Tigercat N45 Tier 4f Engine N67 Tier 4f Engine Operation & Maintenance Manual - PDF DOWNLOAD

OPERATION AND MAINTENANCE MANUAL

N45 Tier 4f Engine N67 Tier 4f Engine

IMPORTANT! CATASTROPHIC ENGINE FAILURES CAN BE PREVENTED WITH PROPER MAINTENANCE. LISTED BELOW ARE SOME OF THE MAJOR CAUSES OF DOWNTIME AND SERIOUS ENGINE DAMAGE. • WATER IN FUEL • CONTAMINATION IN FUEL • CONTAMINATION IN DEF FLUID • PLUGGED AIR FILTERS • IMPROPER OIL CHANGE INTERVALS REFER TO THIS MANUAL AND THE MACHINE’S OPERATOR’S AND/OR SERVICE MANUALS FOR PROPER MAINTENANCE INTERVALS AND PROCEDURES. THIS ENGINE USES DIESEL EXHAUST FLUID TO MEET TIER 4/STAGE 4 EMISSION STANDARDS. READ OPERATOR’S MANUAL FOR SPECIAL OPERATING AND MAINTENANCE INSTRUCTIONS.

INTRODUCTION

Tigercat FPT N45 Tier 4f Tigercat FPT N67 Tier 4f

This manual is provided by Tigercat to assist the dealer, customer, and operator in becoming familiar with the safety, operation and maintenance of the Tigercat FPT N45 and N67 Tier 4f engines.

OPERATION AND MAINTENANCE

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

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

Every effort is made to send out updates on a regular basis.

If the engine in question was built after the release date of this manual and there is a discrepancy, please call the Tigercat service department. The release date appears at the bottom of this page.

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

CALIFORNIA Proposition 65 Warning

42939AMUL

ISSUE 3.0 November 2015

1

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

Table of Contents GENERAL INFORMATION ................................................................................................................... 6 NON-APPROVED FIELD PRODUCT CHANGES................................................................................. 6 AUTHORIZATION BY ANY OTHER PERSON IS UNACCEPTABLE.................................................... 6 SAFETY................................................................................................................................................. 7 UNDERSTANDING SIGNAL WORDS................................................................................................... 7 IN CASE OF AN EMERGENCY ..........................................................................................................11 ENGINE IDENTIFICATION ................................................................................................................. 13 SERIAL NUMBER LOCATION ............................................................................................................ 13 ENGINE TECHNICAL DATA N45 ....................................................................................................... 14 COMPONENT LOCATION DIAGRAMS - N45 ENGINE ..................................................................... 15 ENGINE TECHNICAL DATA N67 ....................................................................................................... 17 COMPONENT LOCATION DIAGRAMS - N67 ENGINE ..................................................................... 18 ENGINE USE ..................................................................................................................................... 20 PRELIMINARY CHECKS ................................................................................................................... 20 2

STARTING AND STOPPING THE ENGINE ....................................................................................... 20 COLD START HEATER ....................................................................................................................... 20 TO PREVENT ENGINE DAMAGE .................................................................................................... 21 SPECIAL WARNINGS ........................................................................................................................ 21 ENGINE COOLANT LEVEL LOW ....................................................................................................... 21 ENGINE COOLANT TEMPERATURE HIGH....................................................................................... 21 CONTROLS AND MAINTENANCE ................................................................................................... 22 MAINTENANCE PERSONNEL .......................................................................................................... 22 ACCIDENT PREVENTION ................................................................................................................. 22 MAINTENANCE SCHEDULE .............................................................................................................. 23 FLUID CAPACITIES .......................................................................................................................... 24 LUBRICATION CIRCUIT DIAGRAM .................................................................................................. 25 LUBRICATION CIRCUIT .................................................................................................................... 26 OIL LEVEL CHECK ............................................................................................................................. 26 REPLACEMENT OF ENGINE OIL AND FILTER ................................................................................ 27 AIR INTAKE AND EXHAUST GAS CIRCUITS ................................................................................... 29 AIR FILTER ......................................................................................................................................... 29 3

