (located on the top of the receiver-drier) on the high pressure side. The switch has two settings:

880D-064

A Thermometer B Louvres

• The high pressure protection activates at 27 bar (391 psig) for rising pressure and 21 bar (304 psig) for falling pressure.

7. Use a thermometer to check the air temperature exiting vents in the cab.

• The low pressure protection activates at 1.9 bar (29 psig) for falling pressure and 2 bar (30 psig) for rising pressure.

8. Listen to the compressor and blower motor for abnormal noises.

9. Verify the compressor clutch engages.

3.53

Lubrication and Maintenance

Tigercat H250D Processor

ENGINE BELTS

BELT REMOVAL AND REPLACEMENT

The engine belts are accessible through either the engine compartment front and rear access doors.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

A

B

C

A

D 201047

A Cooling Fan Guard 200544

A B C D

A/C Compressor Adjusting Bolts A/C Compressor Pivot Bolts A/C Compressor Belt Serpentine Belt

The cooling fan (not shown) is driven by the serpentine belt. Belt tension is automatically tightened by a spring loaded tensioner.

The A/C compressor is driven by a separate belt. Belt tension is tightened by loosening the pivot bolts below the compressor and the adjusting bolts above to enable the compressor to swing.

Check the condition and tension of the belts every 250 hours and replace every 1000 hours.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for inspection and replacement information for the serpentine belt.

2. Remove the cooling fan guard from the cooler package.

3. Remove the cooling fan from the front of the engine.

4. Loosen the A/C compressor adjusting bolts and swing the compressor towards the engine.

5. Remove the A/C compressor belt.

6. Remove and replace the serpentine belt.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for inspection and replacement information for the serpentine belt.

7. Install a new A/C compressor belt and swing the compressor away from the engine and tighten the A/C compressor adjusting bolts.

NOTE: Belt tension specification is 55 ± 2 kgf (121 ± 5 lbf).

8. Install the cooling fan on the engine.

9. Install the cooling fan guard on the cooler package.

3.54

Tigercat H250D Processor

Lubrication and Maintenance

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

FUSE AND RELAY PANEL – CAB The cab fuse and relay panel is located on the right side of the cab below the main console behind a removable cover.

2000195

3.55

Lubrication and Maintenance

Tigercat H250D Processor

FUSES AND RELAYS – ENGINE COMPARTMENT This main fuse and relay electrical box is located in the engine compartment.

234B-020

3.56

Tigercat H250D Processor

Lubrication and Maintenance

ECU FUSE

ENGINE DIAGNOSTICS CONNECTION

A

A 234B-012

234B-271

A ECU Fuse

Earlier Design

A Engine Diagnostics Connection

The engine diagnostics connection is located in the cab on the right side, under the main console.

Plug a remote electronic diagnostic device into this connection such as a laptop computer with appropriate engine manufacturer’s programming to perform engine performance analysis and tuning.

IMPORTANT! This operation can only be performed by a trained service technician.

BATTERY CARE

A

Tigercat uses two types of batteries dependent on the machine application, model and design.

200325

A ECU Fuse

• Absorbed Glass Mat (AGM)

Later Design

• Flooded Lead Acid (FLA).

The ECU fuse is mounted directly below the battery disconnect switch. This fuse supplies power to the following fuses in the main engine fuse panel.

NOTICE

• ECU power fuse • DEF lines fuse NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

Before charging, identify the type of battery installed. 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.

• Hydraulic Oil Tank Vacuum Relay fuse • RTC fuse (Real Time Clock for Computer) NOTE: The RTC fuse also supplies power to the After Run Relay.

Refer to BATTERY MANUFACTURER'S instructions for charging or maintaining FLA batteries.

3.57

Lubrication and Maintenance

ENGINE FILTERS – REMOVE AND REPLACE

IMPORTANT! Failure to service and replace engine filters at the proper intervals specified in the ENGINE OPERATION AND MAINTENANCE MANUAL could cause damage to the machine and result in the product warranty becoming null and void. Check the Tigercat parts catalog for replacement filters.

Tigercat H250D Processor FUEL FILTERS These engines use filters with a very fine micron rating.

If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in SCHEDULED MAINTENANCE in THIS SECTION. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended to drain the fuel filter/ water separator bowl daily.

NOTICE

Refer to the appropriate ENGINE OPERATION AND MAINTENANCE MANUAL for the oil and fuel filter replacement procedure. Read and understand the SAFETY section in each of THESE MANUALS.

ENGINE OIL FILTER

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the fuel system caused by unfiltered fuel. Unfiltered fuel used to pre-fill filters enters directly into the fuel circuit. Contaminants in unfiltered fuel can cause significant and costly damage to fuel system components. The cleanliness of fuel cannot be guaranteed unless it is pre-filtered before use.

A

201049

A Engine Oil Filter

Rear Access Door

The engine oil filter is located on the rear of the engine.

It is accessed through the engine compartment rear access door.

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.

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 to ENGINE OPERATION AND MAINTENANCE MANUAL for more detailed information.

3.58

Tigercat H250D Processor

Lubrication and Maintenance

ENGINE 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

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.

A 201050

A Engine Fuel Filter

6. Check the seating area for the O-ring on the filter head and wipe clean.

Front Access Door

The engine fuel filter is located on the front of the engine. It is accessed through the engine compartment front access door.

The engine fuel filter is equipped with a pressure switch with sends a message to the computer when a clog is detected. Refer to COMPUTER – MESSAGES– CRITICAL – MAIN FUEL FILTER CLOGGED– ENGINE DERATE and COMPUTER – MESSAGES– ALERT– MAIN FUEL FILTER CLOGGED in SECTION 2.

7. Lubricate the O-ring on top of the new filter with clean engine oil. Do not pre-fill the new filter.

8. Screw the new filter onto the filter head as specified by the filter manufacturer.

NOTE: Mechanical over tightening can damage the filter element.

9. Prime the fuel system using the hand primer on the remote fuel filter/water separator before starting the engine.

Loosen the plug on the top of the remote fuel filter/ water separator. Pump the hand primer until fuel begins to seep out around the loosened plug, continue to pump until no air bubbles are visible (approximately 30 pumps). Tighten the plug. Pump the hand primer 30 more times.

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.

10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

3.59

Lubrication and Maintenance

Tigercat H250D Processor

FUEL FILTER/WATER SEPARATOR

DRAINING FUEL FILTER/WATER SEPARATOR A

B

C

E

D

I

H

G

F

822D-025 200555

C

B

A B C D E F G H I

A

O-Ring Hand Primer Pump Vent Plug Filter Head Fuel Filter Heater Harness (Heater Element not shown) Sensor, Water in Fuel Drain Valve with Hose Barb Separator Bowl

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

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

3. Place a suitable container under the filter and/or place rags below to catch the spillage of fuel.

4. Loosen the metal vent plug on the filter head.

5. Turn the drain valve open on the separator bowl to allow the fuel to drain completely from the separator bowl into a suitable container.

NOTE: A drain hose can be attached to the drain valve if required.

6. Close the drain valve.

D

E

F

701086

A B C D E F

Hand Primer Pump Vent Plug Fuel Supply from Fuel Tank Fuel Separator Bowl Drain Valve with Hose Barb Fuel Supply to Engine

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 nonfunctional. For service and replacement intervals, refer to SERVICE AND LUBRICATION POINTS in THIS SECTION.

The fuel filter/water separator is located in the front engine compartment.

3.60

Tigercat H250D Processor

Lubrication and Maintenance

CHANGING FUEL FILTER/WATER SEPARATOR

WARNING

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS SECTION for filter replacement intervals.

To lower the risk of causing accidental fires, do not leave fuel or oil soaked rags laying around.

WARNING

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

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

2. Drain the fuel from the filter/water separator as described previously in this section.

3. Disconnect the fuel heater and the 'water-in-fuel' sensor from the wiring harness.

A

FUEL HEATER

801168

A

802236

A Filter Removal Tool (BH859)

4. Remove the water separator bowl from the filter head.

NOTE: A bowl wrench is supplied with the machine (Tigercat Part Number: BH859).

5. Dispose of any fuel properly.

6. Remove and discard the O-ring from the top of the separator bowl.

B

7. Clean the separator bowl.

8. Remove the filter cartridge from the filter head (pressure fit) and discard properly.

9. Place the new filter into position on the filter head.

10. Lubricate the O-ring with clean engine oil and install at the top of the separator bowl.

11. Install (screw) separator bowl onto the filter head, hand tighten, then turn an additional 3⁄4 turn only.

12. Reconnect the fuel heater and the 'water-in-fuel' to their respective wiring harness.

13. Turn the ignition key to the RUN position to energize the fuel supply shut-off solenoid valve.

14. Prime the fuel system using the hand primer until fuel spills out the metal vent plug.

15. Close the vent plug.

16. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

3.61

200555

A Fuel Filter/Water Separator B Fuel Heater (Bottom of Clear Bowl)

The fuel heater is incorporated into the fuel filter/water separator and is controlled electronically by the engine ECU.

