Tigercat 635 SKIDDER OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL Tigercat 635 SKIDDER Issue 2.3, SEPTEMBER 2003

TABLE OF CONTENTS SECTION INTRODUCTION .............................................................................................................. iii SAE STANDARDS ........................................................................................................... iv NON-APPROVED FIELD PRODUCT CHANGES ............................................................. v SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ........................................................................................ 2 LUBRICATION AND MAINTENANCE ............................................................................... 3

635-OM00

635 Available Literature Operator's Manual (This Manual) ............................................. Part No. 15160A Manual de Operación (Español) .............................................. Part No. 20487A Service Manual ......................................................................... Part No. 14968A NAF Bogie Axle, Service and Repair ....................................... Part No. 15023A Tandem de Ejes NAF, Servicio y Raparación (Español) ......... Part No. 20645A Parts Catalog ............................................................................ Part No. 15195A Hydraulic Adapters Book ............................................................ Part No. 1472A Hose Assemblies Book .............................................................. Part No. 3707A

Tigercat

®

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

ii

Tigercat 635 Skidder

Introduction

Tigercat 635 Skidder INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 635 Skidder.

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

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

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

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

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

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

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

Tigercat Industries Inc.

iii

Tigercat 635 Skidder

Introduction

S.A.E. STANDARDS ROLL-OVER PROTECTION STRUCTURES (ROPS) FALLING OBJECTS PROTECTION STRUCTURES (FOPS) OPERATOR PROTECTION STRUCTURES (OPS) * MODIFICATIONS AND REPAIRS: The integrity of the ROPS, FOPS, OPS 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 that the certification of approval of the ROPS, FOPS, OPS structure will become void if any such modifications take place.

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

Both of the above are provided that 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's cabs are designed to ROPS, FOPS, OPS standards so that 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 (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, 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 roll-over protective structures.

NOTICE OF CERTIFICATION

Tigercat Industries Inc.

THIS STRUCTURE MEETS THESE REQUIREMENTS OR RECOMMENDED PRACTICES MANUFACTURED BY

Tigercat Industries Inc. Paris, Ont., Canada

ROPS SAE J1040

MAY94

FOPS SAE J231

JAN81

OPS SAE J1084

APR80

Tigercat Model 620/630 MAXIMUM GROSS WEIGHT MANUFACTURERS CERTIFICATION NO.

iv

47,000 lbs.

901099

6958A R03

Tigercat 635 Skidder

Introduction

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

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

Authorization by any other person is unacceptable.

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

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

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

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

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

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

Tigercat Industries Inc.

v

Tigercat 635 Skidder

Introduction

vi

Tigercat 635 Skidder SECTION 1 - SAFETY MARCH 2003

CONTENTS - SECTION 1 ARTICULATION LOCK ................................................................................ 1.10 BATTERY DISCONNECT SWITCH .............................................................. 1.7 CAB SAFETY CABLE .................................................................................. 1.11 CAB SUPPORT BRACE .............................................................................. 1.11 COOLING SYSTEM ....................................................................................... 1.9 EXHAUST FUMES ....................................................................................... 1.12 FIRE PREVENTION FIRE PREVENTION GUIDELINES ........................................................... 1.13 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.14 WHAT TO DO AFTER A FIRE ................................................................. 1.15 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.14 FIRST AID ...................................................................................................... 1.4 FLUID LEAKS ................................................................................................ 1.9 HYDRAULIC PRESSURE HAZARD .............................................................. 1.9 LOOSE CLOTHING HAZARD ..................................................................... 1.10 PARKING THE MACHINE ............................................................................. 1.7 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY PRECAUTIONS, GENERAL ................................................... 1.4, 1.5 SAFETY PRECAUTIONS, OPERATING ....................................... 1.6, 1.7, 1.8 SAFETY PRECAUTIONS, SERVICING ........................... 1.9, 1.10, 1.11, 1.12 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2

Tigercat 635 Skidder

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 identifies the most serious hazards

DANGER where failure to follow listed procedures would result in a high probability of death or serious injury.

WARNING denotes a hazard exists which can

WARNING result in serious injury or death if proper precautions are not taken.

CAUTION is used in areas where failure to follow

CAUTION listed procedures may cause personal injury, component damage or subsequent malfunction.

IMPORTANT is used to focus attention on items

IMPORTANT that should be checked, controlled, adjusted or cleaned to ensure the efficiency and long term operation of the machine.

Remember that safety is a prime responsibility of

1.2

Tigercat 635 Skidder

Safety good condition. Repair or replace damaged labels.

GENERAL SAFETY PRECAUTIONS all.

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

Always read the operator’s manual before operating the machine. Pay close attention to WARNINGS and HAZARD identifications.

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

Prolonged exposure to loud noise can cause permanent hearing loss.

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.

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

Do not let an untrained person operate the machine.

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

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

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

These safety rules highlight both general and specific measures the operator should 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

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

1.3

Tigercat 635 Skidder

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

GENERAL SAFETY PRECAUTIONS continued Machines should be completely cleaned of debris at least daily, particularly around the engine exhaust components. Hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) should be eliminated immediately.

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

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

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

Machine should be washed completely at every major service.

•

Visually inspect any seals or gaskets which have suffered from heat; they will appear black and sticky.

•

If these are found, Do Not Touch!!!

•

Determine the material composition of any seals or gaskets, If fluro-elastomer seals (Viton, fluorel, or tecmoflon) have been used, the affected area must be decontaminated before undertaking further work. Natural rubber and nitrile materials are not hazardous.

•

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

•

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

Inspect the machine daily for signs of damage or unusual wear, to ROPS, FOPS, OPS structures.

The machine should be inspected daily for signs of fluid leaks, damage, unusual wear, or faulty operation. Repair or replace malfunctioning parts and systems immediately.

Check window and door guards for damage.

Check protective windows for cracks, a damaged window has reduced strength to stop flying objects.

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

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

NOTE:

Check all fluid levels.

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

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

Do not operate the machine with the cab retaining pins removed. Always install retaining pins and fasten front guards to cab roof after lowering the cab.

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

1.4

Tigercat 635 Skidder

Safety

GENERAL SAFETY PRECAUTIONS continued

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 charged fire extinguisher on the vehicle at all times and KNOW HOW TO USE IT. Do not carry passengers either in the cab or anywhere else on the machine. The vehicle seating accommodation is for one operator only.

WARNING

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

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

When operating the machine, ensure there is adequate clearance on both sides and above the machine or any of its attachments. Additional clearance may be necessary where the ground is uneven.

Extreme caution should be exercised when approaching any area where overhanging electrical powerlines are present. Serious injury or death by electrocution can result if the machine or any of its attachments are not kept a safe distance from these lines.

Maintain a distance of 10 ft. (3m) between any part of the machine or boom and any power line carrying up to 50,000 volts or less plus 1/2 inch (10mm) for each additional 1,000 volts above the 50,000 volt level.

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

If the machine must be transported, make sure that it is adequately secured to the transporting vehicle.

Even though the brakes are fully engaged, block the wheels to prevent movement during transport.

Install articulation lock whenever the machine is to be transported.

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

Read, understand and follow all general safety precautions specified by grapple head manufacturer.

Access to a cell phone or radio to call for assistance in an emergency is advised. Be aware that signal strength for cell phones and radios changes with terrain and location.

1.5

Tigercat 635 Skidder

Safety Secure loose items in the cab.

OPERATING SAFETY PRECAUTIONS

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

Make sure that all safety screens and guards are installed and properly secured.

Do not open an escape hatch or the cab doors to increase ventilation when operating the machine.

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

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

Sound the machine horn before starting the machine.

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

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

Never operate the winch from the ground. Control it only from the operator’s seat.

The operator's seat is equipped with a lap belt.

Use this restraint system at all times when operating the machine.

Never use the parking brake to slow down or stop the machine except in an emergency.

Keep the brakes properly adjusted at all times.

Always rest the grapple and dozer blade on the ground when operation is stopped, regardless if the engine is running or shut off.

Start the engine by following the instructions in this manual. Refer to OPERATING MACHINE in SECTION 2 of the OPERATOR’S MANUAL.

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

Before moving the machine to the worksite, check to ensure that all doors, panels, and access covers are installed properly and secured.

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

Skidder operations should only be performed from the operator’s seat.

Before leaving the operator's cab, apply the parking brake and lower the grapple and dozer blade onto the ground.

1.6

Tigercat 635 Skidder

Safety

OPERATING SAFETY PRECAUTIONS continued If out of the operator’s cab for an extended period shut the machine off.

When parking the machine: •

Park on level ground ONLY and engage parking brake

•

Do not park on a hillside or incline.

•

Before leaving the operator's cab, apply the parking brake and lower the grapple and dozer blade onto the ground.

•

Stop the engine and release pilot system pressure by performing the following steps:

Never operate the boom or grapple over the heads of bystanders.

When reeling in winch cable, make sure all personnel are far enough away in case of rolling logs or whipping cables.

Use only prearranged and approved signalling practices.

1. Fully apply brake foot pedal 50 times or more.

Obey flagger’s signal and signs Operate the machine only from a seated position in the operator’s seat.

2. Pressure may remain in the system after completing all of the above steps.

Use caution when loosening hydraulic connections.

Do not carry passengers either in the cab or anywhere else on the machine.

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

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

When working on slopes, travel straight up or down the slope to prevent roll-over.

NEVER travel across a STEEP slope or side hill:

•

•

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

• • • • •

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 ensure that no person approach the machine while in use, the risk zone is 60 m (200 feet).

If you travel across a MODERATE slope, NEVER make an uphill turn as this could cause a tip-over situation.

Keep load low and close to skidder for best stability.

A load of logs will change the handling and stability of the skidder.

Always be prepared to dump the load in case of emergency.

Never approach an unstable log from the downhill side.

Do not winch in a load at a sharp angle. This could cause your machine to tip over.

Do not overload your skidder as this can create an unstable condition and cause a roll-over.

CAUTION Do not open cab doors or window screens when machine is on a slope. The doors and screens are heavy and could swing out with considerable force.

1.7

Tigercat 635 Skidder

Safety

OPERATING SAFETY PRECAUTIONS continued Before moving the machine, lift the grapple and dozer blade off the ground and keep them high enough to clear obstacles such as stumps.

Check for correct tire air pressure. If the pressure is too low it will result in swaying. If the pressure is too high it will result in bouncing.

If the machine is to travel on public roads, use accessory lights (when installed) and other caution devices to alert operators of other vehicles of your presence. Ensure your machine meets all regulatory requirements.

When transporting the machine, ensure that enough clearance is available on both sides and above the machine or any of its attachments to avoid contact with power or telephone lines, bridge structures, etc.

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

Read, understand and follow all general safety precautions specified by grapple head manufacturer.

1.8

Tigercat 635 Skidder

SERVICING SAFETY PRECAUTIONS

Safety grounding clamp so current does not pass through bearings, especially the centre joint bearing. Also, turn off the master disconnect switch and disconnect the positive (+) battery cable from both batteries.

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

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

When servicing or repairing equipment, shut the engine down, and disconnect the positive (+) battery cable from both batteries.

Install a “DO NOT START ENGINE” sign on the operator’s cab door and in the engine compartment when making repairs to the machine.

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

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

This machine is equipped with a reversible cooling fan to facilitate cleaning of the radiator/oil cooler assembly and engine compartment doors.

Exercise care when working in this area with the engine running. If the FAN CONTROL SWITCH (later machines) is in the AUTOMATIC position, the fan could turn ON and/or go into PURGE mode.

Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location. Care must be taken in attaching the welding machine

Never use bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower grapple and dozer blade to the ground and relieve trapped pressure from brake accumulator before performing work on components, or disconnecting any hoses. For the procedure on how to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

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

1.9

Tigercat 635 Skidder

Safety

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

SAFETY CABLE

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

••

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

302-13

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE

SUPPORT BRACE

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.

302-16

•• TILTED CAB SUPPORTED BY SUPPORT BRACE

Before working under cab, machine must be parked on level ground. Cab must be fully tilted with safety cable completely tight or cab support brace must be installed between frame and cab to prevent injury.

The hydraulic cylinder is to raise and lower cab, it must not be used as a support.

SAFETY7

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

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

Always wear your safety gloves when handling cables, chains or logs.

1.10

Tigercat 635 Skidder

Safety

SERVICING SAFETY PRECAUTIONS continued

HAND KNOBS

••

UPPER DOORS

••

• LOWER PANELS

••

••

•• ••

•

HAND KNOBS

••

QUICK ACCESS

302-15

ENGINE COMPARTMENT ACCESS PANELS 285-14

ARTICLUATION LOCK IN POSITION

Before working in the centre joint area, install the frame articulation lock between the frames to prevent accidental articulation and injury. Always replace the lock bar in its storage position after use.

WARNING DO NOT work below or behind a machine that is parked on a grade.

191-5ALT

CAUTION Do not open cab doors or window screens when machine cab is tilted . The doors and screens are heavy and will swing out with considerable force.

REMOVE LOWER PANELS

CAUTION The LOWER engine compartment access panels are NOT HINGED or permanently attached to the machine, but are held in place by the UPPER DOORS (some also have a hand knob). Therefore they can fall during the process of removing them from the machine. Once the UPPER DOOR is opened (and the hand knob loosened) the LOWER PANEL is not fully supported and it is not safe to apply any weight or pressure to the panel, as it may fall out of the remaining supports. Do not use these LOWER PANELS as hand grips, when servicing the machine.

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

Compartment door and panel handles should be hand tight only at all times for easy access to the engine compartment and the pressurized water system in the event of a fire or other emergency. Refer also to FIRE PREVENTION in THIS SECTION.

20231A R1

1.11

Tigercat 635 Skidder

Safety

SERVICING SAFETY PRECAUTIONS continued

If the engine is running inside a building, ensure that 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.

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.

Dispose of fluids properly.

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

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

1.12

Tigercat 635 Skidder

Safety dislodged by vibration this smoldering debris can fall into other areas of the machine and thereby spread a fire.

FIRE PREVENTION

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

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

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

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT.

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

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

7. Steam clean the engine, transmission, brake, fuel and hydraulic tank compartments of all equipment at least once a month or more frequently depending on logging conditions.

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

9. Shut down equipment immediately when a problem is suspected or smoke is detected.

2. Inspect the machine for any signs of fuel or hydraulic system leakage and check for worn or eroded fuel or hydraulic lines before starting up any equipment.

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

3. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/ C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL.

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

4. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions.

Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If

11. Turn the battery disconnect switch to OFF at shut down to avoid loss by electrical short.

13. Once a fire has started on a machine hoses will quickly burn through causing pressurized fluids (diesel fuel, hydraulic oil, etc.) to fuel the fire. NEVER leave the machine parked with booms or arches suspended off the ground, as they will inject hydraulic oil into the fire if a supporting hose burns through.

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

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

16. Use only nonflammable solutions for cleaning the machine or components.

1.13

Continued on page 14

Tigercat 635 Skidder FIRE PREVENTION continued

Safety WHAT TO DO IN CASE OF A MACHINE FIRE •

At all times ensure your own personal safety and the safety of anyone that may be in the area. Approach any fire with extreme caution.

•

If the machine is in a dangerous position, attempt to move to a safe position. Lower working attachment to the ground.

•

Shut the engine off.

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

•

Exit the machine taking fire extinguisher or water hose (if applicable) with you.

•

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

WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE

•

If you can safely do so, attempt to extinguish the fire.

•

Ensure that you are familiar with emergency procedure in the event of a fire.

•

A dry chemical fire extinguisher should be used first, if available.

•

Ensure that your fire suppression system* is charged and functional.

•

Use the PASS method with most extinguishers.

•

Ensure that any hand held fire extinguishers are charged and functional.

•

Pull the pin. This will allow you to discharge the extinguisher.

•

Ensure that any stored water systems on the machine are charged and functional.

•

•

Ensure that the nozzle of any hand held extinguishers available at the work site fits within the access holes in the doors of the machine.

Aim at the base of the fire. If you aim at the flames (which is frequently the temptation), the extinguishing agent will fly right through and do no good. You want to hit the fuel.

•

Squeeze the top handle or lever. This depresses a button that releases the pressurized extinguishing agent in the extinguisher.

•

Sweep from side to side until the fire is completely out. Once the fire is out, keep an eye on the area in case it re-ignites.

Continued from page 13

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

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

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

•

•

Ensure that you have the proper fire extinguishers on site. Most fires involving mobile equipment will be of the A or B type.

You should have a dry chemical extinguisher rated ABC and a pressurized water extinguisher rated A. Prevent the fire from happening by ensuring that the machine is cleaned regularly and all systems are well maintained. *NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some of the Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

1.14

Tigercat 635 Skidder FIRE PREVENTION continued

20229A

Safety WHAT TO DO AFTER A FIRE •

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

•

Ensure that the cause of the fire is determined and all appropriate repairs are completed before returning the machine to work.

•

Ensure that the fire suppression system* is properly serviced and returned to a functional state (if applicable).

•

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

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

If you are unable to open the access door(s), but can safely reach the fire extinguisher access hole, place the nozzle of the fire extinguisher into the appropriate fire extinguisher access hole and discharge the extinguisher.

•

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

•

Use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available) after the discharge of a dry chemical extinguisher or suppression system* to remove heat build up from the area. A fire suppressed by a dry chemical powder may re-ignite with the latent heat of any debris in the area.

•

Remain with the machine until help arrives to ensure that the fire does not re-ignite.

1.15

Tigercat 635 Skidder

Safety

1.16

Tigercat 635 Skidder SECTION 2 - CONTROLS & OPERATION SEPTEMBER 2003

Read and understand the entire manual including Safety section prior to operating any equipment. Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 2 AIR CONDITIONER/HEATER ..................................................................... 2.30 ARTICULATION LOCK ................................................................................ 2.54 BATTERY DISCONNECT,SWITCH ............................................................ 2.33 BRAKE PEDAL .............................................................................................. 2.5 CARE OF THE MACHINE ............................................................................ 2.50 CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR ............. 2.52 CLEANING INSTRUCTIONS FOR LEXAN WINDOWS ........................... 2.50 CENTER JOINT ........................................................................................... 2.46 CHARGE PRESSURE FILTER .................................................................... 2.36 DIFFERENTIAL LOCK, REAR (BOGIE) AXLE, SWITCH .............................. 2.7 DOORS AND ACCESS PANELS ................................................................. 2.32 DOZER BLADE CONTROL LEVER ............................................................... 2.8 DRIVE PEDAL CONTROL ............................................................................. 2.5 ENGINE AIR CLEANER AIR CLEANER .......................................................................................... 2.34 AIR CLEANER UNLOADER VALVE ......................................................... 2.35 AIR PRECLEANER ................................................................................... 2.34 FAN CONTROL LEVER (EARLIER DESIGN) ............................................. 2.11 FAN CONTROL SWITCH (LATER DESIGN) .............................................. 2.10 FILTER, FRESH AIR .................................................................................... 2.31 FILTER, RECIRCULATING AIR, A/C UNIT ................................................. 2.31 FILTERS, HYDRAULIC ................................................................................ 2.36 FIRE EXTINGUISHER, PORTABLE ............................................................ 2.12 FIRE PREVENTION FIRE EXTINGUISHER, PORTABLE ......................................................... 2.12 PRESSURIZED WATER SYSTEM ........................................................... 2.35 FUEL TANK ................................................................................................. 2.33 GRAPPLE ....................................................................................................2.46 GRAPPLE CONSTANT PRESSURE, SWITCH ............................................ 2.7 GRAPPLE OPEN/CLOSE, SWITCH .............................................................. 2.7 GRAPPLE, OPERATING ............................................................................. 2.46 GRAPPLE ROTATE, SWITCH ...................................................................... 2.7 HOT WATER SHUT OFF VALVE ................................................................ 2.31 HYDRAULIC FILTERS ................................................................................. 2.36 HYDRAULIC HAND FILL PUMP .................................................................. 2.37 HYDRAULIC OIL TANK ............................................................................... 2.36 INSTRUMENT PANEL (6350101 TO 6350115) ........................................... 2.14 BULB TEST,SWITCH ............................................................................... 2.16 DIFFERENTIAL LOCK FRONT, LIGHT .................................................... 2.15 DIFFERENTIAL LOCK REAR (BOGIE), LIGHT ........................................ 2.15 ENGINE AIR FILTER, LIGHT ................................................................... 2.15 Continued on page 2

Tigercat 635 Skidder SECTION 2 - CONTROLS & OPERATION INSTRUMENT PANEL (6350101 TO 6350115) CONTINUED ENGINE COOLANT LEVEL, LIGHT ......................................................... 2.15 ENGINE COOLANT TEMP, GAUGE ........................................................ 2.17 ENGINE COOLANT TEMP, LIGHT/HORN ............................................... 2.14 ENGINE OIL PRESS, LIGHT/HORN ........................................................ 2.15 ENGINE OIL PRESSURE,GAUGE ........................................................... 2.17 ETHER STARTING AID, SWITCH ........................................................... 2.16 FILTER BYPASS, LIGHT ......................................................................... 2.15 FUEL GAUGE ........................................................................................... 2.18 FUEL HEATER, SWITCH ......................................................................... 2.17 FUSE PANEL ............................................................................................ 2.17 GRAPPLE PRESSURE, LIGHT ................................................................ 2.15 HOURMETER ........................................................................................... 2.18 HYDRAULIC OIL LOW, LIGHT/HORN ..................................................... 2.14 HYDRAULIC OIL TEMPERATURE, LIGHT/HORN .................................. 2.15 HYDRAULIC OIL TEMPERATURE,GAUGE ............................................. 2.18 IGNITION,SWITCH .................................................................................. 2.17 LIGHT ENGINE SERVICE,SWITCH ......................................................... 2.16 LIGHTER .................................................................................................. 2.17 LIGHTS, WORKING, SWITCH ................................................................. 2.16 MAIN PUMP UNLOADING VALVE, LIGHT .............................................. 2.15 MAIN PUMP UNLOADING VALVE,SWITCH ............................................ 2.16 PARKING BRAKE, LIGHT ........................................................................ 2.15 TACHOMETER ......................................................................................... 2.18 VOLT METER, GAUGE/LIGHT ................................................................ 2.18 INSTRUMENT PANEL (6350116 TO 6350134) .......................................... 2.19 BULB TEST,SWITCH ............................................................................... 2.22 DIFFERENTIAL LOCK FRONT, LIGHT ................................................... 2.20 DIFFERENTIAL LOCK REAR(BOGIE), LIGHT ......................................... 2.20 ENGINE AIR FILTER,LIGHT .................................................................... 2.20 ENGINE COOLANT LEVEL, LIGHT ......................................................... 2.20 ENGINE COOLANT TEMP, GAUGE ........................................................ 2.22 ENGINE COOLANT TEMP, LIGHT/HORN ............................................... 2.19 ENGINE OIL PRESS, LIGHT/HORN ........................................................ 2.20 ENGINE OIL PRESSURE,GAUGE ........................................................... 2.22 ETHER STARTING AID, SWITCH ........................................................... 2.21 FILTER BYPASS, LIGHT ......................................................................... 2.20 FUEL GAUGE ........................................................................................... 2.23 FUEL HEATER, SWITCH ......................................................................... 2.22 FUSE PANEL ............................................................................................ 2.23 GRAPPLE PRESSURE, LIGHT ................................................................ 2.20 HOURMETER ........................................................................................... 2.23 HYDRAULIC OIL LOW, LIGHT/HORN ..................................................... 2.19 HYDRAULIC OIL TEMPERATURE, LIGHT/HORN ................................. 2.20 HYDRAULIC OIL TEMPERATURE,GAUGE ............................................. 2.23 IGNITION,SWITCH .................................................................................. 2.22 LIGHT ENGINE SERVICE,SWITCH ......................................................... 2.21 LIGHTER .................................................................................................. 2.23 LIGHTS, WORKING, SWITCH ................................................................. 2.21 MAIN PUMP UNLOADING VALVE, LIGHT .............................................. 2.20 2.2