TURBOCHARGER .............................................................................................................................. 29 ELECTRICAL STARTER SYSTEM .................................................................................................... 29 RUNNING IN ...................................................................................................................................... 29 ELECTRICAL COMPONENT LOCATIONS ........................................................................................ 30 FUEL CIRCUIT DIAGRAM .................................................................................................................. 31 REFUELLING .................................................................................................................................... 32 FUEL CIRCUIT ................................................................................................................................... 32 FUEL LEVEL LOW .............................................................................................................................. 32 LOW TEMPERATURE DIESEL .......................................................................................................... 32 RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL ............................................................. 32 CHECK FOR WATER IN FUEL FILTER/WATER SEPARATOR ......................................................... 33 PRIMARY FUEL FILTER COMPONENTS .......................................................................................... 33 REPLACEMENT OF FUEL FILTER .................................................................................................. 34 INSPECTION/REPLACEMENT OF SERPENTINE BELT ................................................................. 35 WHEN PERFORMING ENGINE MAINTENANCE: ............................................................................ 36 VISUAL ENGINE CHECK .................................................................................................................. 36 MOVING THE ENGINE ...................................................................................................................... 37 4

DISPOSAL OF WASTE ...................................................................................................................... 37 ENGINE MALFUNCTIONS ................................................................................................................. 37 ENGINE OIL CHART ........................................................................................................................... 38

5

AUTHORIZATION BY ANY OTHER PERSON IS UNACCEPTABLE.

GENERAL INFORMATION NON-APPROVED FIELD PRODUCT CHANGES

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

Unauthorized changes made of any kind to this Tigercat product could affect the product’s ability to perform as originally intended. The product’s integrity, and it’s ability to perform safely could be at serious risk.

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER.

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

Official approval to make changes or install options is only to be undertaken as follows:

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.

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

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

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

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

6

SAFETY

SAFETY SYMBOLS

THE FOLLOWING INFORMATION IS INTENDED TO ENCOURAGE CAUTION WHEN USING THE ENGINE, SO AS TO AVOID DAMAGE TO PERSONS OR PROPERTY AS A RESULT OF IMPROPER OR INCORRECT BEHAVIOR. The engines must only be used for the purposes indicated by the Manufacturer.

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

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

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

UNDERSTANDING SIGNAL WORDS

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

Pay particular attention to moving parts of the engine, to high temperature components and to circuits containing pressurised fluids; its electrical equipment houses electrical currents and voltage.

WARNING

The exhaust fumes produced by the engine are bad for your health.

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

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

The operations required to guarantee the best possible use and preservation of the engine must only be carried out by persons of proven experience, equipment with tools considered suitable by Tigercat .

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

7

WARNING

SAFETY PRECAUTIONS

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

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

Wash hands after handling.

WARNING

CAUTION

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

Use only diesel exhaust fluid (DEF) which is American Petroleum Institute (API) Certified DEF Fluid or meet ISO 22241 specifications.

NEVER fill the DEF tank with any other fluid. Doing so may cause a fire risk which could result in death or serious injury, damage to the aftertreatment system, and void your warranty.

Lead-acid batteries contain sulfuric acid which can severely damage eyes or skin on contact. Always wear a safety face shield, rubber gloves and protective clothing to reduce risk of accidents.

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

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

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

8

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

WARNING

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

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

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

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

Dispose of fluids properly. Do not pour fluids into the ground, stream, pond or lake. Before draining any fluids, know the proper way to dispose of them.

9

WARNING

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

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

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

•

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

•

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

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

10

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

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

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

In closed rooms, carbon monoxide is extremely dangerous, as it can reach critical concentrations within a very short time.

When assisting a person who has been exposed in a closed room: 1. Ventilate the room immediately, to reduce the concentration of gas.

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

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

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

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

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

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

Burns and scalds 1. Extinguish any flames on the burned person’s clothing, by: • throwing water over them; • using a powder fire-extinguisher, without directing the jet at the person’s face; • covering with blankets or rolling the victim on the ground.

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

11

Electrocution

Special situations

A. The engine’s 12 V or 24 V electrical system does not involve the risk of electrocution, however, in the event of a shortcircuit caused, for example, by a metal tool, there is a risk of burning due to overheating of the object through which the electrical current runs. In these circumstances: 1. Remove the object that caused the short-circuit, using means that provide sufficient insulation.