Lubrication and Maintenance

Tigercat H250D Processor

FUEL TANK COMPONENTS

IN-TANK FUEL STRAINER

FILL CAP

A

A B

201064

201062

A Fuel Fill Cap B Fuel Tank

The fuel tank and fuel fill cap are located on the front of the upper structure below the cab. The fuel tank has a capacity of 300 L (80 US gal).

Lower Rear of Fuel Tank

A In-tank Fuel Strainer

A stainless steel 150 micron fuel strainer is screwed onto the end of the fuel supply line.

Check the fuel tank strainer every 1000 hours.

CHANGING/CLEANING THE IN-TANK FUEL STRAINER NOTE: Changing the in-tank fuel strainer is only required if excessive quantities of foreign material have built up inside the fuel tank.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove the fuel line to the strainer and remove the fuel strainer from the fuel tank by turning counterclockwise.

3. Carefully clean the in-tank fuel strainer.

NOTE: Use caution when cleaning the in-tank fuel strainer or damage may occur.

4. Check for buildup of foreign material where the strainer screws to the fuel tank.

WARNING To lower the risk of causing accidental fires, do not leave fuel or oil soaked rags laying around.

5. Reinstall the fuel strainer by threading clockwise into the tank.

6. Reconnect the fuel line.

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Tigercat H250D Processor

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 steps and handles needed to access the fuel tank.

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

5. Clear any debris from around the fuel fill cap.

6. Remove the fuel fill cap slowly to allow pressure to escape from the tank.

S≤15 mg/kg

7. Inspect the fuel fill cap gasket.

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.

A B

WARNING

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

201063

A Air Vent Passage B Inner Fuel Fill Tube

CAUTION

Fuel Fill Tube

8. Insert the fuel nozzle into the inner fuel fill tube. Air from the tank will vent out via the air vent passage.

Do not leave the machine unattended during the refuelling process.

9. Fill the tank until fuel level reaches the top of the inner 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.

3.63

Lubrication and Maintenance

Tigercat H250D Processor

AIR INTAKE SYSTEM

HOW IT WORKS 1. Dirty air (A) enters the precleaner, which is clamped onto the engine air intake.

ENGINE AIR PRECLEANER

2. Specially-designed vanes (B) , curved and angled to precisely direct air flow, move the dirty air toward the stainless steel impeller (C).

3. The dynamically balanced, one piece impeller (C) (only moving part) creates a tornado inside the housing.

A

4. The centrifugal force of the tornado expels the heavier than air dirt particles (D), chaff, dust, snow, rain, etc., out the discharge louvre.

T250D-033

A Engine Air Precleaner – Top of Engine Compartment

The engine air precleaner cleans engine air before it reaches the air cleaner filter elements. It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance.

5. Cleaned air (E) enters the engine air cleaner intake pipe, and the filter element has only the very light particles to remove.

AIR INTAKE TUBING AND JOINTS A

B

C

D

C

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.

201052

C

C

A B C D

D

B A E

480-017

A B C D E

Dirty Air Specially-designed Vanes Stainless Steel One Piece Impeller Foreign Particles Cleaned Air

Engine Air Precleaner Air Cleaner Air Intake Rubber Elbows Air Intake Tube

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

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

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

3.64

Tigercat H250D Processor

Lubrication and Maintenance

AIR CLEANER A

In addition to the SERVICE AND LUBRICATION SCHEDULE outlined in THIS SECTION, the following instructions should also be noted.

B

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.

C

200301

IMPROPER SERVICING

A Air Cleaner B Air Filter Restriction Indicator C Air Cleaner Unloader Valve

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.

B

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS 1. Release the cover latches gently to reduce the amount of dust dislodged.

2. Avoid dislodging dust from filter element(s) by gently pulling the element out of the housing.

3. Check your old filter sealing surfaces, This will help detect foreign material on the sealing surface that is causing leakage.

NOTE: Do not clean and reuse filter elements.

Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media.

The dust is then drawn directly into the engine.

A 726D-006

4. Clean the inside of the housing.

A Primary Element B Secondary (Safety) Element

The air cleaner on this machine uses two filter elements, a primary element and a secondary (safety) element.

It is accessible through the engine compartment front access door.

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

3.65

5. Clean the sealing surface before inserting a new filter element.

6. Inspect the new filter for damage.

7. Insert the new filter properly. Apply pressure to the filter frame not the pleated filter surface.

8. Check connections hoses and tubes for an air tight fit. All clamps, bolts and connections must be tight.

Check rubber elbows for splits or wear points. Leaks in these locations send dust directly to the engine.

Lubrication and Maintenance

Tigercat H250D Processor

AIR FILTER RESTRICTION INDICATOR

AIR CLEANER UNLOADER VALVE

A

B A

200301

200301

A Air Filter Restriction Indicator B Hose to Air Filter Restriction Sensor

An air filter restriction indicator is connected to the outlet side of the air filter. Service to the air filter is required when the restriction indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After servicing the filter, reset the indicator by pressing the reset button.

AIR FILTER RESTRICTION SENSOR

T250D-147

A

A Engine Air Intake Filter Restriction Icon

The machine is also equipped with an engine air filter restriction sensor on the outlet of the air cleaner which sends a signal to the computer in the event of filter restriction. The engine air intake pressure icon turns YELLOW when service to the filter is required and turns RED, along with a CRITICAL message, when service to the air filter has reached a critical state.

A Air Cleaner Unloader Valve

Check the rubber air cleaner unloader valve on the air cleaner housing every 8 hours. If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective.

Replace the unloader valve every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. A good valve should be soft and flexible. Check and clean the valve. If it is plugged, check the filter elements as they may also need to be replaced. Reattach the valve to the tube. The valve should suck closed at about one-third of HIGH engine speed. When operating in high dust conditions this valve should be checked and squeezed every two hours to release dust buildup.

Refer to AIR INTAKE SYSTEM– AIR CLEANER UNLOADER VALVE in SERVICE AND LUBRICATION POINTS in THIS SECTION.

Refer to AIR INTAKE SYSTEM – OVER SERVICING and AIR INTAKE SYSTEM– IMPROPER SERVICING in THIS SECTION. Refer to COMPUTER – MESSAGES– CRITICAL – ENGINE AIR INTAKE FILTER RESTRICTED in SECTION 2.

3.66

Tigercat H250D Processor

Lubrication and Maintenance

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

AFTERTREATMENT SYSTEM Tier 4f machines are equipped with a combination Diesel Oxidation Catalyst (DOC) and high-efficiency Selective Catalytic Reduction (SCR) aftertreatment system to limit the nitrogen oxide exhaust gas values (NOX) to meet Tier 4f emission standard requirements with low fuel consumption. This process is electronically controlled by the DENOX 2.2 system.

The DOC uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). In addition, the DOC converts nitrogen oxide (NO) into nitrogen dioxide (NO2). Increased NO2 levels enhance the performance of the SCR catalyst at low temperatures and increase the effectiveness of the DOC/SCR aftertreatment system as a whole.

The high-efficiency SCR process is based on a series of chemical reactions which involve the reaction of ammonia with the oxygen in the exhaust gas to reduce nitrogen oxides (NOX) in the exhaust gas by transforming it into inert compounds: free nitrogen (N2) and water vapour (H2O). In addition, the high-efficiency catalytic converter includes a clean up catalyst (CUC) which reduces any excess ammonia (NH3), which may result from the SCR process.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the aftertreatment system and the engine.