Tigercat 635 Skidder SECTION 2 - CONTROLS & OPERATION INSTRUMENT PANEL (6350116 TO 6350134) CONTINUED MAIN PUMP UNLOADING VALVE,SWITCH ............................................ 2.22 PARKING BRAKE, LIGHT ........................................................................ 2.20 TACHOMETER ......................................................................................... 2.23 INSTRUMENT PANEL (6350135 TO 6350499) ........................................... 2.24 BULB TEST/ENGINE START - SWITCH ................................................. 2.27 CHARGE FILTER BYPASS, LIGHT ......................................................... 2.25 DIFF. LOCK FRONT, LIGHT .................................................................... 2.25 DIFF. LOCK REAR, LIGHT ....................................................................... 2.25 ENGINE AIR FILTER, LIGHT ................................................................... 2.25 ENGINE COOLANT LEVEL, LIGHT ......................................................... 2.25 ENGINE COOLANT TEMP., LIGHT/HORN .............................................. 2.24 ENGINE OIL PRESS., LIGHT/HORN ....................................................... 2.25 ENGINE OIL PRESSURE, GAUGE .......................................................... 2.28 ENGINE START/BULB TEST, SWITCH ................................................... 2.27 ETHER STARTING AID, SWITCH ........................................................... 2.26 FUEL GAUGE ........................................................................................... 2.28 FUEL HEATER, SWITCH ......................................................................... 2.27 FUSE PANEL ............................................................................................ 2.28 GRAPPLE PRESSURE, LIGHT ................................................................ 2.25 HOURMETER ........................................................................................... 2.29 HYDRAULIC OIL LOW, LIGHT/HORN ..................................................... 2.24 HYDRAULIC OIL TEMPERATURE, GAUGE ............................................ 2.28 HYDRAULIC OIL TEMPERATURE, LIGHT/HORN .................................. 2.25 IGNITION, SWITCH ................................................................................. 2.27 LIGHT, ENGINE SERVICE, SWITCH ....................................................... 2.26 LIGHTER .................................................................................................. 2.29 LIGHTS, WORKING, SWITCH ................................................................. 2.26 MAIN PUMP UNLOADING VALVE, LIGHT .............................................. 2.25 MAIN PUMP UNLOADING VALVE, SWITCH ........................................... 2.27 PARKING BRAKE, LIGHT ........................................................................ 2.25 TACHOMETER ......................................................................................... 2.29 VOLT METER, GAUGE/LIGHT ...................................................... 2.23, 2.29 JOYSTICK CONTROL LEVER ...................................................................... 2.6 OPERATING MACHINE CENTER JOINT ........................................................................................ 2.46 OPERATING GRAPPLE ........................................................................... 2.46 OPERATING WINCH ............................................................................... 2.46 PRE-START CHECKS .............................................................................. 2.38 RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL .................. 2.43 STARTING ENGINE ................................................................................. 2.42 STARTING IN COLD WEATHER ............................................................. 2.43 STOPPING ENGINE ................................................................................. 2.45 SYSTEM TEST AND WARM-UP .............................................................. 2.44 TRAVELLING ........................................................................................... 2.45 OPERATOR'S SEAT .................................................................................... 2.12 Continued on page 4

2.3

Tigercat 635 Skidder

Controls and operation

SECTION 2 - CONTROLS & OPERATION PARKING BRAKE .......................................................................................... 2.6 PRE-START CHECKS ................................................................................. 2.38 PRESSURIZED WATER SYSTEM .............................................................. 2.35 RADIO, AM/FM CASSETTE ........................................................................ 2.11 RADIO, CB ................................................................................................... 2.11 SKIDDING .................................................................................................... 2.47 CABLE SKIDDING .................................................................................... 2.48 GRAPPLE SKIDDING ............................................................................... 2.48 SAFETY .................................................................................................... 2.47 SKIDDING TECHNIQUE .......................................................................... 2.47 SPEED CONTROL LEVER ............................................................................ 2.8 STARTING ENGINE .................................................................................... 2.42 STEERING WHEEL ....................................................................................... 2.5 STEREO, AM/FM CASSETTE ..................................................................... 2.11 SYSTEM TEST AND WARM-UP ................................................................. 2.44 TEST PORTS ............................................................................................... 2.33 THROTTLE CONTROL, ELECTRIC, SWITCH ............................................. 2.9 TOWING INSTRUCTIONS .......................................................................... 2.55 TRANSMISSION DIPSTICK ........................................................................ 2.33 TRANSMISSION OIL FILL ........................................................................... 2.33 TRANSPORTING INSTRUCTIONS ............................................................. 2.54 WINCH CONTROL LEVER ............................................................................ 2.8 WINCH FREE SPOOL, SWITCH ................................................................... 2.9 WINCH, OPERATING .................................................................................. 2.46 WINCH SPEED RANGE, SWITCH ............................................................... 2.9

2.4

Tigercat 635 Skidder

Controls and operation IMPORTANT

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

CONTROLS-CAB

NOTE: As a safety precaution before working on or around the machine; After the engine has been shut off, depress this pedal 30-40 times to relieve any pressure that may be stored in the hydraulic system.

1

••

•

139-4

1.

DRIVE PEDAL CONTROL

3

Press the RIGHT foot pedal to drive FORWARD.

•

Press the LEFT foot pedal to drive in REVERSE. The position of the foot pedal, in conjunction with the position of the speed control lever, is directly proportional to the travel speed of the machine.

NOTE: A backup horn will sound when travelling in reverse.

139-3

2

3.

STEERING WHEEL This machine is equipped with Variable Ratio Load Sensing Steering. The speed that the vehicle responds to the steering wheel input will vary, depending on the speed that the steering wheel is moved. When operating on the road, a slow movement of the steering wheel will not overcorrect and will steer a straight normal course. Operating in the woods requires quick steering changes and this is produced by a rapid movement of the steering wheel, which will quickly change the vehicles direction.

•

139-7

2. BRAKE PEDAL Depress the foot pedal to apply the hydraulic brakes in the front axle. This will also apply braking to the rear axle since they are mechanically locked together by the drive shafts and transmission.

The lever on the left side of the Steering Column allows the selection of Telescopic and Tilt options.

The horn button is located in the centre of the steering wheel.

2.5

Tigercat 635 Skidder

Controls and operation The brake is correctly adjusted when: • Resistance is encountered half way through the brake lever's free travel.

NOTE: The drive prevent limit switch must be disconnected for this test.

21-2AA

WARNING

PARKING BRAKE ~ ENGAGED POSITION

Reconnect the drive prevent limit switch immediately after this test is completed.

The parking brake linkage must be kept properly adjusted at all times and should be serviced (adjusted and lubricated) every 500 hours during normal operating conditions.

21-3A

4.

PARKING BRAKE ~ DISENGAGED POSITION

6

•

PARKING BRAKE PULL up on handle to ENGAGE parking brake.

PUSH down on the handle to DISENGAGE parking brake.

A Warning light on the main control panel will come ON when the Brake is ON (engaged).

This parking brake operates ONE of the TWO disc brake callipers on the transmission. The second calliper is used in setting up the hydraulics on the machine.

NOTE: The parking brake must be in the ENGAGED position to START the engine, and in the DISENGAGED position to DRIVE the machine.

290-20X

The drive prevent circuit prevents the machine from being driven when the parking brake is ON.

6.

JOYSTICK MOUNTED ON ARMREST

JOYSTICK CONTROL LEVER Boom Move the joystick BACK to RAISE the boom.

A proximity switch is attached to the brake lever housing. When the brake lever is in the ON position a pin on the lever CLOSES the proximity sensor contacts. When the lever is in the fully OFF position, the contacts are OPEN.

Move the joystick FORWARD to LOWER the boom.

Arch Move the joystick to the RIGHT to tilt arch OUT.

Keep the brake properly adjusted at all times.

Move the joystick to the LEFT to tilt arch IN.

Brake adjustment: There are two ways to adjust the parking brake to compensate for wear; (1) Turning the knob on the end of the brake lever or, (2) at the calliper. Refer to PARKING BRAKE ADJUSTMENT in SECTION 9 of the SERVICE MANUAL. 2.6

Tigercat 635 Skidder

Controls and operation

FRONT REAR

9063BJSX

6d. Differential Locks - Two Push Buttons (Top Right)

11285B-1

6a Two push buttons (top left) -grapple rotate

Left button - Front axle

Push LEFT BUTTON to rotate grapple COUNTER CLOCKWISE.

Press button to activate differential locks.

Locks up front axle to provide torque to both front wheels.

Push RIGHT BUTTON to rotate grapple CLOCKWISE.

Push button a second time to deactivate.

6b Two push buttons (bottom) - grapple open/close

Right button - Rear (bogie) axle LATER MACHINES (6350135 TO 6350499) Press and hold button to activate differential locks. Locks up rear (bogie) axle to provide torque to all four rear wheels. This is a momentary switch.

Push RIGHT BUTTON to OPEN grapple.

Push LEFT BUTTON to CLOSE grapple.

6c Trigger switch - constant pressure Push this switch IN and release it to maintain a constant pressure HOLD on the grapple load and help prevent slipping.

Release button to deactivate.

EARLIER MACHINES (6350101 TO 6350134) NOTE: The machine must be brought to a complete stop before the rear (bogie) axle differential locks can be activated.

Also refer to OPERATING GRAPPLE in THIS SECTION.

Press and hold button to activate differential locks. Locks up rear (bogie) axle to provide torque to all four rear wheels. Remember that the machine must be stationary in order to engage the rear (bogie) axle differential locks.

Release button to deactivate. Rear (bogie) axle differential locks can be disengaged while the machine is in motion.

IMPORTANT Use differential locks sparingly and for brief periods and only when additional traction is needed or serious damage may occur.

2.7

Tigercat 635 Skidder

Controls and operation

8

8. WINCH CONTROL LEVER

9

•

10

•

11

Pull and hold the lever BACK to wind in the winch cable.

12

The control lever will return to the centre neutral position when the handle is released.

• 7

•

•

Push the lever FORWARD to unwind the winch cable in a controlled freespool by partially releasing the freespool clutch.