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

•

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

•

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

The area can also be covered with petroleum jelly.

•

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

•

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

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

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

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

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

•

Prevent contaminated irrigation solution from running onto unaffected skin.

•

Remove contaminated clothes.

12

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

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

The engine serial number is also stamped on the engine, above the oil cooler.

SERIAL NUMBER LOCATION

13

ENGINE TECHNICAL DATA N45 The technical code and serial number are indicated on a plate, which is located on different parts of the engine, according to the model: flywheel casing, tappet cover, other.

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

policy and the certification on the modified product becoming NULL and VOID.

N45 Engine family

F4

Cycle

4-stroke diesel

Number and arrangement of cylinders

4, in line

Bore x stroke

104 x 132 mm

Total displacement

4,485 cm3

Air system

Turbocharged - with intercooler

Engine direction of rotation

Counterclockwise (seen from flywheel side)

Dry weight

402 kg

Electrical system

24V

14

COMPONENT LOCATION DIAGRAMS N45 ENGINE

1 16

20

17

19

15 6 3

2

12 13 18

14

10 4 11

7

8

9

21

15

1. Turbocharger 2. Lifting eyelet 3. Alternator 4. Crankshaft pulley 5. Oil supply to turbocharger 6. Oil cap 7. Electrical harness 8. ECU module 9. Diesel fuel filter 10. Fan drive pulley 11. Damper 12. Drive belt 13. Belt tensioner 14. Oil filler neck 15. Turbo air inlet 16. Turbo air outlet to CAC 17. Engine air inlet 18. Water pump 19. Fuel Rail 20. Exhaust flap valve 21. Oil drain plug

5

18

15

12 1

16 2 17 3 2 14 9

6

13 10 4 7

11

8

16

1. Turbocharger 2. Lifting eyelet 3. Alternator 4. Flywheel 5. Oil cap 6. Oil filter 7. Starter 8. Exhaust manifold 9. Crankcase ventilation filter 10. Oil pan 11. Flywheel housing 12. Turbo oil line inlet 13. Turbo oil line return 14. Turbo exhaust outlet 15. Turbo air outlet to CAC 16. Engine air inlet 17. Electrical harness 18. Exhaust flap valve

ENGINE TECHNICAL DATA N67 IMPORTANT! Any alteration of the above mentioned specifications are strictly prohibited, and will result in the product warranty

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

policy and the certification on the modified product becoming NULL and VOID.

N67 Engine family

F4

Cycle

4-stroke diesel

Number and arrangement of cylinders

6, in line

Bore x stroke

104 x 132 mm

Total displacement

6,700 cm3

Air system

Turbocharged - with intercooler

Engine direction of rotation

Counterclockwise (seen from flywheel side)

Dry weight

530 kg

Electrical system

24V

17

1 20

16

17

19

15 6 3

2

12 13 9

18 10 7

4 11

8

14

21

18

COMPONENT LOCATION DIAGRAMS N67 ENGINE 1. Turbocharger 2. Lifting eyelet 3. Alternator 4. Crankshaft pulley 5. Oil supply to turbocharger 6. Oil cap 7. Electrical harness 8. ECU module 9. Diesel fuel filter 10. Fan drive pulley 11. Damper 12. Drive belt 13. Belt tensioner 14. Oil filler neck 15. Turbo air inlet 16. Turbo air outlet to CAC 17. Engine air inlet 18. Water pump 19. Fuel Rail 20. Exhaust flap valve 21. Oil drain plug

18

5

15

12 1

16 2 17 3

2

14

9

6

13 10 4 11

8

7

19

1. Turbocharger 2. Lifting eyelet 3. Alternator 4. Flywheel 5. Oil cap 6. Oil filter 7. Starter 8. Exhaust manifold 9. Crankcase ventilation filter 10. Oil pan 11. Flywheel housing 12. Turbo oil line inlet 13. Turbo oil line return 14. Turbo exhaust outlet 15. Turbo air outlet to CAC 16. Engine air inlet 17. Electrical harness 18. Exhaust flap valve

ENGINE USE

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

PRELIMINARY CHECKS Before starting the engine each time a walk around inspection should be performed.: Check all fluid levels (fuel, engine oil, coolant, and DEF), and top-up if necessary.