3.67

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 H250D Processor

AFTERTREATMENT SYSTEM COMPONENTS R

V

K M

E

G

J

T

W

B C

X

A

H I

201019

3.68

D

Tigercat H250D Processor

Lubrication and Maintenance

F N

W

M

Q

F

P

U

V

R

C A

B

H I

D

J K

T

S

G

O

L

201020

A B C D E F G H I J K L

DEF Tank Sending Unit (includes Level Sensor) DEF Quality Sensor (In Sending Unit) Heater Valve ECU – Engine (Denox 2.2 Dosing System) Exhaust Flap Diesel Oxidation Catalyst (DOC) DEF Supply Module DEF Dosing Module Filter (in Supply Module) Dosing Module (DEF Injector) Mixer Tube Catalytic Converter (includes SCR and CUC)

M N O P Q R S T U V W X

3.69

Humidity and Temperature Sensor DOC Inlet Temperature Sensor Catalytic Converter Inlet Temperature Sensor Catalytic Converter Outlet Temperature Sensor NH3 Sensor ECU – NH3 Sensor Inlet NOx Sensor ECU – Inlet NOx Sensor Outlet NOx Sensor ECU – Outlet NOx Sensor Air Filter Engine

Lubrication and Maintenance

Tigercat H250D Processor M

W

T E

F

HC

S

V

R

U

Q

NOx I

CO

N

HC – Hydrocarbons NOx– Nitrogen Oxides CO – Carbon Monoxide NH3 – Ammonia N2 – Free Nitrogen H2O – Water CO2 – Carbon Dioxide

H

B X

P

L

O

C

G

D H2O

N2

NH3

CO2

K 630E-276

A B C D E F G H I J K L

EXHAUST GAS FLOW DIRECTION

A

COOLANT LINE

DEF Tank Sending Unit (includes Level Sensor) DEF Quality Sensor Heater Valve ECU – Engine (Denox 2.2 Dosing System) Exhaust Flap Diesel Oxidation Catalyst (DOC) DEF Supply Module DEF Dosing Module Filter (in Supply Module) Dosing Module (DEF Injector) Mixer Tube Catalytic Converter (includes SCR and CUC)

M N O P Q R S T U V W X

J DEF LINE

Humidity and Temperature Sensor DOC Inlet Temperature Sensor Catalytic Converter Inlet Temperature Sensor Catalytic Converter Outlet Temperature Sensor NH3 Sensor ECU – NH3 Sensor Inlet NOx Sensor ECU – Inlet NOx Sensor Outlet NOx Sensor ECU – Outlet NOx Sensor Air Filter Engine

The DOC/SCR aftertreatment system is electronically managed by the DENOX 2.2 system incorporated into the engine ECU. The ECU calculates and adjusts the flow rate of the DEF solution into the system based on current engine speed, torque delivered, exhaust temperature, amount of nitrogen oxides and ammonia present.

The first phase of the SCR process takes place in the first part of the catalytic converter: high temperature exhaust gas evaporates the DEF solution instantly and, by hydrolysis, converts it into ammonia (2NH3) and carbon dioxide (CO2). Evaporation of the solution lowers exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The exhaust passes through the diesel DOC which uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). It also converts nitrogen oxide (NO) into nitrogen dioxide (NO2) which enhances the performance of the SCR catalyst.

The exhaust fumes and ammonia at the proper reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place: by reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

The supply module pump picks up the DEF solution from the tank and sends it under pressure through the dosing module filter to the dosing module (DEF injector) to be injected into the exhaust at the outlet of the DOC and pass through the mixer tube upstream of the catalytic converter.

Finally the high efficiency catalytic converter incorporates a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

3.70

Tigercat H250D Processor

Lubrication and Maintenance

DIESEL EXHAUST FLUID (DEF) TANK

41581AUNI R0

B

C

A

A

201015

803099

A DEF Tank B Fill Cap/Fill Strainer C Sending Unit/Level Sensor/DEF Quality Sensor

The DEF tank includes a fill cap/fill strainer and a sending unit which has an integral level sensor and a combination DEF quality sensor/temperature sensor.

SENDING UNIT/DEF QUALITY SENSOR

A B C

A B

201016

DEF Tank Location

A Primary Access Cover B DEF Tank C DEF Tank Fill Cap

C

The DEF tank is located in the compartment beside the boom saddle. The DEF tank fill cap can be accessed by lifting the hinged lid on top of the compartment. The DEF tank fill point is equipped with a fill strainer to prevent contaminants from entering the tank. Do not remove this strainer when filling the DEF tank.

D

A DEF level indicator is shown on the main menu of the computer display, below the fuel gauge.

3.71

C

803101

A B C D

DEF tank capacity is 4 6 L (1 2 .1 US g a l ). Do not overfill tank. This tank is equipped with an expansion capacity of 7% required to allow for the expansion of DEF in cold temperature conditions. DEF freezes at −11°C (12°F).

D

Coolant Heater Coil Level Sensor Inlet Strainer DEF Quality Sensor/Temperature Sensor

The sending unit incorporates a DEF quality sensor, a heater coil, vent port, level sensor, strainer, temperature sensor, heating system inlet/outlet connections, DEF inlet/outlet connections and an electrical connector.

Lubrication and Maintenance

Tigercat H250D Processor

DRAINING AND CLEANING THE DEF TANK Drain and clean the DEF tank when: • A DEF-related alarm occurs and the problem may be due to a blocked DEF line or a pressurization problem.

• Any situation where a contaminated DEF supply is suspected.

A

The DEF tank does not have to be removed from the machine for draining.

B

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

C

2. Read the DEF level indicator on the computer display to estimate the container capacity required to properly drain the DEF solution.

3. Remove the DEF tank fill cap.

A

B 201021

Sending Unit Removal

A DEF Tank Cover Plate B Sending Unit C DEF Tank

6. Remove the DEF tank cover plate on the top of the compartment.

201022

DEF Tank Drain Plug Location

A DEF Tank Drain Plug B DEF Tank

4. Locate the DEF tank drain plug under the upper structure.

5. Remove the DEF tank drain plug and drain the DEF into a suitable container and dispose according to local regulations.

3.72

Tigercat H250D Processor F

E

D

C

Lubrication and Maintenance B

A

A

B

802429

A Inlet Strainer B Clip

12. Inspect the inlet strainer at the bottom of the sending unit.

13. Remove the inlet strainer clip.

200431

A B C D E F

DEF Sending Unit

A

Electrical Connector Coolant Inlet DEF Supply DEF Return Vent Hose Coolant Outlet

B

7. Disconnect the DEF lines, coolant lines and electrical connector from the sending unit. Make note of the connections. Press the white and green tabs to release the connector locks.

8. Plug or cap the hoses and sending unit ports.

9. Use a large oil filter wrench to turn the sending unit counterclockwise approximately 10 degrees. Slowly lift the sending unit straight up and out of the tank.

10. Remove and clean the DEF fill strainer. Refer to DIESEL FLUID EXHAUST TANK – FILL STRAINER, CLEANING in THIS SECTION. 11. Clean the inside of the tank with clean DEF, distilled water or demineralized water. Thoroughly drain the tank after cleaning.

Do not reuse the DEF that has been drained from the tank. Use a licensed waste disposal contractor or as otherwise required by local laws to dispose of DEF. If any DEF has spilled, rinse well with water.

802431

A O-ring B Inlet Strainer

14. Remove and clean the inlet strainer. Inspect the O-ring, replace if required.

15. Clean the sending unit.

16. Reinstall the inlet strainer, O-ring and clip.

17. Reinstall the sending unit in the tank. Turn the sending unit approximately 10º clockwise using the large oil filter wrench.

18. Clean and reinstall the DEF tank drain plug.

19. Reconnect the DEF lines, coolant lines and electrical connector to the sending unit.

20. Fill the DEF tank. Refer to DIESEL EXHAUST FUEL TANK – FILLING in THIS SECTION.

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Tigercat H250D Processor

CLEANING THE DEF FILL STRAINER

A

Remove and clean particles and debris from the fill strainer every 500 hours.

B

C

D

1. Clean the area around the outside of the fill cap to prevent DEF contamination.

A

B

701048

A B C D 701047

A DEF Tank Fill Cap B DEF Tank Fill Neck

2. Remove the DEF tank fill cap.

DEF Tank Fill Cap Capscrews and Washers Fill Neck Flange DEF Fill Strainer

4. Remove the six capscrews and washers holding the fill neck flange to the DEF tank and remove the flange.

5. Remove the fill strainer from the fill neck.

3. Clean the area under the fill cap to prevent DEF contamination.

A

802170

A DEF Fill Strainer

6. Invert the fill strainer and lightly tap it against a clean, hard surface to dislodge and remove any particles.

7. Rinse the fill strainer with clean DEF, distilled water or demineralized water.

8. Install the clean fill strainer into the fill neck.

9. Install the fill neck flange with the six capscrews and washers.

10. Install the DEF tank fill cap.

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Tigercat H250D Processor

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FILLING THE DEF TANK

NOTICE

1. Park the machine as described in PARKING THE MACHINE in SECTION 1.

Do not remove the DEF fill strainer when filling the tank. Contamination of the DEF can occur.