SIDE INSTRUMENT PANEL (EARLIER DESIGN)

350-8A

7

•

•

The neutral or centre position actuates the winch pinion brake and prevents the drum from rotating.

8

•

9

10

13

11

Operating the WINCH FREE SPOOL switch (on side instrument panel) permits the cable to unwind freely. The cable can then be pulled from the drum by the operator.

12

•

Also refer to OPERATING WINCH in THIS SECTION.

• •• •• •

630-D36

9. SPEED CONTROL LEVER The speed control lever allows the operator to set the maximum speed of the machine to maintain a given speed without having to feather the drive pedals. The speed control lever is located beside the throttle control switch.

SIDE INSTRUMENT PANEL (LATER DESIGN)

7. DOZER BLADE CONTROL LEVER Pull the lever BACK to RAISE the dozer blade.

Push the lever forward to increase the maximum speed.

Push the lever FORWARD to LOWER the blade.

Pull the lever back to decrease the maximum speed of the machine. If the lever is pulled all the way back, there will be no pilot pressure to the foot pedals, and therefore the machine will be unable to move forward/backward.

The control lever will return to the centre neutral position when the handle is released.

NOTE: Always travel with the dozer blade in the raised position to avoid obstacles.

This lever can be used while the machine is in motion.

Refer also to SPEED CONTROL LEVER ADJUSTMENT in SECTION 3 of THIS MANUAL.

CAUTION Never use the dozer blade to remove tree stumps or large boulders.

WARNING When leaving the cab, always lower the grapple and dozer to the ground, engage the parking brake and turn the ignition switch off.

If leaving the Skidder unattended, also remove the ignition key and switch the electrical disconnect switch to “off”.

2.8

Tigercat 635 Skidder

Controls and operation

10

11

When setting low idle pressures the throttle control should be adjusted to 1100 RPM.

12 11

The engine RPM should be checked regularly with a calibrated hand tachometer.

•

350-8AX

•

This rocker switch disconnects the drive motor from the drum in the winch and allows the cable to be freely pulled from the spool.

Must be turned off to activate a pull with the winch.

SIDE INSTRUMENT PANEL (EARLIER DESIGN) 10

•

12. WINCH SPEED RANGE - SWITCH (OPTIONAL)

13 11 11

This rocker switch controls the speed of the winch motor. Press the switch ON to operate winch motor at high speed. Press the switch again to return the winch motor to low speed.

12 11

• •

630-D36X

11. WINCH FREE SPOOL - SWITCH

•

••

SIDE INSTRUMENT PANEL (LATER DESIGN)

10. ELECTRIC THROTTLE CONTROL SWITCH For HIGH IDLE engine RPM press and hold the top of the rocker switch, release when the desired increase in RPM level is reached.

For LOW IDLE engine RPM press and hold the bottom of the rocker switch, release when the desired decrease in RPM level is reached.

NOTE: Skidding operations can be performed at INTERMEDIATE engine speeds . However, maximum performance is obtained at MAXIMUM engine speed.

Maintaining Correct Engine RPM It is most important that the engine speeds be correct at all times: Cummins 'C' Series Engine 635 Low Idle 1100 to 1200 RPM (No Load) 635 High Idle 2400 to 2450 RPM (No Load) NOTE: The above values are with the hydraulic and engine oil at normal operating temperatures and no functions activated.

2.9

Tigercat 635 Skidder 10

Controls and operation

11 11

•

12 11

•• ••

630-D36X

cooling fan to run at half the engine speed.

This is to ensure that sufficient air flow is available for the cab A/C even while the machine is still warming up.

13

FULL ON POSITION - When the switch is in the FULL ON position, the FDC system is overridden and the fan will run at FULL speed for cooling regardless of coolant or oil temperatures. Normally the fan control switch is placed in the AUTOMATIC position for optimal cooling. The FULL ON position is intended for use in the event of a temporary failure of the FDC.

•

PURGE POSITION - When the switch is in the PURGE position the direction of rotation is reversed. Reverse rotation is used to clean the radiator, oil cooler, A/C condenser and air intake door screens. By "reversing" the flow of the fan, air flow is propelled in the opposite direction, thereby forcing dust and debris off of the radiator, oil cooler, A/C condenser and air intake door screens. This operation can be done while operating the machine. Ensure that there are no personnel standing directly to the right of the machine when performing this operation, as dust and debris will fly out.

The FDC module will also turn the A/C system OFF for as long as the fan switch is in the PURGE position. The amount of time that the switch is held in the PURGE position need not be more than 20 - 30 seconds.

SIDE INSTRUMENT PANEL (LATER DESIGN)

13. FAN CONTROL - SWITCH (LATER DESIGN) On later machines, the hydraulic fan is controlled by the fan control switch located on the side instrument panel.

This is a three position switch, labelled FULL ON / AUTOMATIC / PURGE. This switch controls the operation of the hydraulic cross-flow fan.

AUTOMATIC Position - AUTOMATIC is the normal operating position for the fan control switch. When the switch is in the AUTOMATIC position, the fan will operate completely in an automatic mode. It will start, speed up, slow down or stop all based on the temperature of the engine coolant and the temperature of the hydraulic oil. The FDC (Fan Drive Control) module automatically adjusts fan speed to the minimum required level to maintain optimal operating conditions.

It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in THIS SECTION.

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

Note that when the switch is in the AUTOMATIC position and the fan has stopped due to low engine coolant and hydraulic oil temperatures, turning ON the A/C will cause the FDC to immediately turn the

2.10

Tigercat 635 Skidder

Controls and operation with the control lever, air flow is propelled in the opposite direction, thereby forcing dust and debris off of the radiator, oil cooler, A/C condenser and air intake door screens. This operation can be done while operating the machine. Ensure that there are no personnel standing directly to the right of the machine when performing this operation, as dust and debris will fly out. The amount of time that the lever is held in the CLEAN (REV) position need not be more than 20 - 30 seconds.

Care should be taken not to leave the fan in the reverse position for long periods of time as this will decrease the cooling ability of the radiator, oil cooler and A/C condenser.

14

•

303-6

FAN CONTROL LEVER

It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures.. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in THIS SECTION.

14. FAN CONTROL LEVER (EARLIER DESIGN) On earlier machines, the hydraulic fan control lever is located on the left arm rest in the cab and is used to control fan speed and direction.

OFF (center neutral) Position - When the lever is in the OFF position the fan is stopped.

RUN (FWD) - Push the lever forward to operate the fan in the "forward", cooling, direction. Fan speed is infinitely adjustable as the lever is moved forward fan speed increases.

CLEAN (REV) - Pull the lever back to operate the purge function of the fan in the "reverse", cleaning, direction. Fan speed is infinitely adjustable as the lever is moved back fan speed increases.

Adjusting fan speed for efficient operation can reduce operating costs. In high temperature operating conditions the fan speed should be increased to improve cooling ability and efficient operation of the oil cooler, radiator and air conditioning systems. In low temperature operating conditions fan speed can be reduced, as less cooling is required for efficient operation of the oil cooler and radiator. Correctly setting the fan speed according to your operating conditions can lower fuel consumption and reduce operating costs.

Fan direction control is used to operate the purge function which cleans the radiator, oil cooler, A/C condenser and air intake door screens . By “reversing” the flow of the fan

290-22

15. AM/FM STEREO CASSETTE With two front mounted speakers. Consult the manufactures instruction manual for additional information.

630-D37

16. RADIO - CB Consult the manufacturer's instruction manual for additional information.

2.11

Tigercat 635 Skidder

Controls and operation 18. OPERATOR'S SEAT (SEATS INC.)

LOCATED IN OPERATOR'S CAB

•

CHARGE GAUGE

WARNING The seat belt supplied with this seat must be used at all times when operating this machine.

17

••

630-D53

ADJUSTMENTS HEIGHT ADJUSTMENT PROCEDURES The SPRING-ASSISTED height adjustment is controlled by the height adjustment lever located on the front left side of the seat chassis.

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

FIRE EXTINGUISHER, PORTABLE

17. FIRE EXTINGUISHER, PORTABLE A portable fire extinguisher is located in operator's cab. The extinguisher should be checked daily to ensure that it is charged.

The pointer on the charge gauge should point to the green region. If the indicator falls out of this green area, the extinguisher should be serviced immediately. Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL.

To Raise Firmly lift up on the height adjustment lever.

When the lever releases, hold it up while partially lifting the operator’s body weight from the seat.

When the seat is at the desired height, FIRMLY PUSH DOWN on the lever until the seat locks (a click should be heard).

To Lower Firmly lift up on the height adjustment lever.

When the lever releases, partially apply operator body weight to the seat until the seat is at the desired height. FIRMLY PUSH DOWN on the lever. Hold lever down until the seat locks into position (a click should be heard).

SEAT ADJUSTMENTS

•

SHOULDER STRAPS NOT ON ALL MACHINES

4-WAY LUMBAR VERTICAL ADJUSTMENT

•

4-WAY 4-WAY LUMBAR LUMBAR HORIZONTAL HORIZONTAL ADJUSTMENT ADJUSTMENT

BACK ANGLE ADJUSTMENT KNOB

•

•

• • RIDE ADJUSTMENT KNOB 332-1

2.12

••

HEIGHT ADJUSTMENT LEVER FORE/AFT SLIDE LEVER

Tigercat 635 Skidder

Controls and operation

RIDE ADJUSTMENT After adjusting height, the ride adjustment should be made by turning the ride adjustment knob counter-clockwise until the seat cushion is level.

4-WAY LUMBAR HORIZONTAL ADJUSTMENT

• • • ARMREST ADJUSTMENT 332-6

VIEW FROM RIGHT REAR OF SEAT

4-WAY ADJUSTABLE LUMBAR To position lumbar mechanism vertically, move vertical adjustment knob up or down. For foreand-aft displacement, rotate horizontal adjustment knob.

BACK ANGLE ADJUSTMENT Rotate back angle adjustment knob to place seat at the desired angle.

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

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

PROBLEMS AND CORRECTIVE ACTION RIDES TOO STIFF/SEAT TENDS TO PUSH OR THROW OPERATOR FORWARD The ride adjustment knob has been tightened (turned counter-clockwise) too much. This typically happens because the operator is trying to use additional ride adjustment knob rather than the height adjustment lever to raise the seat.

Operator is riding the seat in the low height position setting. Refer to HEIGHT ADJUSTMENT. RIDES TOO SOFT OR BOTTOMS OUT AND PINCHES OPERATOR The seat ride adjustment knob has not been tightened (turned counter-clockwise) enough.

Insufficient ride adjustment exaggerates the kneeaction movement of the seat. This usually happens because the operator is trying to lower the seat by decreasing the amount of ride adjustment instead of using the Height Adjustment lever. Refer to HEIGHT ADJUSTMENT. SEAT TOO HIGH/SEAT TOO LOW There are several things which can cause improper seat height. Refer to the HEIGHT ADJUSTMENT and adjust seat to the desired position. If the proper height cannot be reached using one of the four height adjustment settings, it may be necessary to install the seat on a higher base.

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

2.13

Tigercat 635 Skidder 21

Controls and operation 22

23

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2548DIL1

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INSTRUMENT PANEL (6350101 TO 6350115)

INSTRUMENT PANEL (6350101 TO 6350115)

21. HYDRAULIC OIL LOW RED LIGHT AND HORN This light will come ON and a horn will SOUND when the hydraulic oil level falls approx. 10 gal. US (38L) below the FULL mark.