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

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

Inspect the engine for signs of oil leakage, (eg. oil pan, oil filter, valve cover, and front and rear crankshaft seals.)

Make sure that the air intake filter is not blocked or obstructed. (Note: See SECTION 3 of the machine Operator’s or Service manual for AIR FILTER MAINTENANCE.)

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

Check that the area around rotating parts are free from obstructions.

Check all belts and hoses for cracks and signs of wear.

Inspect all wiring harnesses for signs of damage.

WARNING

STARTING AND STOPPING THE ENGINE

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

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

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

20

TO PREVENT ENGINE DAMAGE

SPECIAL WARNINGS

Do not hold the key in the start position after the engine has started.

ENGINE COOLANT LEVEL LOW This warning will be displayed, alarm warning light will flash and alarm will sound when the coolant level drops below a safe operating level.

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

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

It is not efficient to leave the engine running at minimum speed while waiting for it to reach the proper working temperature; it is preferable that, after approximately 3 to 5 minutes from start-up, you gradually increase the engine load.

Engine should not idle longer than 9 consecutive hours, Damage to the emission control system will result.

CAUTION

The engine speed must be increased and decreased gradually, to allow regular combustion and proper operation of all engine components.

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

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

The running speed and power values must comply with the specifications on the technical and commercial documentation.

ENGINE COOLANT TEMPERATURE HIGH This message will be displayed, alarm light will flash, and alarm will sound when engine temperature exceeds 225°F (107°C).

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

DO NOT continue to operate machine.

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

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

21

CONTROLS AND MAINTENANCE

Replacing or topping up lubricant (hot engine oil may cause burns and scalds. Only carry out these operations when the oil has dropped to a temperature of below 50°C/122°F).

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

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

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

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

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

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

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

Use protective hand creams.

Immediately replace wet overalls.

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

The most qualified Assistance Centres are Authorized Tigercat Dealers.

Store cloths in flame-proof containers.

ACCIDENT PREVENTION

Do not leave foreign bodies on the engine.

Always wear heavy-duty footwear and overalls.

Use suitable, safe containers for used oil.

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

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

Always wear protective gloves and goggles when: Filling up batteries with acid solution Refuelling with inhibitors or antifreeze

22

MAINTENANCE SCHEDULE Regular maintenance

Special maintenance

Frequency

Visual engine check

Daily

Check for water in the fuel filter or pre-filter

Daily

Check and adjustment of valve lash

Aftertreatment System Scheduled Maintenance

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

Planned maintenance

Filter replacement (Bosch) on supply module

Frequency 2400 hours

Frequency 1000 hours (1)

1) Fuel filtration for Tigercat by FPT Engines must meet Tigercat’s filtration and water separation specifications. Using a fuel filter that does not meet the manufacturer’s filtration and water separation specifications can severely impact fuel system life and reliability.

Frequency

Replacement of engine oil and filter

250 hours

Tigercat recommends the use of the appropriate Tigercat fuel filter part number for the product application being serviced and filters must meet the specification below:

Replacement of fuel pre-filter

250 hours(1)

Water separator filter: 99% water separation

Replacement of fuel primary filter

250 hours(1)

Fuel main filter: 4 μm filtration, 98.7% particle separation

Replacement of crankcase ventilation filter

1500 hours

23

FLUID CAPACITIES

WARNING

Parts to be supplied

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

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

Cooling circuit (1) Lubrication circuit (2) Total capacity (3) Periodic changing: Oil sump at minimum level Oil sump at maximum level

IMPORTANT! Note that Tigercat machines are equipped with an After Run/Accessory Relay which delays by 90 seconds the power disconnect to engine related fuses and relays (ECU /ATS relay, NOx Sensor relay, NOx Sensor fuse, ECU Power fuse, DCU fuse). Whenever 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.

Fuel tank (4)

N45 litres (gal)

N67 litres (gal)

refer to machine manual 18 (4.75) 18 (4.75)

7 (1.8) 14 (3.7)

8 (2.1) 14 (3.7) Model dependant

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

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

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

(4) Use ULTRA LOW SULFUR diesel fuel ONLY. (S≤15 mg/kg) Engines are designed and warranted for optimum operation with mixtures of diesel and biodiesel up to 7%. No fuel additive are required.Any use of fuel additive must be approved by Tigercat.