2. Clean the area around the top of the fill cap to prevent DEF contamination.

A

IMPORTANT! Avoid contamination of DEF when performing maintenance on the system as this may cause costly damage to SCR system components and will affect the proper operation of the aftertreatment system and the engine.

B

4. Insert the filling container spout into the flap on the top of the fill strainer and fill the tank. Do not remove the fill strainer to fill the tank.

NOTE: To avoid contamination, do not re-use DEF. Fill the tank with new DEF only. Refer to DIESEL EXHAUST FLUID (DEF) in THIS SECTION for DEF specifications.

NOTE: A section of the DEF tank remains empty when the DEF level reaches the strainer to accommodate DEF expansion when it freezes.

5. Install the fill cap.

701047

A Fill Cap B Fill Neck

3. Remove the fill cap. Clean the area under the fill cap to prevent DEF contamination.

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Lubrication and Maintenance

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DIESEL EXHAUST FLUID (DEF) DEF is used by the DOC/SCR aftertreatment system to lower the concentration of nitrogen oxides from the diesel engine exhaust.

DEF is an aqueous urea solution with 32.5% high purity urea and 67.5% deionized water.

NOTE: DEF may also be referred to as AUS32 or AdBlue. All DEF must be American Petroleum Institute (API) Certified DEF or meet ISO 22241 specifications.

IMPORTANT! Store DEF between −5°C (23°F) and 30°C (86°F) and out of direct sunlight to maximize shelf life and to avoid DEF quality problems caused by improper storage.

IMPORTANT! Avoid contamination of DEF when performing maintenance on the system as this may cause costly damage to SCR system components and will affect the proper operation of the aftertreatment system and the engine.

NOTE: Extremely low levels of DEF or DEF quality problems will generate computer messages and these conditions may affect engine performance and damage to the DOC/SCR aftertreatment system components.

Take action to correct DEF quality problems immediately.

NOTE: DEF quality problems may result in derating of engine performance to meet emission standard requirements. Take action immediately to correct DEF quality problems to avoid affecting engine performance and damage to the DOC/SCR aftertreatment system components.

WARNING Use only Diesel Exhaust Fluid (DEF) which meets ISO 22241 specifications. Do not fill the DEF tank with any other fluid.

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

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

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

Refer to AFTERTREATMENT SYSTEM in THIS SECTION for more information regarding the use of DEF and its function in the DOC/SCR aftertreatment system.

Refer to COMPUTER – MESSAGES in SECTION 2.

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Tigercat H250D Processor

Lubrication and Maintenance

DIESEL EXHAUST FLUID (DEF) HANDLING AND STORAGE

AVOID DEF QUALITY PROBLEMS WITH PROPER HANDLING PRACTICES

DEF is an aqueous urea solution with 32.5% high purity urea and 67.5% deionized water.

Most DEF quality problems can be avoided entirely with a little care and proper handling of DEF.

NOTE: DEF may also be referred to as AUS32 or AdBlue and must meet ISO 22241 specifications. Use only DEF meeting this standard.

WHEN FILLING THE DEF TANK:

It is important to avoid contamination of DEF as this may cause costly damage to SCR system components and affect the proper operation of the SCR system and the engine.

When a problem with DEF quality is detected information messages are sent to the computer display.

NOTE: DEF quality problems may result in derating of engine performance to meet emission standard requirements. Take action immediately to correct DEF quality problems to avoid affecting engine performance and damage to SCR aftertreatment system components.

Refer to COMPUTER – MESSAGES in SECTION 2.

For safety information refer to DIESEL EXHAUST FLUID (DEF) in SECTION 1.

• Clean the area around the fill cap and avoid introducing contaminants into the DEF tank when filling.

• Use only DEF that meets ISO 22241 specifications.

The use of any other fluid will contaminate the aftertreatment system and will pose a safety hazard.

PROPER STORAGE CONTAINERS • To prevent contaminants from affecting DEF quality, handle DEF only in storage, transport and filling containers intended exclusively for that purpose.

• Polyethylene or stainless steel containers are recommended. Refer to DEF MANUFACTURER'S DOCUMENTATION for recommendations.

• DEF is corrosive to metals other than stainless steel.

Transport in metal containers other than stainless steel will result in contamination.

PROPER STORAGE CONDITIONS DEF quality problems can often be avoided with proper storage and handling practices to maximize shelf life.

• Store DEF between −5°C (20°F) and 30°C (86°F).

• Store DEF in areas out of direct sunlight.

• Store DEF away from heat sources.

• DEF shelf life is limited. Use DEF on a first in-first out basis, within DEF manufacturer's recommended shelf life limits. DEF beyond manufacturer's recommended shelf life limits may not meet ISO 22241 specifications.

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HEATER VALVE

Heating is switched OFF when: • DEF tank temperature >16°C (61°F) • Supply module temperature >10°C (50°F) • Ambient air temperature >−4°C (25°F) Heating is switched ON when:

A

• DEF tank temperature <15°C (59°F) • Supply module temperature: +8°C (46°F) • Ambient air temperature: −5°C (23°F) When conditions require heating the system will thaw DEF within 30 minutes of engine start for proper operation of the aftertreatment system.

250D-051

A Heater Valve A B

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

HEATED DEF SUPPLY LINES C 630E-265

A B C D

D

Connector Coolant Outlet Coolant Inlet Coolant Bypass

The DEF supply lines are heated by an electrical wire element built into each hose. The electrical connector is at the Supply Module end of the line. There are three heated lines and two types. There is one 24V line and two 12V lines. The lines can be identified by the electrical connector. The 24V line has a male connector and the 12V lines have female connectors.

A

The heater valve is mounted on the frame directly under the engine. Access it from underneath the rear of the machine.

The heater valve controls the flow of engine coolant through the DEF tank heater coil and the supply module when heating of the DEF is required. The heater valve also controls the constant flow of engine coolant to the dosing module for cooling purposes. This machine is equipped with electrically heated DEF supply lines.

IMPORTANT! If removing the heater valve care should be taken to reconnect the cooling hoses correctly. The heater valve is directional and if the hoses are connected incorrectly the DEF may overheat which will reduce its quality.

DEF freezes at −11°C (12°F).

Temperature sensors signals control the operation of both the electrically heated DEF supply lines and the heater valve which, depending on the temperature, opens or closes the flow of hot engine coolant to the heater coil and supply module.

B T250D-117

24 V Heated DEF Line A

C T250D-118

12 V Heated DEF Line

A DEF Line B Male Electrical Connector C Female Electrical Connector

The two 12V lines run from the Supply Module to the DEF Tank. These two lines are connected electrically in series, so if any one of these two lines fail the element in the other line would not function. For full description of wiring, refer to SECTION 6 of the SERVICE MANUAL.

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Tigercat H250D Processor

Lubrication and Maintenance

DENOX 2.2 DOSING SYSTEM

EXHAUST FLAP

A

A

200313

630E-259

A Engine ECU

A Exhaust Flap

DENOX 2.2 control system is incorporated into the engine ECU. The DOC/SCR aftertreatment system is electronically managed by the DENOX 2.2 control system. The engine ECU calculates and adjusts the flow rate of the DEF solution into the system based on current engine speed, torque delivered, exhaust temperature, amount of nitrogen oxides and ammonia present and the humidity levels in incoming air.

3.79

An exhaust flap is located at the exhaust outlet from the engine. The computer controls the exhaust flap to automatically regulate temperature of the exhaust entering the diesel oxidation catalyst (DOC) to optimum levels for proper operation of the aftertreatment system.

Lubrication and Maintenance DIESEL OXIDATION CATALYST (DOC)

Tigercat H250D Processor DEF SUPPLY MODULE A

A

T250D-146

A Diesel Oxidation Catalyst

The diesel oxidation catalyst (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.

250D-052

A DEF Supply Module

The supply module is located on the frame under the engine. Access it from underneath the rear of the machine.

The supply module pump picks up the DEF solution from the tank and sends it under pressure to the dosing module, mounted on the mixer tube incorporated into the diesel oxidation catalyst. DEF is injected into the exhaust at the outlet of the diesel oxidation catalyst and upstream of the catalytic converter.

The DOC is located upstream of the catalytic converter (SCR/CUC) and at its outlet incorporates the mixer tube and the mounting for the dosing module.

3.80

Tigercat H250D Processor

Lubrication and Maintenance

DEF DOSING MODULE FILTER

REMOVE DEF DOSING MODULE FILTER

The DEF dosing module filter should be replaced as part of scheduled maintenance every 250 hours.

If DEF and/or aftertreatment fault codes have occurred then Tigercat recommends performing a DEF flushing test and Urea Dosing System Test (UDST) at every DEF dosing module filter change to ensure proper operation of the DEF supply module.