SIGHT GAUGE

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

• LOW LEVEL SENDER

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

22. COOLANT TEMP - RED LIGHT AND HORN The light will come on and horn will sound when engine coolant temperatures reach 215°F. Stop the machine when this alarm is activated and check oil cooler and radiator for debris blocking air flow. See CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR and FAN CONTROL in THIS SECTION for details.

• 257-4

2.14

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

Tigercat 635 Skidder

Controls and operation

23. ENGINE OIL PRESS - RED LIGHT AND HORN

WARNING

The light will come on and horn will sound when engine oil pressure falls below 10 psi.

Stop the engine when this alarm is activated.

Check engine oil levels. See OPERATING MACHINE in this SECTION for more information.

DO NOT remove the radiator cap when the engine is hot, release of pressurized coolant can cause serious burns.

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

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

24. MAIN PUMP UNLOADING VALVE - RED LIGHT This light will come ON when the main pump unloading valve switch is turned ON. 25. PARKING BRAKE - RED LIGHT

28. ENGINE AIR FILTER - RED LIGHT This light will come ON when the elements in the engine air cleaner become excessively clogged with dust causing air intake restriction.

This light will come ON when the parking brake is engaged.

When the parking brake is disengaged the light will be OFF.

There is a second restriction indicator connected to the side of the filter housing in the engine compartment.

NOTE: The machine will not move when this light is ON (brake engaged).

26. HYDRAULIC OIL TEMPERATURE - RED LIGHT AND HORN

29. CHARGE FILTER BYPASS-YELLOW LIGHT This light will come ON when an oil flow restriction in excess of 50 psi is encountered at the hydrostatic oil charge filter. This pressure build up also opens the filter bypass valve in the filter head allowing oil to bypass the filter element.

This light will come on and horn will sound when the oil temperature exceeds normal operating temperatures (180°F).

If the temperature goes above 180°F check the following:

When this happens the filter requires immediate service. If this light comes on during cold start-ups, the engine speed should be reduced and the warm-up procedure continued.

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

30. GRAPPLE PRESSURE - GREEN LIGHT

Operation above 180°F will shorten hydraulic component life.

Shows that a constant closing pressure is being applied to the tongs. Activated by the trigger switch on the back of the joy stick.

Deactivated by pushing the grapple open button on the joystick.

If the temperature reaches 185°F DO NOT continue to operate the machine. Refer to FAN CONTROL in THIS SECTION. 27. LOW COOLANT -RED LIGHT This light will come ON when the coolant level drops below a safe operating level. The sensor is located on the radiator header. If this light comes on when the engine is running, stop the engine immediately and correct the fault. With engine running, top up radiator using correct solution of coolant antifreeze.

31. DIFFERENTIAL LOCK FRONT - GREEN LIGHT This light will come ON when the front axle differential lock is activated by pushing the button on the joystick.

32. DIFFERENTIAL LOCK REAR - GREEN LIGHT This light will come ON when the rear axle differential lock is activated by pushing the button on the joystick.

2.15

Tigercat 635 Skidder 21

Controls and operation 22

23

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2548DIL1

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INSTRUMENT PANEL (6350101 TO 6350115) 33. LIGHTS - SWITCH

valve reduces the pump pressure from 3000 psi to 250 psi. This removes some of the load from the engine in order to improve cold weather starting ability. The machine can be operated with this switch in the on position and the parking brake disengaged.

This switch turns on working lights.

34. LIGHTS - SWITCH This switch turns on working lights.

35. AUX (OPTIONAL)

40. ETHER STARTING AID SWITCH, SPRING RETURN (OPTIONAL)

Applicable to optional light packages.

36. AUX (OPTIONAL)

This is a two position momentary switch, spring return to OFF position labelled ON, OFF.

Applicable to optional light packages.

IMPORTANT: To avoid damage, crank engine with starter one or two revolutions before injecting starter fluid. Inject fluid only when engine is turning. To inject starting fluid, momentarily depress the ETHER switch, using short “bursts” while cranking the engine at the same time. Stop injecting fluid after engine starts. If engine begins to die during the first few minutes, inject another “shot” of fluid.

37. BULB TEST - SWITCH This switch is used to test the warning light bulbs on the instrument panel. Replace burnt out light bulbs immediately to ensure that all warning lights are in working order at all times.

38. LIGHT ENGINE SERVICE - SWITCH This switch will turn on the lights that illuminate the engine service area to facilitate engine service.

TO INSTALL A NEW CAN OF STARTING FLUID Clean the area around the valve before removing the canister. Loosen the band clamp that holds the empty canister, unscrew the can from the solenoid assembly and discard properly. Check the valve gasket under the cylinder and replace if damaged or missing.

Remove the protective cap from the new

39. MAIN PUMP UNLOADING VALVE-SWITCH The parking brake must be engaged in order to activate the main pump unloading valve with this switch. The main pump unloading

2.16

Tigercat 635 Skidder

Controls and operation 41. FUEL HEATER SWITCH (OPTIONAL) This switch manually turns on the fuel heater element in the fuel filter/water separator. An automatic thermostat turns the fuel heater on when the fuel temperature drops below 45°F and off when the fuel temperature reaches 75°F.

CANISTER

••

42. FUSE PANEL

ETHER STARTING AID CANISTER canister of starting fluid and screw the can (hand-tight) onto the solenoid assembly. Retighten the band clamp to hold the can in place.

The fuses and relays are protected beneath a panel which can be opened by removing two screws.

284-5A

43. IGNITION SWITCH - 3 POSITION OFF position - All electrical power fed through the ignition switch is turned “OFF”

IMPORTANT: To prevent dust from being drawn into the engine, leave a can in place on the solenoid assembly. A common cause of system failure occurs because dirt was allowed into the system when changing the fuel canisters.

RUN position - Connects the battery to all functions. Used for normal machine operation.

START position - This position energizes the starter motor and will crank over the engine.

NOTE - Parking Brake must be ON to start the engine.

DANGER • When working on this starting aid system always make sure that you are in a well ventilated area, away from heat, open flames or sparks.

44. LIGHTER Cigarette lighter is supplied.

45. ENGINE OIL PRESSURE - GAUGE The oil pressure should be greatest after starting a cold engine. It should operate between 35 and 70 psi when the engine is running at rated speed, with SAE 10W30 oil and at operating temperature. If the gauge registers less than the above with engine running at high idle, check the engine oil level. If the pressure drops below 15 psi, shut the machine down immediately.

• The Ethyl Ether used in this system is extremely flammable, toxic, harmful or fatal if swallowed. Avoid contact with skin or eyes. Do not breath the fumes. If swallowed, DO NOT INDUCE VOMITING. Call physician immediately.

• If fuel enters eyes or fumes irritate eyes, they should be washed with large amounts of clean water for 15 minutes. A physician should be contacted.

Oil pressure MUST register on the gauge immediately after starting the engine.

NOTE - During low idle rpm the oil pressure will be low. This is not an abnormal condition, but must be closely monitored.

DANGER Do not store canisters above 160°F. Do not incinerate, puncture or attempt to remove the centre core valve or the side safety valve from the cylinder.

46. COOLANT TEMPERATURE - GAUGE The gauge displays the current engine coolant temperature. It should normally indicate between 190°F and 210°F. If temperature goes above 220°F check for low fan speed setting, plugged air intake door screens or plugged radiator. DO NOT continue to operate machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR and FAN CONTROL in THIS SECTION.

WARNING Ether starting fluid is highly flammable. Do not use near fire, sparks or flames. Read the warning label on the container.

2.17

Tigercat 635 Skidder 21

Controls and operation 22

23

24

33

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2548DIL1

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INSTRUMENT PANEL (6350101 TO 6350115) 47. HYDRAULIC OIL TEMPERATURE GAUGE

49. FUEL GAUGE - GAUGE/LIGHT This gauge measures the total amount of fuel in the two interconnected fuel tanks. The sensor is in the left tank and the filler cap and dip stick are in the right tank. Capacity when full is 118 gal. (US). The gauge reads empty at 26 gal. (US).

This gauge shows the current hydraulic oil temperature registered in the hydraulic tank.

If the temperature goes above 180°F check the following: • Plugged oil cooler

50. HOURMETER

• Malfunction in a hydraulic system

Powered through the engine oil pressure switch, this meter records the total number of hours the engine has run.

• High loads on the hydraulic system • Low hydraulic oil level

51. TACHOMETER This meter indicates the rpm of the engine.

For engine rpm values, refer to THROTTLE CONTROL in THIS SECTION. See also TACHOMETER SET-UP INSTRUCTIONS in SECTION 7 of the SERVICE MANUAL.

Operation above 180°F will shorten hydraulic component life.

If the temperature reaches 185°F DO NOT continue to operate the machine. Refer to FAN CONTROL in THIS SECTION. 48. VOLT METER - GAUGE/LIGHT Normal operating range for the electrical system is between 12 and 13.5 volts.

A reading in excess of 15 volts indicates a possible faulty voltage regulator.

A reading less than 12 volts indicates a possible faulty battery or alternator.

2.18

Tigercat 635 Skidder 21 33

Controls and operation

22

23

34 35

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2550DIL1

INSTRUMENT PANEL (6350116 TO 6350134)

INSTRUMENT PANEL (6350116 TO 6350134)

21. HYDRAULIC OIL LOW RED LIGHT AND HORN SIGHT GAUGE

This light will come ON and a horn will SOUND when the hydraulic oil level falls approx. 10 gal. US (38L) below the FULL mark.

•

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

LOW LEVEL SENDER

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

22. COOLANT TEMP - RED LIGHT AND HORN The light will come on and horn will sound when engine coolant temperatures reach 215°F. Stop the machine when this alarm is activated and check oil cooler and radiator for debris blocking air flow. See CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR and FAN CONTROL in THIS SECTION for details.

• 257-4

2.19

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

Tigercat 635 Skidder

Controls and operation

23. ENGINE OIL PRESS - RED LIGHT AND HORN

WARNING

The light will come on and horn will sound when engine oil pressure falls below 10 psi.

Stop the engine when this alarm is activated.

Check engine oil levels. See OPERATING MACHINE in this SECTION for more information.

DO NOT remove the radiator cap when the engine is hot, release of pressurized coolant can cause serious burns.

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

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

24. MAIN PUMP UNLOADING VALVE - RED LIGHT This light will come ON when the main pump unloading valve switch is turned ON.

28. ENGINE AIR FILTER - RED LIGHT

25. PARKING BRAKE - RED LIGHT

This light will come ON when the elements in the engine air cleaner become excessively clogged with dust causing air intake restriction.

This light will come ON when the parking brake is engaged.

When the parking brake is disengaged the light will be OFF.

There is a second restriction indicator connected to the side of the filter housing in the engine compartment.

NOTE: The machine will not move when this light is ON (brake engaged).

29. CHARGE FILTER BYPASS -YELLOW LIGHT

26. HYDRAULIC OIL TEMPERATURE - RED LIGHT AND HORN

This light will come ON when an oil flow restriction in excess of 50 psi is encountered at the hydrostatic charge oil filter. This pressure build up also opens the filter bypass valve in the filter head allowing oil to bypass the filter element.

This light will come on and horn will sound when the oil temperature exceeds normal operating temperatures (180°F).

If the temperature goes above 180°F check the following:

When this happens the filter requires immediate service. If this light comes on during cold start-ups, the engine speed should be reduced and the warm-up procedure continued.