Refer to SELECTIVE CATALYTIC REDUCTION SYSTEM in your machine’s Operator’s Manual for more information.

24

LUBRICATION CIRCUIT DIAGRAM

4

1 5 2

3

Pressurised oil route Oil return route Oil introduction

25

LUBRICATION CIRCUIT

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

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

If the oil level is low,

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

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

Rotary oil pump (5), housed in the front of the crankcase, operated by the straight toothed gear on the crankshaft tang.

Water/oil heat exchanger (3), housed in the crankcase, behind the oil filter mount.

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

Oil pressure regulation valve (1), built in to the filter mount.

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

By-pass valve (4) for excluding the filter if blocked, built into the filter mount.

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

Oil filter cartridge (2).

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

OIL LEVEL CHECK

Failure to follow these rules may void your warranty.

IMPORTANT! Checking the oil level should be done only with the engine stopped.

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

MIN

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

26

MAX

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

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

Refer to STARTING AND STOPPING THE ENGINE for more information.

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

See FLUID CAPACITIES in this manual for oil specifications.

REPLACEMENT OF ENGINE OIL AND FILTER The lubricating oil and filters should be changed at regular intervals. See the Planned Maintenance chart for frequency of oil and filter changes.

Draining the engine oil

Warm up engine Place an oil collection container under the oil pan, directly beneath the oil drain plug. (Ensure that the container will hold approx. 20 litres.)

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

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

27

Wait 10 mins, then check the oil level on the dipstick.

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

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

Clean the area around the top of the filter where it meets the filter head.

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

Using a filter wrench, remove the old oil filter.

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

Clean the gasket surface of the filter head, making sure that the o-ring from the old filter has been removed.

Failure to follow these rules may void your warranty.

Apply a light coating of oil to the seal at the top of the new filter cartridge, and fill the filter cartridge with clean oil, making sure no contaminants are poured into the filter.

MIN

Install the new filter by turning it manually until the gasket is in contact with the filter head.

MAX

WARNING

Further tighten until hand tight, or to a torque of 20 ± 2 Nm using a filter wrench.

Used motor oil is a pollutant and can be harmful.

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

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

Dispose of the residual properly following the rules.

Fill the engine with clean oil. (See the Oil Viscosity Chart in the back on this manual.) DO NOT PRE-FILL THE FILTER. Check the level on the dipstick periodically while filling, do not fill past the “MAX” fill line.

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

Start the engine and let run until it reaches operating temperature, then shut off the engine.

See FLUID CAPACITIES in this manual for oil specifications.

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AIR INTAKE AND EXHAUST GAS CIRCUITS

exhaust outlet, which increases output temperature. This is used to bring the catalytic converter up to it’s thermal operating condition.

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

Check the oil supply and drain lines for damage. Replace if necessary.

Check the compressor housing for cracks or discolouration.

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

Check that the exhaust flap and linkage is free from damage.

CAUTION

Tier 4F engines are equipped with an exhaust flap which is a throttle valve controlled by the ECU through an electric actuator. The purpose of this exhaust flap is to choke the

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

Start engine only from operator’s seat.

ELECTRICAL STARTER SYSTEM TURBOCHARGER EXHAUST FLAP

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

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

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ELECTRICAL COMPONENT LOCATIONS ELECTRICAL COMPONENTS

3 2 5 1

4

11

6

13 7

12 8

10 9

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1.

2.

3.

4.

Coolant temperature sensor Electro-injector RAIL pressure sensor Air temperature/pressure sensor 5. Starter motor 6. Camshaft sensor 7. Fuel flow rate regulator solenoid valve 8. Fuel temperature sensor 9. ECU electronic control unit 10. Crankshaft sensor 11. Engine oil pressure/ temperature sensor 12. Heating element for pre-heating incoming air 13. Alternator

FUEL CIRCUIT DIAGRAM COMMON RAIL RELIEF

INJECTOR

FUEL /WATER SEPARATOR

PRESSURE SENSOR

FUEL PUMP

COMMON RAIL

FUEL FILTER

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FUEL CIRCUIT

LOW TEMPERATURE DIESEL

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

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

Use only ULTRA LOW SULFUR diesel fuel.