If no DEF and/or aftertreatment fault codes have occurred then only the DEF dosing module filter replacement is required.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

NOTE: Verify that engine is at operating temperature before turning OFF the engine.

2. Wipe clean the area around the DEF supply module and filter including the supply module ports with particular attention to the inlet port and filter cap to avoid introducing contamination into the filter housing while performing this procedure.

3. Place container below to catch the spills.

CHANGING DEF dosing module FILTER, DEF FLUSHING TEST AND UDST (urea dosing system test) TOOLS REQUIRED 27 mm (1 1⁄16 in) wrench Container to catch DEF and flushing water Clean distilled/demineralized water 1 L (0.25 US gal) plastic water bottle with hose attached* Laptop computer with Tigercat by FPT E.A.SY. engine diagnostic software to run UDST test*

630E-281

4. Turn the filter cover counterclockwise to remove from the supply module. Use a 27 mm (1 1⁄16 in) wrench.

PT-Box* IMPORTANT! Do not contaminate the DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine. *Items required if performing a DEF flushing test and UDST.

630E-282

5. Remove the equalizing element and note the colour of the filter inside (black or grey).

630E-285

6. Find the filter removal tool provided with the replacement parts select the correct edge BLACK (B) for black filters or GREY (G) for grey filters.

3.81

Lubrication and Maintenance

Tigercat H250D Processor DEF FLUSHING TEST A

630E-284

7. Insert the tool edge completely until a click is felt or heard.

630E-333

A Inlet Port

1. Disconnect the DEF hose from the inlet port of DEF supply module.

2. Fill the plastic bottle with distilled/demineralized water.

A

630E-286

8. Pull out the filter, using a tool in the slot on the filter removal tool if required.

630E-332

A Inlet Port 630E-287

9. Clean surfaces with distilled/demineralized water only to avoid DEF contamination.

3. Connect the water bottle hose to the inlet port of the DEF supply module.

Check the area around the filter for cracks. If cracks are found the supply module must be replaced.

10. Thoroughly clean the filter cover to avoid introducing contamination.

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Tigercat H250D Processor

Lubrication and Maintenance

630E-328

8. The results of the UDST will show a flat line for DEF pressure (red line) because the pump cannot build pressure without the filter in place.

9. Repeat the UDST test a second time to ensure the supply module is thoroughly flushed and working correctly.

630E-334

4. Raise the water bottle above the DEF supply module.

5. A small amount of water will flow through the supply module and out the bottom where the filter has been removed.

6. With the aid of an assistant run a UDST test from the laptop computer. Refer to PT BOX MANUAL FOR UDST test information.

630E-331

7. Distilled water will be drawn from the bottle and flushed through the DEF supply module. Suction may begin to collapse the bottle and water flow out the bottom of the module will increase.

3.83

10. When the UDST flushing procedure has been performed twice successfully remove the bottle and hose.

11. Reinstall the DEF module inlet hose.

Lubrication and Maintenance REPLACE FILTER

Tigercat H250D Processor 4. Check that all personnel are clear of the machine before starting the engine.

5. Insert the ignition key and turn to the RUN position.

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

7. Start the engine.

8. Check for leaks.

9. Turn OFF the engine.

630E-288

1. Install the new filter. Lubricate the O-rings on the filter with clean DEF solution for easy installation.

10. Remove the ignition key.

IMPORTANT! Do not contaminate the DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine.

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

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

630E-289

2. Install the new equalizing element.

NOTE: The equalizing element must be replaced with each filter change.

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

630E-290

3. Reinstall the clean filter cover, tighten to 20 N-m (15 lbf-ft). Use a 27 mm (1 1⁄16 in) wrench.

3.84

Tigercat H250D Processor

Lubrication and Maintenance

UDST (UREA DOSING SYSTEM TEST) 1. With the aid of an assistant run a UDST test from the laptop computer. Refer to PT BOX MANUAL for UDST test information.

630E-327

2. If the supply module is functioning correctly the test should show a characteristic curve as shown above, DEF pressure (red line).

3. A confirmation screen will indicate System is OK if the supply module is functioning correctly.

4. Repeat the UDST test a second time to confirm results.

630E-330

5. If the UDST test passes twice the supply module is OK.

630E-329

6. If the UDST test fails twice note the error mode(s) and contact customer service.

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Lubrication and Maintenance

Tigercat H250D Processor

DOSING MODULE (DEF INJECTOR) B

MIXER TUBE A

A

200316

A DOC B Dosing Module

The dosing module is mounted on the DOC outlet upstream of the catalytic converter. The dosing module injects DEF into the exhaust pipe.

NOTE: This module must be mounted at the correct specified angle to function properly.

B

T250D-119

A DOC B Mixer Tube

The mixer tube is incorporated into the outlet of the DOC upstream from the catalytic converter.

The insulated high-turbulence mixer tube is used to mix the DEF solution and exhaust gases together before they enter the catalytic converter.

The dosing module is cooled by a constant flow of engine coolant supplied by the heater valve to maintain optimum temperature for the aftertreatment process.

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Tigercat H250D Processor

Lubrication and Maintenance

CATALYTIC CONVERTER

The catalytic converter is located on the left side of the engine compartment. Chemical reactions inside the catalytic converter reduce nitrogen oxides (NOx) in the exhaust gas.

A

The catalytic converter is equipped with soundproofing material and replaces the exhaust silencer. It incorporates both the selective catalytic reduction (SCR) and the cleanup catalyst (CUC) components of the aftertreatment system.

The first phase of the SCR process takes part in the first part of the catalytic converter: high temperature exhaust gas evaporates the DEF solution instantly and, by hydrolysis, converts it into ammonia (2NH3) and carbon dioxide (CO2).

Evaporation of the solution lowers exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The exhaust fumes and ammonia at the proper reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place: by reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

201027

A Catalytic Converter

Finally the high efficiency catalytic converter incorporates a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

3.87

Lubrication and Maintenance

Tigercat H250D Processor

HUMIDITY SENSOR

The control system uses this information to calculate the amount of DEF to be injected into the system.

NOTE: All three temperature sensors are identical. Note the location for analysis purposes when replacing a temperature sensor.

200101

The humidity sensor is located on the air intake just past the air cleaner.

A

A

250D-060

A DOC Inlet Temperature Sensor

250D-059

A Humidity Sensor Location

This sensor monitors the temperature and humidity of intake air sending signals to the DENOX 2.2 control system. This information is used to calculate the amount of DEF to be injected into the system.

TEMPERATURE SENSORS

A

250D-061

A Catalytic Converter Inlet Temperature Sensor

A

250D-062

A Catalytic Converter Outlet Temperature Sensor M00013

Temperature sensors are mounted at the inlet of the DOC, the inlet of the catalytic converter and the outlet of the catalytic converter. These three sensors send exhaust temperature signals to the DENOX 2.2 control system.

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Tigercat H250D Processor

Lubrication and Maintenance

NH3 SENSOR

A A

B B 250D-063

A Catalytic Converter Outlet Tube (Exhaust) B NH3 Sensor

630E-264

A Electronic Control Unit B Sensor

The NH3 sensor detects and sends information about the NH3 levels in the exhaust. This information is used to calculate the amount of DEF to be injected into the system and to monitor DOC/SCR aftertreatment system operation.

The NH3 sensor is mounted at the outlet of the catalytic converter.

A

250D-064

A NH3 Sensor ECU

The NH3 sensor ECU is mounted on a bracket next to the radiator on the left side of the engine compartment .

Refer to AFTERTREATMENT SYSTEM– APPROVED ANTI-SEIZE PASTES FOR SENSORS in THIS SECTION.

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Lubrication and Maintenance

Tigercat H250D Processor

NOx SENSOR A

A

B

250D-066

A Inlet NOx Sensor ECU

620E-088

A Electronic Control Unit B NOx Sensor

The inlet NOx sensor ECU is mounted above the vacuum pump at the back of the hydraulic oil tank.

There are two NOx sensors and two NOx sensor ECU's in the aftertreatment system.

A

The NOx sensors detect and send information about the dosing of DEF solution and the efficiency of the catalytic converter to the DENOX 2.2 control system.

This information is used to calculate the amount of DEF to be injected into the system and to monitor DOC/SCR aftertreatment system operation.

Each NOx sensor consists of a ceramic sensor and an electronic control unit linked by a cable. The sensor detects the concentration of nitrogen oxides in the exhaust.

The sensor, cable and control unit are considered to be one part for service/replacement purposes.