• Plugged oil cooler • Malfunction in a hydraulic system

30. GRAPPLE PRESSURE - GREEN LIGHT

• High loads on the hydraulic system

Shows that a constant closing pressure is being applied to the tongs. Activated by the trigger switch on the back of the joystick.

Deactivated by grapple open rocker switch on joystick.

• Low hydraulic oil level Operation above 180°F will shorten hydraulic component life.

If the temperature reaches 185°F DO NOT continue to operate the machine. Refer to FAN CONTROL in THIS SECTION.

31. DIFFERENTIAL LOCK FRONT - GREEN LIGHT

27. LOW COOLANT -RED LIGHT

This light will come ON when the front axle differential lock is activated by pushing the button on the joystick.

This light will come ON when the coolant level drops below a safe operating level. The sensor is located on the radiator header. If this light comes on when the engine is running, stop the engine immediately and correct the fault. With engine running, top up radiator using correct solution of coolant antifreeze.

32. DIFFERENTIAL LOCK REAR - GREEN LIGHT This light will come ON when the rear axle differential lock is activated by pushing the button on the joystick.

2.20

Tigercat 635 Skidder 21 33

Controls and operation

22

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2550DIL1

INSTRUMENT PANEL (6350116 TO 6350134) 33. LIGHTS - SWITCH This switch turns on working lights.

CANISTER

34. LIGHTS - SWITCH This switch turns on working lights.

•

35. LIGHT ENGINE SERVICE - SWITCH This switch will turn on the lights that illuminate the engine service area to facilitate engine service.

36. ETHER STARTING AID SWITCH, SPRING RETURN (OPTIONAL) This is a two position momentary switch, spring return to OFF position labelled ON, OFF.

ETHER STARTING AID CANISTER TO INSTALL A NEW CAN OF STARTING FLUID 284-5A

Clean the area around the valve before removing the canister. Loosen the band clamp that holds the empty canister, unscrew the can from the solenoid assembly and discard properly. Check the valve gasket under the cylinder and replace if damaged or missing. Remove the protective cap from the new canister of starting fluid and screw the can (hand-tight) onto the solenoid assembly.

Re-tighten the band clamp to hold the can in place.

IMPORTANT: To avoid damage, crank engine with starter one or two revolutions before injecting starter fluid. Inject fluid only when engine is turning. To inject starting fluid, momentarily depress the ETHER switch, using short “bursts” while cranking the engine at the same time. Stop injecting fluid after engine starts. If engine begins to die during the first few minutes, inject another “shot” of fluid.

IMPORTANT: To prevent dust from being drawn into the engine, leave a can in place on

2.21

Tigercat 635 Skidder

Controls and operation

the solenoid assembly. A common cause of system failure occurs because dirt was allowed into the system when changing the fuel canisters.

39. IGNITION SWITCH - 3 POSITION OFF position - All electrical power fed through the ignition switch is turned “OFF” RUN position - Connects the battery to all functions. Used for normal machine operation.

DANGER • When working on this starting aid system always make sure that you are in a well ventilated area, away from heat, open flames or sparks.

• The Ethyl Ether used in this system is extremely flammable, toxic, harmful or fatal if swallowed. Avoid contact with skin or eyes.

Do not breath the fumes. If swallowed, DO NOT INDUCE VOMITING. Call physician immediately.

• If fuel enters eyes or fumes irritate eyes, they should be washed with large amounts of clean water for 15 minutes. A physician should be contacted.

START position - This position energizes the starter motor and will crank over the engine.

NOTE - Parking Brake must be ON to start the engine.

40. BULB TEST - SWITCH This switch is used to test the warning light bulbs on the instrument panel. Replace burnt out light bulbs immediately to ensure that all warning lights are in working order at all times.

41. AUX (OPTIONAL) Applicable to optional light packages.

WARNING

42. AUX (OPTIONAL) Applicable to optional light packages.

Ether starting fluid is highly flammable. Do not use near fire, sparks or flames. Read the warning label on the container.

43. COOLANT TEMPERATURE - GAUGE The gauge displays the current engine coolant temperature. It should normally indicate between 190°F and 210°F. If temperature goes above 220°F check for low fan speed setting, plugged air intake door screens or plugged radiator. DO NOT continue to operate machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR and FAN CONTROL in THIS SECTION.

DANGER Do not store canisters above 160°F. Do not incinerate, puncture or attempt to remove the centre core valve or the side safety valve from the cylinder.

37. FUEL HEATER SWITCH (OPTIONAL)

44. ENGINE OIL PRESSURE - GAUGE

This switch manually turns on the fuel heater element in the fuel filter/water separator. An automatic thermostat turns the fuel heater on when the fuel temperature drops below 45°F and off when the fuel temperature reaches 75°F.

The oil pressure should be greatest after starting a cold engine. It should operate between 35 and 70 psi when the engine is running at rated speed, with SAE 10W30 oil and at operating temperature. If the gauge registers less than the above with engine running at high idle, check the engine oil level. If the pressure drops below 15 psi, shut the machine down immediately.

38. MAIN PUMP UNLOADING VALVE- SWITCH The parking brake must be engaged in order to activate the main pump unloading valve with this switch. The main pump unloading valve reduces the pump pressure from 3000 psi to 250 psi. This removes some of the load from the engine in order to improve cold weather starting ability. The machine can be operated with this switch in the on position and the parking brake disengaged.

Oil pressure MUST register on the gauge immediately after starting the engine.

NOTE - During low idle rpm the oil pressure will be low. This is not an abnormal condition, but must be closely monitored.

2.22

Tigercat 635 Skidder 21 33

Controls and operation

22

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34 35

25

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2550DIL1

INSTRUMENT PANEL (6350116 TO 6350134) full is 118 gal. (US). The gauge reads empty at 26 gal. (US).

45. HYDRAULIC OIL TEMPERATURE- GAUGE This gauge shows the current hydraulic oil temperature registered in the hydraulic tank.

48. VOLT METER - GAUGE/LIGHT

If the temperature goes above 180°F check the following:

Normal operating range for the electrical system is between 12 and 13.5 volts.

• Plugged oil cooler

A reading in excess of 15 volts indicates a possible faulty voltage regulator.

• Malfunction in a hydraulic system

A reading less than 12 volts indicates a possible faulty battery or alternator.

• High loads on the hydraulic system • Low hydraulic oil level

49. HOURMETER

Operation above 180°F will shorten hydraulic component life.

If the temperature reaches 185°F DO NOT continue to operate the machine. Refer to FAN CONTROL in THIS SECTION. 46. FUSE PANEL The fuses and relays are protected beneath a panel which can be opened by removing two screws.

47. FUEL GAUGE - GAUGE/LIGHT This gauge measures the total amount of fuel in the two interconnected fuel tanks. The sensor is in the left tank and the filler cap and dip stick are in the right tank. Capacity when

Powered through the engine oil pressure switch, this meter records the total number of hours the engine has run.

50. LIGHTER Cigarette lighter is supplied.

51. TACHOMETER This meter indicates the rpm of the engine.

For engine rpm values, refer to THROTTLE CONTROL in THIS SECTION. See also TACHOMETER SET-UP INSTRUCTIONS in SECTION 7 of the SERVICE MANUAL.

2.23

Tigercat 635 Skidder 21 33

Controls and operation

22

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34 35

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36

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14156BILR

INSTRUMENT PANEL (6350135 TO 6350499)

INSTRUMENT PANEL (6350135 TO 6350499)

21. HYDRAULIC OIL LOW RED LIGHT AND HORN This light will come ON and a horn will SOUND when the hydraulic oil level falls approx. 10 gal. US (38L) below the FULL mark.

SIGHT GAUGE

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

• LOW LEVEL SENDER

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

22. COOLANT TEMP - RED LIGHT AND HORN The light will come on and horn will sound when engine coolant temperatures reach 215°F. Stop the machine when this alarm is activated and check oil cooler and radiator for debris blocking air flow. See CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR and FAN CONTROL in THIS SECTION for details.

• 257-4

2.24

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

Tigercat 635 Skidder

Controls and operation

23. ENGINE OIL PRESS - RED LIGHT AND HORN

WARNING

The light will come on and horn will sound when engine oil pressure falls below 10 psi.

Stop the engine when this alarm is activated.

Check engine oil levels. See OPERATING MACHINE in this SECTION for more information.

DO NOT remove the radiator cap when the engine is hot, release of pressurized coolant can cause serious burns.

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

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

24. MAIN PUMP UNLOADING VALVE - RED LIGHT This light will come ON when the main pump unloading valve switch is turned ON.

28. ENGINE AIR FILTER - RED LIGHT This light will come ON when the elements in the engine air cleaner become excessively clogged with dust causing air intake restriction.

25. PARKING BRAKE - RED LIGHT This light will come ON when the parking brake is engaged.

There is a second restriction indicator connected to the side of the filter housing in the engine compartment.

When the parking brake is disengaged the light will be OFF. NOTE: The machine will not move when this light is ON (brake engaged).

29. CHARGE FILTER BYPASS - YELLOW LIGHT This light will come ON when an oil flow restriction in excess of 50 psi is encountered at the hydrostatic oil charge filter. This pressure build up also opens the filter bypass valve in the filter head allowing oil to bypass the filter element.

26. HYDRAULIC OIL TEMPERATURE - RED LIGHT AND HORN This light will come on and horn will sound when the oil temperature exceeds normal operating temperatures (180°F).

If the temperature goes above 180°F check the following:

When this happens the filter requires immediate service. If this light comes on during cold start-ups, the engine speed should be reduced and the warm-up procedure continued.

• Plugged oil cooler • Malfunction in a hydraulic system • High loads on the hydraulic system

30. GRAPPLE PRESSURE - GREEN LIGHT

• Low hydraulic oil level

Shows that a constant closing pressure is being applied to the tongs. Activated by the trigger switch on the back of the joystick.

Deactivated by pushing the grapple open button on the joystick.

Operation above 180°F will shorten hydraulic component life.

If the temperature reaches 185°F DO NOT continue to operate the machine. Refer to FAN CONTROL in THIS SECTION. 27. LOW COOLANT - RED LIGHT This light will come ON when the coolant level drops below a safe operating level. The sensor is located on the radiator header. If this light comes on when the engine is running, stop the engine immediately and correct the fault. With engine running, top up radiator using correct solution of coolant antifreeze.

31. DIFFERENTIAL LOCK FRONT - GREEN LIGHT This light will come ON when the front axle differential lock is activated by pushing the button on the joystick.

32. DIFFERENTIAL LOCK REAR - GREEN LIGHT This light will come ON when the rear axle differential lock is activated by pushing the button on the joystick.

2.25

Tigercat 635 Skidder 21 33

Controls and operation

22

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14156BILR

INSTRUMENT PANEL (6350135 TO 6350499) 33. LIGHTS - SWITCH This switch turns on working lights.

CANISTER

34. LIGHTS - SWITCH This switch turns on working lights.

•

35. LIGHT - ENGINE SERVICE - SWITCH This switch will turn on the lights that illuminate the engine service area to facilitate engine service.

36. ETHER STARTING AID SWITCH, SPRING RETURN (OPTIONAL)

284-5A

IMPORTANT: To avoid damage, crank engine with starter one or two revolutions before injecting starter fluid. Inject fluid only when engine is turning. To inject starting fluid, momentarily depress ETHER (“START AID”) push button switch, using short “bursts” while cranking the engine at the same time. Stop injecting fluid after engine starts. If engine begins to die during the first few minutes, inject another “shot” of fluid.