D

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

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

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

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

REFUELLING

RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL 1.

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

2.

3.

4.

5.

IMPORTANT!

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

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

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

Bleed the system according to the FUEL FILTER section of this manual.

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

CHECK FOR WATER IN FUEL FILTER/WATER SEPARATOR

PRIMARY FUEL FILTER COMPONENTS

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

FILTER HEAD

Only proceed with the engine stopped.

FOR PROCEDURE ON CHECKING AND CHANGING THE PRIMARY FUEL FILTER/WATER SEPARATOR, PLEASE REFER TO YOUR MACHINE’S OPERATOR’S MANUAL.

TEMPERATURE SENSOR

NOTE: The components of the common rail system can be damaged very quickly by the presence of water or other impurities within the fuel.

FILTER

WARNING

HEATER ELEMENT

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

IMPORTANT !

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

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INSPECTION/REPLACEMENT OF CRANKCASE VENTILATION FILTER

REPLACEMENT OF FUEL FILTER Filter position may change depending on the application.

The crankcase ventilation filter is designed to collect and filter the lubricating oil vapours. Within the filter unit (1) two cartridge filters are included (2).

However, the following operations are valid for all applications.

Unscrew the filter cartridge using a filter wrench.

Carefully remove the filter cartridge, allowing any fuel to collect in a clean container.

Collect any remaining fuel inside the filtering cartridge.

Check the filtering elements by removing the cover and removing the cartridges (2).

1

Clean the gasket seat on the filter head and apply a light coating of clean oil to the seal at the top of the new filter cartridge. DO NOT PRE-FILL the new filter.

2

Install the new filter by turning it manually until the gasket is in contact with the filter head.

Further tighten until hand tight, or to a torque of 20 ± 2 Nm using a filter wrench.

WARNING During this operation do not smoke or use open flames.

Avoid inhaling the vapours coming from the filter.

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

INSPECTION/REPLACEMENT OF SERPENTINE BELT

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

1

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

2

Release the tensioner to apply tension to the new belt.

Refer to machine manual for proper belt routing.

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

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

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

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

Wait for the motor to cool to avoid very serious accidents.

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WHEN PERFORMING ENGINE MAINTENANCE:

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

1. Do not disconnect the batteries with the engine running.

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

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

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

5. Disconnect battery/batteries when recharging.

6. Do not paint the electrical connectors or components on the engine.

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

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

9. Before servicing the engine, clean all caps and plugs to reduce the chance of contamination.

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

Listen for noise or unusual rattle with engine running.

Verify, using the machine gauges/display, the prescribed pressure temperature and other parameters.

Visual check of fumes (color of exhaust emissions) Visual check of cooling liquid level in the expansion tank.

IMPORTANT!

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

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

WARNING

VISUAL ENGINE CHECK

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

Avoid direct contact of hot oil with your skin.

It is a good habit to perform a series of simple checks before starting the engine, that may prevent future, more serious problems. Such checks are usually up to the machine operators.

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

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MOVING THE ENGINE

ENGINE MALFUNCTIONS

Removing and re-installing the engine must only be carried out by qualified technicians from your Tigercat dealer.

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

When lifting the engine only, use the lifting eyelets indicated in this manual in the section ENGINE TECHNICAL DATA and marked on the engine with special labels.

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

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

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

DISPOSAL OF WASTE The engine is made up of parts and elements that, if improperly disposed of, can be harmful to the environment.

Starter batteries.

Used lubricants.

Mixtures of water and antifreeze

CAUTION

Filters.

Do not leave machines with the engine running without first putting the parking brake on.

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

Always dispose of waste according to local regulations.

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ENGINE OIL CHART

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

-30°C -22°F

-20°C -4°F

-10°C 14°F

0°C 32°F

10°C 50°F

20°C 68°F

30°C 86°F

40°C 104°F

50°C 122°F

- ENGINE BLOCK HEATER AND WEBASTO COOLANT HEATER REQUIRED IN THIS RANGE 38

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