250D-063

A Outlet NOx Sensor

The outlet NOx sensor is mounted at the outlet of the catalytic converter.

NOTE: Cable length cannot be changed as this will affect the proper operation of the sensor.

A

250D-064

A Outlet NOx Sensor ECU A

250D-065

The outlet NOx sensor ECU is mounted on the same bracket as the NH3 sensor ECU next to the radiator on the left side of the engine compartment.

A Inlet NOx Sensor

The inlet NOx sensor is mounted upstream of the DOC.

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Tigercat H250D Processor

Lubrication and Maintenance

APPROVED ANTI-SEIZE PASTES FOR EXHAUST/AFTERTREATMENT SENSORS (TIGERCAT BY FPT TIER 4F ENGINES) If replacement of these components is necessary in the field, NOx sensors and NH3 sensors are pre-coated at the factory with the required anti-seize paste. The application of anti-seize is not required.

In the event anti-seize must be re-applied, use only the following approved products: • NOx sensors – Weicon® High Tech Anti-seize only • NH3 sensor – Loctite® X203 Dry Film Moly Anti-Seize

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Lubrication and Maintenance

START-UP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE Follow this procedure: • After major service or a rebuild.

• Whenever the machine has been drained of hydraulic oil.

• When any major component has been removed, repaired or replaced.

Tigercat H250D Processor PRE-STARTUP AND FILLING 1. Check oil levels in the engine.

2. Check the coolant level in the radiator/surge tank.

3. Do a final inspection of all fittings and clamps to ensure they are tight and will not leak.

4. Do not start engine. Purge the air from the hydraulic system as follows: a. All filters must be in place. b. Use the hand fill pump to fill the hydraulic oil tank if the oil level is low, or if it has been drained.

• If the engine fuel supply has been disconnected or drained, refer to ENGINE – RESTARTING AFTER ENGINE RUNS OUT OF FUEL in SECTION 2 for instructions. Alternately, refer to the procedure for priming the fuel system in the ENGINE OPERATION AND MAINTENANCE MANUAL.

c.

Fill all the pumps and motors with pre-filtered hydraulic oil through the highest case drain ports.

d. Bleed the air from the pumps (main, swing, and cooling) by loosening the case drain hose fittings at each pump connection. e. Continue filling the hydraulic oil tank. f.

Tighten the case drain hose fittings to the pumps when oil is seen coming from the pump case drain ports.

IMPORTANT! All air must be evacuated from the pumps.

NOTE: Changing strainers, filters and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, the machine should sit for one hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

5. Proceed to the MACHINE START-UP procedure.

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Tigercat H250D Processor

Lubrication and Maintenance

MACHINE START-UP

4. Crank engine for five seconds, then wait for five seconds. Check hydraulic oil pressure indicator during cranking to observe pressure reading. Repeat five times to pump oil into pumps and system components.

Before beginning this procedure, perform the PRESTART-UP AND FILLING steps.

NOTE: If hydraulic oil pressure readings do not indicate a rise in pressure, check for possible cause (air in system, leaks, loose hose fittings, pumps not turning, etc.). Repair problem. Repeat step 4 until a rise in hydraulic oil pressure readings is noticed.

A

5. Turn the emergency stop switch clockwise to allow it to pop back up to turn the power back ON. 6. Turn ignition key to RUN position and observe computer display. Change to the information mode menus to display the hydraulic oil pressure indicator before starting the engine.

234B-013

A Emergency Stop Switch

1. Push DOWN the emergency stop switch to prevent the engine from starting.

WARNING

7. Start the engine and press the interlock reset switch.

If the hydraulic oil pressure reading does not rise within 20 – 30 seconds, turn OFF the engine. If the hydraulic oil pressure reading is between 18 – 35 bar (260 – 500 psi), run the engine at LOW speed for 20 minutes. Check the engine oil pressure. Do not operate any functions.

8. Set engine speed at LOW and run each BOOM function for two minutes at LOW pressure to purge air from the circuit.

Machine operator must only take directions from the person doing the set-up.

2. Turn ignition key to the RUN position and press the interlock reset switch. This will allow oil to circulate and refill these circuits during the following cranking procedure.

9. Set engine speed at LOW and slowly run the SWING function five revolutions clockwise and then five revolutions counterclockwise to purge air from the circuit.

10. Set engine speed at LOW and slowly operate the drive function forward and reverse a few times.

11. Set engine speed at HIGH and run each function again for two minutes to flush circuit.

12. Set engine speed at LOW and turn OFF the engine.

13. Top up the radiator/surge tank with clean coolant.

A

14. With all cylinders fully retracted, check hydraulic oil level.

15. If required, top up the hydraulic oil tank with clean oil using the oil fill pump. Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – ADDING OIL in THIS SECTION. NOTE: If possible, allow the machine to stand for four to six hours before setting any of the operating pressures. This will allow any air bubbles in the oil to escape and is a good time to check for leaks.

200136

A Hydraulic Oil Pressure Indicator

3. Turn ignition key to the RUN position. Monitor hydraulic oil pressure indicator reading closely.

16. Recheck hydraulic oil level and top up if required.

17. Refer to appropriate section of the SERVICE MANUAL to check and set operating pressures.

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Lubrication and Maintenance

CARE OF THE MACHINE

• All fluid levels must be at the proper level. Refer to SCHEDULED MAINTENANCE in THIS SECTION. • Lubricate all grease points at the required intervals.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION. • The cab emergency exits must be in working order.

Refer to EMERGENCY EXITS in THIS SECTION. • Follow proper procedure for cleaning windows. Refer to CARE OF POLYCARBONATE WINDOWS in THIS SECTION. • Do not allow branches, twigs, leaves or pine needles to build up around radiator intake doors or anywhere else on the machine. Clean as operating conditions warrant but at least once a day all debris must be remove from the machine interior.

Tigercat H250D Processor PRESSURE WASHING Pressure washing is one of the easiest and most economical ways to preserve your investment.

Accumulated 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.

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

• Do not apply load to a cold engine.

• Never park machine with the attachment raised off the ground. Be sure the attachment is resting on the ground before servicing or parking the machine.

Refer to PARKING THE MACHINE in SECTION 1.

• SAFETY FIRST! Follow all safety rules and regulations as outlined in SECTION 1.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the after treatment system and the engine.

Use personal protective equipment to guard against flying debris.

IMPORTANT! Use a high volume, low pressure fan nozzle or nozzle setting for all equipment cleaning. High pressure spray can damage paint, penetrate electrical connections and remove labels. Use a mild detergent and make sure pressure settings are below 83 bar (1200 psi).

A

B

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.

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Tigercat H250D Processor

Lubrication and Maintenance

PRESSURE WASHING PROCEDURE – UNDERCARRIAGE

PRESSURE WASHING PROCEDURE – UPPER STRUCTURE

1. Park the machine on level ground.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Start the engine and set engine speed at LOW.

2. Close and latch the cab door.

3. Swing the boom to the left side of the machine.

5. Apply the swing brake.

3. Open all engine compartment doors. Refer to ACCESS DOORS AND COVERS in THIS SECTION.

6. Turn OFF the engine.

4. Tilt cab forward. Refer to CAB TILT in SECTION 2.

7. Remove the ignition key.

5. Turn OFF the battery disconnect switch.

4. Rest the attachment firmly on the ground.

6. Pressure wash:

200132

• Drive motors and compartments • Oil cooler, cooler package and enclosure screens • Engine compartment • Hydraulic pumps and compartment • Main control valve and compartment

8. Use a jack of suitable design and capacity to safely raise the left track clear of the ground.

Refer to serial number plate for machine weight (less attachment.

Refer to ATTACHMENT MANUFACTURER'S DOCUMENTATION for attachment weight.

9. Use blocks to firmly support the undercarriage frame in the raised position.

10. Insert the ignition key and turn to the RUN position.

11. Sound the horn to warn personnel of machine startup.

12. Start the engine and set engine speed at LOW. 13. Rotate the LEFT TRACK ONLY to shake off mud and dirt.

14. Turn OFF the engine.

15. Remove the ignition key.

16. Turn OFF the battery disconnect switch.

17. Clean the undercarriage and track with a shovel and a broom to remove all debris 18. Pressure wash tracks, undercarriage and lower rotary manifold and compartment.

19. Use the jack to remove the blocks and safely lower the left track to the ground.

20. Repeat the above steps for the RIGHT TRACK.

3.95

• Cab windows. Refer to WINDOWS – CARE OF POLYCARBONATE WINDOWS in THIS SECTION. 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.

Lubrication and Maintenance

Tigercat H250D Processor

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.

The cooler package is located on the right side of the upper structure behind the cooler package access door.