ETHER STARTING AID CANISTER

TO INSTALL A NEW CAN OF STARTING FLUID This is a two position momentary switch, spring return to OFF position labelled ON, OFF. IMPORTANT: To avoid damage, crank engine with starter one or two revolutions before injecting starter fluid. Inject fluid only when engine is turning. To inject starting fluid, momentarily depress the ETHER switch, using short “bursts” while cranking the engine at the same time. Stop injecting fluid after engine starts. If engine begins to die during the first few minutes, inject another “shot” of fluid.

2.26

Tigercat 635 Skidder IMPORTANT: To prevent dust from being drawn into the engine, leave a can in place on the solenoid assembly. A common cause of system failure occurs because dirt was allowed into the system when changing the fuel canisters.

Controls and operation can be operated with this switch in the on position and the parking brake disengaged.

39. IGNITION SWITCH - 3 POSITION OFF position - All electrical power fed through the ignition switch is turned “OFF” RUN position - Connects the battery to all functions. Used for normal machine operation.

START position - This position energizes the starter motor and will crank over the engine.

NOTE - Parking Brake must be ON to start the engine.

DANGER •

•

•

When working on this starting aid system always make sure that you are in a well ventilated area, away from heat, open flames or sparks.

The Ethyl Ether used in this system is extremely flammable, toxic, harmful or fatal if swallowed. Avoid contact with skin or eyes. Do not breath the fumes.

If swallowed, DO NOT INDUCE VOMITING. Call physician immediately.

If fuel enters eyes or fumes irritate eyes, they should be washed with large amounts of clean water for 15 minutes.

A physician should be contacted.

40. BULB TEST/ENGINE START - SWITCH This momentary switch is used to perform two functions: 1. BULB TEST~ Hold this switch in the ON position to test ALL warning light bulbs on the instrument panel. Replace burnt out light bulbs immediately to ensure that all warning lights are in working order at all times.

2. ENGINE START~ Used to override the automatic engine oil pressure shutdown system when starting the engine. While holding this switch in the ON position, turn the ignition key switch to the START position to crank the engine. Once the engine is running and has sufficient oil pressure, release the BULB TEST SWITCH. NOTE: The engine will stop if the oil pressure does not rise above 10 psi.

DANGER Do not store canisters above 160°F. Do not incinerate, puncture or attempt to remove the centre core valve or the side safety valve from the cylinder.

WARNING Ether starting fluid is highly flammable. Do not use near fire, sparks or flames. Read the warning label on the container.

37. FUEL HEATER SWITCH (OPTIONAL)

41. AUX (OPTIONAL) Applicable to optional light packages.

42. AUX (OPTIONAL) Applicable to optional light packages.

43. COOLANT TEMPERATURE - GAUGE The gauge displays the current engine coolant temperature. It should normally indicate between 190°F and 210°F. If temperature goes above 220°F check for low fan speed setting, plugged air intake door screens or plugged radiator. DO NOT continue to operate machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR and FAN CONTROL in THIS SECTION.

This switch manually turns on the fuel heater element in the fuel filter/water separator. An automatic thermostat turns the fuel heater on when the fuel temperature drops below 45°F and off when the fuel temperature reaches 75°F. 38. MAIN PUMP UNLOADING VALVE-SWITCH The parking brake must be engaged in order to activate the main pump unloading valve with this switch. The main pump unloading valve reduces the pump pressure from 3000 psi to 250 psi. This removes some of the load from the engine in order to improve cold weather starting ability. The machine

2.27

Tigercat 635 Skidder 21 33

Controls and operation

22

34 35

23

25

24 37

36

38

• • • •

45

• •

44

26 39

•

28

•

30

29 40

• • • •

• •

• •

27

41

31

32

42

• • • •

46

• •

43 49

47

•

•

51

•

•

•

48

•

•

•

50

•

14156BILR

INSTRUMENT PANEL (6350135 TO 6350499) 45. HYDRAULIC OIL TEMPERATURE - GAUGE This gauge shows the current hydraulic oil temperature registered in the hydraulic tank.

44. ENGINE OIL PRESSURE - GAUGE The oil pressure should be greatest after starting a cold engine. It should operate between 35 and 70 psi when the engine is running at rated speed, with SAE 10W30 oil and at operating temperature. If the gauge registers less than the above with engine running at high idle, check the engine oil level. If the pressure drops below 15 psi, shut the machine down immediately.

If the temperature goes above 180°F check the following: • Plugged oil cooler • Malfunction in a hydraulic system • High loads on the hydraulic system • Low hydraulic oil level

Oil pressure MUST register on the gauge immediately after starting the engine.

Operation above 180°F will shorten hydraulic component life.

NOTE - During low idle rpm the oil pressure will be low. This is not an abnormal condition, but must be closely monitored.

If the temperature reaches 185°F DO NOT continue to operate the machine. Refer to FAN CONTROL in THIS SECTION. 46. FUSE PANEL The fuses and relays are protected beneath a panel which can be opened by removing two screws.

47. FUEL GAUGE - GAUGE/LIGHT This gauge measures the total amount of fuel in the two interconnected fuel tanks. The sensor is in the left tank and the filler cap and dip stick are in the right tank. Capacity when full is 118 gal. (US).

The gauge reads empty at 26 gal. (US).

2.28

Tigercat 635 Skidder

Controls and operation

48. VOLT METER - GAUGE/LIGHT Normal operating range for the electrical system is between 12 and 13.5 volts.

A reading in excess of 15 volts indicates a possible faulty voltage regulator.

A reading less than 12 volts indicates a possible faulty battery or alternator.

49. HOURMETER Powered through the engine oil pressure switch, this meter records the total number of hours the engine has run.

50. LIGHTER Cigarette lighter is supplied.

51. TACHOMETER This meter indicates the rpm of the engine.

For engine rpm values, refer to THROTTLE CONTROL in THIS SECTION. See also TACHOMETER SET-UP INSTRUCTIONS in SECTION 7 of the SERVICE MANUAL.

2.29

Tigercat 635 Skidder

Controls and operation

AIR CONDITIONER/HEATER

3.

This control panel contains all the controls to allow the temperature in the cab to be either heated or cooled for operator comfort.

AIR SOURCE This is a two position rocker switch used to add fresh air to the cab. In the ON position fresh air is brought into the cab. In the OFF position air from the cab is recirculated along with fresh air.

A/C HEATER CONTROL PANEL 2

•

3

4

••

1

•

• 350-4A

1.

A/C-HEATER CONTROL PANEL

A/C AND FAN CONTROL This is a rotary, seven position switch. In the center (neutral) position the fan and air conditioning are off. In the three positions counter clockwise from center the air conditioning is activated at one of three fan speeds. In the three positions clockwise from center the fan only is activated at one of three fan speeds. To maximize efficiency of the air conditioning system make sure the temperature control is at the coolest setting (full counterclockwise) when using the air conditioning .

2.

••

193-8

R.H. DOOR POST VENTS - 2

•

4

•• REAR DASH VENTS - 2

151-11

5

TEMPERATURE CONTROL

••

This is a variable, rotary control to adjust the temperature of air in the cab for both heating and air conditioning. The blue area of the scale indicates cooler temperatures the red area indicates warmer temperatures.

Temperature is adjusted by regulating the flow of engine coolant into the heater core. To maximize efficiency of the air conditioning system make sure the temperature control is at the coolest setting (full counterclockwise) when using the air conditioning.

•

4

151-9

4.

VENTS BEHIND SEAT - 2

AIR VENTS The Air Conditioner/Heater package has 10 air outlets in the cab.

If the hot water shut off valve is closed the temperature control will have no effect on cab air temperature for heating or cooling. Refer to HOT WATER SHUT OFF VALVE in THIS SECTION for details.

• 2 in the top half of the left door post.

• 2 in the top half of the right door post.

• 2 on the rear dash, below the window.

• 1 behind seat on the lower right.

• 1 behind seat on the lower left.

NOTE: To increase flow to a given vent, other vents must be closed in order to redirect the air.

2.30

Tigercat 635 Skidder

Controls and operation

5. FILTER, RECIRCULATING AIR - A/C UNIT

7

Air in the cab is drawn into the A/C-HEATER unit via this filter and recirculated. The filter is located at the base of the A/C unit. It should be cleaned or replaced every 125 hours. This is done by removing two thumb screws in the filter box cover.

••

• 303-20

ENGINE

•

6 SHUT-OFF VALVE

274-5

HOSE TO A/C HEATER UNIT

FRESH AIR FILTER

7. FILTER - FRESH AIR When the control switch is in the FRESH AIR position , outside air is drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. To reduce dust in the cab area, use the FRESH AIR option with the A/C on. This pressurizes the cab, forcing dust out and reducing dust coming in.

The FRESH AIR filter is accessible from outside of the cab, at the back between the lights. It should be cleaned or replaced every 125 hours. This is done by removing 6 bolts (3/8”) and removing the air inlet cover. Next remove two nuts (1/4”) and remove the filter box cover. This will allow access to the filter.

•

HOT WATER SHUT OFF VALVE

6. HOT WATER SHUT OFF VALVE (ENGINE) During times when cab heating is not required the HOT WATER SHUT OFF VALVE, on the heater hose from the engine, can be closed to prevent hot water from seeping through the A/C unit, thereby reducing the cooling system effect.

WARNING - These filters may require cleaning or replacement more frequently under extreme operating conditions.

2.31

Tigercat 635 Skidder

Controls and operation

CHASSIS DOOR

••

••

DOOR PIN

191-5ALT

REMOVE LOWER PANELS

NUT AND BOLT HAND KNOBS

•

UPPER DOORS

• •

LOWER PANELS

••

•

HAND KNOBS

•

•

•• •

• QUICK ACCESS

272-21

FRONT DOOR

302-15

ENGINE COMPARTMENT ACCESS PANELS

DOORS AND ACCESS PANELS FRONT DOOR

CAUTION

TO OPEN: Park machine on level ground and lower the grapple and dozer to the ground.

The LOWER engine compartment access panels are NOT HINGED or permanently attached to the machine, but are held in place by the UPPER DOORS and a handknob.

Therefore they can fall during the process of removing them from the machine. Once the UPPER DOOR is opened and the handknob loosened the LOWER PANEL is not supported and it is not safe to apply any weight or pressure to the panel, as it may fall out of the remaining supports. Do not use these LOWER PANELS as hand grips, when servicing the machine.

Remove the TWO door pins from ONE SIDE ONLY. The door can be opened from either side or totally removed from the machine.

When the maintenance is complete, close the door and reinstall ALL door pins.

Do not operate DOZER with door open.

If the ground is not level, swing the door towards the downhill side to prevent it from swinging closed on the operator/mechanic.

CAUTION Park on level ground to prevent unexpected door closing.

2.32

Tigercat 635 Skidder

Controls and operation 1

•• ••

DIPSTICK

•

275-3

•

285-2

FILLER SCREEN

Located in the rear chassis, the fuel reservoir consists of two tanks interconnected. There is one filling location (right tank) with a dipstick under the filler cap.

The filler tube also contains a fuel tank filler screen. The dipstick slides through a hole in the side of the filler screen. DO NOT drop the dipstick into the filler tube or it will punch a hole in the bottom of the filler screen.

The filler screen should be removed and cleaned every 125 Hours (reach in and lift it out) Replace the screen if it is damaged.