D

C

B

A

200545

A B C D

Right Side of Machine

Charge Air Cooler A/C Condenser Radiator Hydraulic Oil Cooler

The cooler package comprises four horizontally aligned core elements – charge air cooler (turbocharger air), A/C condenser (refrigerant), radiator (engine coolant), and hydraulic oil cooler.

The cooling fan is located behind the cooler package on the front of the engine. The fan draws air from the right side of the machine through the door screen and the cooler package blowing it out of the opposite side of the machine.

3.96

Tigercat H250D Processor

Lubrication and Maintenance

CLEANING PROCEDURE

CAUTION

1. Park the machine on level ground. Refer to PARKING THE MACHINE 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 using compressed air for cleaning, use at 2 bar (30 psi) or less.

Use personal protective equipment (eye wear) to guard against flying debris.

A

6. Replace all access doors and covers 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.

201060

A Cooler Package Access Door

NOTE: The cooler package must be checked daily and may have to be thoroughly cleaned on a daily, weekly or monthly basis, depending on operating conditions.

Use personal protective equipment (eye wear) to guard against flying debris. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces. Care must be taken not to set the pressure too high otherwise damage to the components could result.

2. Remove the three bolts and washers and swing open the cooler package access door.

Pay particular attention to cleaning in the corners of the cooler as these areas usually plug deeply. Reversing the variable-pitch fan (if equipped) at least once per hour will help reduce the dust accumulation in the cooler cores.

Refer to SWITCHES – FAN CONTROL – VARIABLEPITCH FAN in SECTION 2 to manually reverse the fan.

The auto clean cycle is adjustable through the computer control system menu. Refer to COMPUTER – MAIN MENU – ADJUST MENU – FAN in SECTION 2.

A

For more information on fire prevention refer to FIRE PREVENTION in SECTION 1.

201065

A Cooler Package Access Door Safety Stop

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the reversible fan’s ability to remove dust and dirt particles.

3. Engage the door safety stop to prevent the door from closing during cleaning.

4. Remove any accumulated debris.

5. Use compressed air or water for cleaning.

3.97

Lubrication and Maintenance

Tigercat H250D Processor

CARE OF POLYCARBONATE WINDOWS

INSPECTION AND MAINTENANCE

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

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

• Inspect all windows daily and immediately after any impacts.

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

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

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

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

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

• The edges of the polycarbonate window must be evenly and fully supported on a flat surface around the entire window opening at all times. Bent or dented skylight structures must be replaced immediately. Bent or dented cab structures must be evaluated immediately for possible repair or replacement.

• The edges of the polycarbonate window must be free from cracks, chips, notches or scarring and must not be pinched or stressed. These defects will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

• Cracks, chips, notches or scarring anywhere on the viewing surface of the window will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

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

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

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

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

3.98

Tigercat H250D Processor

Lubrication and Maintenance

RESISTANCE TO CHEMICALS

CLEANING INSTRUCTIONS

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

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

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

Other chemicals however can seriously weaken the polycarbonate.

1. Rinse the window thoroughly with lukewarm water

Do not permit any of the following chemicals to come into contact with polycarbonate windows:

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

• Acetone • Air conditioning refrigerant

Brand name soaps and detergents recommended for cleaning polycarbonate are:

• Ammonia • Anti-freeze

• Formula 409

• Benzene

• Hexcel F.O. 554

• Brake fluid

• Joy

• Carbon tetrachloride

• Neleco-Placer

• Cutting oils

• Top Job

• Gasoline

3. Rinse the window thoroughly with lukewarm water.

• Lacquer thinner

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

• Toluene • Turpentine

5. To remove grease or oil, first rub lightly with a good grade of VM&P naphtha or isopropyl alcohol followed by the same rinse, wash, rinse and dry procedure described in steps 1 to 4.

• Xylene

RESISTANCE TO WATER Polycarbonate material has good resistance to water up to approximately 65°C (150°F). Above this temperature the effect of water is time-temperature related. This means the higher the water temperature, the shorter the time before the polycarbonate is adversely affected.

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

3.99

Refer to WINDOWS– CARE OF POLYCARBONATE WINDOWS – RESISTANCE TO CHEMICALS in THIS SECTION for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

Lubrication and Maintenance CAUTION

Tigercat H250D Processor GRAFFITI REMOVAL

• Do not use abusive cleaning procedures

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

• Do not use brushes, razor blades, scrapers, squeegees or other sharp tools on polycarbonate windows.

• To remove labels, stickers, etc., the use of kerosene, VM&P naphtha, or petroleum spirits is generally effective. When the solvent will not penetrate sticker material, apply heat (hair dryer) to soften the adhesive and promote removal.

either by hand or pressure washing on polycarbonate windows.

• Do not clean polycarbonate windows when the daytime temperature is high or in direct sunlight.

• Do not use abrasive or highly alkaline cleaners on polycarbonate windows.

• Do not use glass cleaners in either aerosol or non aerosol containers to clean polycarbonate windows.

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

Refer to WINDOWS– CARE OF POLYCARBONATE WINDOWS – RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

FIRE PRECAUTIONS Polycarbonate window material will ignite when exposed to an ignition source in excess of 427°C (800°F). When working around polycarbonate windows, observe similar fire precautions to those in place for wood.

CONCEALING HAIRLINE SCRATCHES The appearance of scratches and minor abrasions on the surfaces of polycarbonate windows can be minimized by using a mild automotive polish such as: • Johnson’s Paste Wax • Novus Plastic Polish #1 and #2 • Mirror Glaze Plastic Polish Be certain to clean the polycarbonate window as outlined prior to application of an automotive polish. Refer to WINDOWS– CARE OF POLYCARBONATE WINDOW– CLEANING INSTRUCTIONS in THIS SECTION.

3.100

Tigercat H250D Processor

Lubrication and Maintenance

SIDE WINDOW SCREENS

IMPORTANT! Retighten window screen knobs hand-tight only to ensure quick exit in case of emergency.

REMOVAL OF ANTI-CORROSION SPRAY (IF APPLICABLE) Some machines, particularly machines shipped outside North America, are shipped with an optional anticorrosion spray to protect the machine from corrosion during shipment.

This anti-corrosion spray should be removed when the machine reaches its destination as it may cause debris to stick to the treated surfaces of the machine.

201067

Right Side Shown

The anti-corrosion spray can be removed with a pressure washer, a sponge and soap.

The right side window screen can be opened to clean the window. Screen must be closed immediately after cleaning is complete.

A hand knob is provided on both the inside and the outside of the cab on the window screen. Unscrew one hand knob only (not both) to allow the screen to swing out on the hinges.

201068

Opened for Window Cleaning

3.101

Lubrication and Maintenance

Tigercat H250D Processor

TRACKS IMPORTANT TRACK DRIVE NOTES NEW MACHINE 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.

B

During the initial operating period, frequent track sag adjustments are necessary.

A

B

TRACK SAG Inspect track sag often. Maintaining correct track sag increases track life by as much as 50%. A track that is set too tight will wear out prematurely due to excessive chain tension.

MEASURING TRACK SAG TOP SLIDER UNDERCARRIAGE

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.

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.

200132

Blocking the Undercarriage

1. Swing the boom to side of machine; apply the swing brake.

7. Repeat this procedure for the opposite track.

2. Use a jack of suitable design and capacity to safely raise the track clear of the ground.

3. Use suitable blocks to firmly support the undercarriage frame in the raised position. Lower the machine to rest on the blocks.

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.

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Tigercat H250D Processor

Lubrication and Maintenance

TOP ROLLER UNDERCARRIAGE 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

A

2. Place a 1.2 m (4 ft) straight edge on top the track over two rollers as shown.

A

B

C B

D

C

400487

A No Sag – Track Too Tight B Too Much Sag – Track Too Loose C Sag 40 mm (1.57) – Track Correct

802708

A B C D E

4. The measured dimension must be 50 mm (1.97 in) for normal operations.

E

NOTE: If track sag is less than specified, track chain wear will be accelerated. If track sag is excessive, it is possible for the track to jump off the sprocket.

Straight Edge Tip of Grouser Sag Dimension Straight Edge Over Two Rollers Rollers

3. Measure the distance from the bottom surface of the straight edge to the tip of the grouser closest to the middle distance between the track rollers.

3.103

Refer to TRACKS – TRACK SAG ADJUSTMENT in THIS SECTION for the track chain tension adjustment procedure.

5. Repeat this procedure for the opposite track.

Lubrication and Maintenance

Tigercat H250D Processor

TRACK SAG ADJUSTMENT

TIGHTEN TRACK 1. Attach the valve coupler onto the fill valve.

WARNING Hydraulic oil or grease under pressure can penetrate the skin and could result in death or serious injury.

CAUTION

2. Connect a grease gun to the grease fitting on the coupler.

3. Add grease until the track sag dimension is within recommended limits.

Refer to TRACKS – MEASURING TRACK SAG in THIS SECTION for recommended limits.

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

C

B

201121

A B C D

Track Sag Fill Valve

Track Fill 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.

3.104

Tigercat H250D Processor

Lubrication and Maintenance

TORQUING UNDERCARRIAGE BOLTS

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 – 125 HOURS in THIS SECTION. 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.

3.105

Lubrication and Maintenance

Tigercat H250D Processor

TORQUE CHART – H250D Location Cylinders Piston nut, main boom cylinder Piston nut, stick cylinder Piston nut, heel cylinder Gland bolts, heel cylinder Gland bolts, main boom cylinder Gland bolts, stick boom cylinder

Thread Diameter

Torque (Lubricated) N-m lbf-ft

M60-2 6H M60-2 6H M60-2 6H M14-2 (10.9) M14-2 (10.9) M14-2 (10.9)

4380 4380 4380 150 150 150

3230 3230 3230 111 111 111

Boom joint and cylinder pin retaining bolts

M20-2.5 (10.9)

393

290

Main and stick boom pin retaining nut

2"-12 UNF (G8)

Until snug

Until snug

1 3/4"-12 UNF (G8)

540

400

Cab securing bolts

7/8"-9 UNC (G8)

540-610

400-450

Swing bearing bolts Swing gearbox mounting bolts Swing motor mounting bolts

7/8"-9 UNC (G8) M20-2.5 (10.9) M14-2 (10.9)

610 540 176

450 400 130

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

7/8"-9 UNC (G8) M12-1.75 (10.9) M10-1.5 (12.9)

540-610 108 120 54

400-450 80 89 40

Pump drive Flex drive coupling to flywheel Plate to bell housing

M10-1.5 (10.9) M10-1.5 (10.9)

46 61

34 45

Pump mounting Main pump to engine Swing pump to main pump Cooling pump to swing pump

M20-2.5 (10.9) M16-2 (10.9) M12-1.75 (10.9)

510 225 101

375 165 75

Undercarriage Track shoe bolts Idler bolts Roller mounting bolts Sprocket bolts Gearbox mounting bolts Drive motor mounting bolts

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

T/T* 175 450 380 380 275

Heel to stick boom pin retaining nut

*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.

3.106

Tigercat H250D Processor

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS

The torque values listed below are for general use only.

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

IMPERIAL GRADE 5 BOLTS

GRADE 8 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS LUBRICATED 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

3.107

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 H250D Processor

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.

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 T6– Code 61 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

Table T7– Code 62 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

3.108

Tigercat H250D Processor

Lubrication and Maintenance

Parker

ASSEMBLY TORQUE JIC 37 Degree Flare

SAE Dash Size

Thread Size

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

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 3-12

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

SAE Dash Size

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

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

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

1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

Thread Size

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

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

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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

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

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok SAE Dash Size

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

SAE Dash Size

NA NA 1/2 TO 3/4 NA 1/2 TO 3/4 1/2 TO 3/4 1/2 TO 3/4 1/3 TO 1/2 NA 1/3 TO 1/2 1/3 TO 1/2 1/3 TO 1/2 NA NA

Thread 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

Tube Connection Swivel or Hose Connection TFFT TFFT

1/8-28 NA 1/4-19 NA 3/8-19 1/2-14 NA 3/4-14 NA 1-11 1 1/4-11 1 1/2-11 2-11 NA

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

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

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE = 10 % -0 SAE DASH SIZE

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

THREAD SIZE

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (85) 10 (155) 18 (260) 29 (280) 32 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

PLUGS

ADJUSTABLE

NON-ADJUSTABLE

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.109

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (60) 7 (100) 11 (180) 20 (250) 28 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

HOLLOW HEX

HEX HEAD

HP5ON-S

P5ON-S

lbf-ft (lbf-in) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

Nm 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

lbf-ft (lbf-in) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

Nm 10 18 29 32 40 70 115 183 237 271 339 414 509

Lubrication and Maintenance

Tigercat H250D Processor

EATON Aeroquip

ASSEMBLY TORQUE

3.110

Tigercat H250D Processor

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

3.111

Lubrication and Maintenance

Tigercat H250D Processor

WEIGHTS OF COMMERCIAL WOOD

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

kg/m3 737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

lb/ft3 46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

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

NOTE: The values shown here are green weights.

3.112

kg/m3 753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

lb/ft3 47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Tigercat H250D Processor

Lubrication and Maintenance

PRESSURE AND SPEED SETTINGS Location

Pressure bar

psi

Engine Speed

Function Speed **

Engine HIGH (No Load)

2100 rpm

LOW (No Load, Pilot OFF)

800 rpm

LOW (No Load, Pilot ON)

1000 rpm

Pilot System Main Relief

35

500

1000 rpm

Margin Pressure (‘xP’ – ‘xLS’) (Note 5)

19

275

1000 rpm

Load Sense Relief (‘xP’ port)

310

4500

2100 rpm

Stick Boom IN

338

4900

1000 rpm

6 seconds **

Stick Boom OUT

338

4900

1000 rpm

6.75 seconds **

Main Boom DOWN

338

4900

1000 rpm

8 seconds **

Main Boom UP

338

4900

1000 rpm

8.5 seconds **

Pump 2

338

4900

1000 rpm

Attachment Rotate CW

103

1500

1000 rpm

Attachment Rotate CCW

103

1500

1000 rpm

Pump 1 ***

250

3625

1000 rpm

Main Valve

Safety Relief – Do not adjust Main Valve Port Reliefs

Auxiliary Valve Feed Reducers

Swing Pump (Note 9) Charge Pressure

28

400

1000 rpm

Pump POR ****

310

4500

2100 rpm

High Pressure Relief, Swing LEFT

352

5100

1000 rpm

High Pressure Relief, Swing RIGHT

352

5100

1000 rpm

Begin of Regulation

248

3600

Drive Brake Release Pressure (Note 7)

49

650

Cab Tilt Main Relief

207

3000

Cab Tilt Counterbalance Valves (Note 10)

241

3500

Track Drive

Cab Tilt

* Set pressure with gauge on main valve 'xLS' test port. ** Set function speeds with engine speed at HIGH. Stop cylinder extend/retract before hitting end of stroke. *** Setting pressure for non-Tigercat attachment. Setting is turned in for Tigercat attachment. **** Plus an additional 1/2 turn in.

3.113

Lubrication and Maintenance

Tigercat H250D Processor

SPEEDS Function

Speed

Engine Speed– rpm

Track Speed – Speed Switch LOW

12 rpm (21.74 seconds per revolution)

2100

Track Speed – Speed Switch HIGH

28 rpm (9.32 seconds per revolution)

2100

Refer to Attachment Manufacturer's Documentation

2100

Track Drive

Attachment Rotate Cycle Time

FLOWS Function

L/min

US gpm

Engine Speed– rpm

Flow 1

181

48

2100

Flow 1+Flow 2

360

95

2100

Flow 1

175

46

2100

Flow 1+Flow 2

284

75

2100

Attachment – Tigercat

Attachment – Non-Tigercat (Note 8)

NOTES: 1. Hydraulic system to be at operating temperature when setting pressures. a. Summer temperatures: 49 – 60°C (120 – 140°F) b. Winter temperatures: 38 – 49°C (100 – 120°F) 2. All pressures measured in bar (psi). All function speeds measured in seconds.

3. Set pressures with engine speed at LOW and pilot system turned ON unless otherwise specified.

4. Pressure and speed values are for reference purposes only. Refer to SERVICE MANUAL for setting procedure.

5. Set margin pressure with the pilot system turned ON. Do not use any functions.

6. Port reliefs on auxiliary valve cannot be adjusted. Each port relief has a specific setting and cannot be interchanged with other port reliefs.

7. Track drive brake release pressure is not adjustable. Turn screw out to allow valve to work.

8. Factory settings shown. Refer to ATTACHMENT MANUFACTURER'S DOCUMENTATION for specific values.

9. Swing Pump: a. Swing machine slowly 5 times in each direction before setting pressures. b. Do not hold pressure over relief more than 8 seconds at a time. Wait 5 seconds to avoid overheating.

10. Cab Tilt (Optional): a. Turn counterbalance valves out fully, then in one turn. b. Tilt valve is factory preset.

3.114