4

3

•

•

TEST PORT COMPARTMENT BELOW LEFT CAB DOOR

TEST PORT COMPARTMENT 1. SWITCH, BATTERY DISCONNECT Located in test port compartment below the cab door on the left side of the machine, this switch is wired to the negative side of the battery. When in the OFF position it completely disconnects all the machine's electrical circuits from the battery.

FUEL TANK

FUEL TANK

2

2.

TRANSMISSION DIPSTICK The transmission dipstick is located in the test port compartment below the left hand cab door.

3. TRANSMISSION OIL FILL LOCATION The transmission oil fill is located in the test port compartment below the left hand cab door.

4. TEST PORTS The test ports for setting hydraulic pressures are located in the test port compartment below the left hand cab door.

A sending unit is installed (left tank) and connected to a fuel level gauge on the cab instrument panel. The fuel tank has a capacity of 118 (US) gallons total.

2.33

Tigercat 635 Skidder

Controls and operation

ENGINE AIR CLEANER ENGINE AIR PRECLEANER

AIR CLEANER

•

•

SENDING UNIT FOR WARNING LIGHT IN CAB

FILTER RESTRICTION INDICATOR

ENGINE AIR CLEANER

••

• •

ENGINE AIR CLEANER

291-3

AIR PRECLEANER The engine air precleaner cleans engine air before it reaches the air cleaner filter elements. It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance. However, it should be checked periodically to make sure that foreign materials have not plugged the intake area or the exhaust port area. For servicing procedures, refer to SECTION 3 of THIS MANUAL.

303-8

AIR CLEANER The air cleaner on this machine uses two filter elements, a primary element and a safety element accessible from the right side of the engine compartment.

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

A warning light on the cab instrument panel will come ON when the elements in the engine air cleaner become excessively clogged with dust causing air intake restriction.

EXHAUST PORT AREA

284-25A

In addition, a filter restriction indicator is mounted to the output side of the filter, this should show green when the engine is running at high RPM. Service is required if the indicator shows red.

REAR VIEW OF PRECLEANER

AS THE AIR SPINS, CENTRIFUGAL FORCE SEPARATES FOREIGN MATERIALS FROM THE CLEAN AIR

CONTAMINANTS ARE BLOWN OUT OF SPECIAL DISCHARGE PORTS BY HIGH VELOCITY, AIR POWERED ROTOR

• • • •

THE TURBO II PRECLEANER HAS SPECIALLY DESIGNED BLADES THAT CAUSE THE INCOMING AIR TO SPIN TURBO 2

ENGINE AIR CLEANER

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

TURBO II PRECLEANER OPERATION

2.34

Tigercat 635 Skidder

Controls and operation PRESSURIZED WATER SYSTEM UNLOADER VALVE

•

WATER TANK

••

PRESSURE GAUGE

••

•

••

DOZER BLADE

•

WATER CONTROL VALVE 303-7

AIR CLEANER UNLOADER VALVE HOSE STORAGE COMPARTMENT

AIR CLEANER UNLOADER VALVE This rubber valve on the tube of the air cleaner housing should be checked at the beginning of every shift. (8 hours) If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective. The valve should suck closed at 1/3 throttle This valve should be replaced every 1000 hours. Remove the unloader valve from the tube of the air cleaner housing. Check and clean the valve. A good valve should be soft and flexible.

If it is plugged, be sure to check the filter elements as they may need replacing as well.

Reattach the valve to the tube.

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

In addition, refer to AIR CLEANER MAINTENANCE in SECTION 3 of THIS MANUAL.

630-D46

PRESSURIZED WATER SYSTEM

A water tank is incorporated into the dozer blade and is pressurized to 60 psi. A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade. Tank capacity is 13.7US gallons (52 litres).

The control valve incorporates an air charge valve, a pressure gauge and a relief valve on the outlet side of the valve. A ball valve is installed on the outlet side of the valve and is used to shut off the water supply to the hose. This ball valve should be in the OFF position when the system is not in use.

The pressure gauge on the valve should read 60 psi check system pressure daily. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3.

Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL.

2.35

Tigercat 635 Skidder

Controls and operation

HYDRAULIC OIL TANK

HYDRAULIC FILTERS

Located at the front of the machine, the hydraulic tank has a capacity of 25 gallons.

The hydraulic oil cooling circuit contains a double filter head with a built in restriction indicator and a 25 psi bypass valve. It is recommended that all machines use two different filter elements:

A sight gauge accessible through the right front side door indicates the HIGH and LOW level of the hydraulic oil. Incorporated into this gauge is a low level sending unit which signals a "low hydraulic oil" light in the cab to come ON when the oil level is low.

1 white, Tigercat high performance, full flow hydraulic oil filter element 1 blue, Tigercat water absorbing, full flow hydraulic oil filter element.

Always keep the hydraulic oil level between the HIGH and LOW calibrations. A low hydraulic oil level can result in severe damage to pumps.

The drive pump charge circuit contains a single element, full flow, Tigercat hydraulic filter with a restriction indicator sending unit and a third port bypass valve. The restriction indicator sending unit is connected to the charge filter bypass warning light on the instrument panel.

The fan drive circuit contains a single element, full flow, Tigercat hydraulic filter with a restriction indicator sending unit and a third port bypass valve. The restriction indicator sending unit for this filter is not connected to a warning light.

SIGHT GAUGE

•

Later machines are equipped with a hydraulic tank breather filter.

LOW LEVEL SENDER

For additional information on these filters refer to FILTERS and SERVICE AND LUBRICATION POINTS in SECTION 3. Refer also to CHARGE FILTER BYPASS LIGHT in THIS SECTION.

DOUBLE ELEMENT FILTER

•

• 257-4

• •

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

•

•

BLUE ELEMENT HYDRAULIC TANK BREATHER FILTER HYDRAULIC TANK

••

630-D44

HYDRAULIC TANK BREATHER (LATER MACHINES)

630B-11

2.36

HYDRAULIC TANK

DRIVE PUMP CHARGE PRESSURE FILTER

Tigercat 635 Skidder

Controls and operation HYDRAULIC HAND FILL PUMP

IMPORTANT

The hydraulic hand fill pump, located in the compartment under the cab on the right side of the machine is used to add oil to the hydraulic oil tank.

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

To add oil to the tank : Park machine on level ground, lower dozer blade to the ground. Open access door on right side below cab. Swing out pump handle and lock. Clean suction hose and remove cap. Open oil fill shut-off valve, insert end of suction tube into supply drum and operate pump. The oil is pumped directly into the hydraulic tank via a filter beside the pump.

The pump should always be operated at a medium speed with a steady motion.

LEFT SIDE BELOW COOLING FAN

333-3

IMPORTANT: Close shut-off valve after filling.

Replace cap on suction tube, wipe dry and store in bracket. Swing pump handle in and lock.

Close and lock the lower door.

COOLING FAN PRESSURE FILTER ELEMENT

HAND FILL PUMP

FILTER

• •

TO OIL SUPPLY DRUM

••

SHUT-OFF VALVE IN OFF POSITION

•

312-18A

HYDRAULIC HAND FILL PUMP (RIGHT SIDE BELOW CAB)

2.37

Tigercat 635 Skidder

Controls and operation

OPERATING MACHINE Before operating this machine, ensure that the proper lubrication and maintenance schedule has been performed as outlined in SECTION 3 of THIS MANUAL. For the Diesel Engine supplied with this machine, refer to the engine manufacturer's operating manual.

FUEL GAUGE

635-P02

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

DIPSTICK

•

Read and understand the entire manual before operating the machine.

PRE-START CHECKS FILLER SCREEN

•

FUEL TANK 3. Check fuel level, gauge in cab or dipstick.

Refer to FUEL GAUGE in THIS SECTION for standard tank capacity information.

285-2

630-D39

IGNITION IN THE OFF POSITION

1. Ensure ignition switch is in the OFF position.

SIGHT GAUGE

••

LOW LEVEL SENDER

PARKING BRAKE ~ ENGAGED POSITION 2. Check parking brake for proper operation and set parking brake ON (ENGAGED).

21-2AA

•• 257-4

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

4. Check hydraulic oil level, the level should be between the HIGH and LOW marks on the level gauge.

2.38

Tigercat 635 Skidder

Controls and operation

••

DIPSTICK

•• FUEL WATER SEPARATOR

PRIMER PUMP

ENGINE OIL LEVEL

270-15A

5. Check the engine oil level. The level of the oil must be between the ADD and the FULL marks on the dipstick.

•

WATER SEPARATOR BOWL

•

DIPSTICK

•

RIGHT SIDE OF ENGINE

DRAIN TAP

•

• 270-9A

PUMP DRIVE GEARBOX

FUEL WATER SEPARATOR

8. Drain water from fuel line water separator.

WARNING

PUMP DRIVE GEARBOX OIL LEVEL

302-24

JUST INSIDE LEFT HAND FRONT UPPER SIDE PANEL DOOR

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

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

FILLER/BREATHER

• FILLER CAP

PUMP DRIVE GEARBOX FILLER/BREATHER

DIG-002

•

6. Check pump drive gearbox oil level (Dipstick provided) DIPSTICK

302-23

ENGINE COOLANT LEVEL

9. Check the engine coolant level.

•

275-3

TRANSMISSION OIL LEVEL

TEST PORT COMPARTMENT LEFT SIDE OF CAB

7. Check transmission oil level (dipstick).

2.39

Tigercat 635 Skidder

Controls and operation

•

•• A/C COMPRESSOR BELT

SENDING UNIT FOR WARNING LIGHT IN CAB

FILTER RESTRICTION INDICATOR

ENGINE AIR CLEANER

• •

•

303-8

ENGINE AIR CLEANER

13. Check engine air cleaner restriction indicator.

FAN BELT

635-01

CHECK ENGINE BELTS

10. Check tension and condition of all engine belts.

ENGINE AIR PRECLEANER

AIR CLEANER

302-19

•

291-3

CLEAN BETWEEN A/C CONDENSER AND OIL COOLER AND CLEAN THE INSIDE OF DOOR SCREENS AND PANELS

•

ENGINE AIR CLEANER

11. Check air intake precleaner for foreign material build-up in air intake area or exhaust port area.

290-11

UNLOADER VALVE

14. Clean radiator, oil cooler and A/C condenser.

Remove debris from door screens and panels on both sides and from around the fan.

•

303-7

Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in THIS SECTION.

AIR CLEANER UNLOADER VALVE

WARNING Fan may begin to operate at any time when engine is running. Stay clear of fan at all times.

12. Check air cleaner unloader valve

2.40

Tigercat 635 Skidder •

WATER TANK PRESSURE GAUGE

Controls and operation

•

•

•

DOZER BLADE

•

WATER CONTROL VALVE HOSE STORAGE COMPARTMENT

PRESSURIZED WATER SYSTEM 15. Check pressurized water system. The pressure gauge should read 60 psi. This system should be tested once every month.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of THIS MANUAL. 630-D46

16. Perform SCHEDULED MAINTENANCE as shown in SECTION 3 of THIS MANUAL. 17. Inspect machine for leaks , damaged or loose components and any other abnormal conditions.

18. Check tire pressures.

19. Check wheel bolts for tightness.

20. Be sure that all covers, guards and doors are securely fastened.

21. Unlock all cab doors.

2.41

Tigercat 635 Skidder

Controls and operation

STARTING ENGINE:

6. Keep throttle in IDLE position until engine oil pressure registers on gauge.

1. Ensure that PRE-START CHECKS have been performed and that the area is clear of personnel prior to starting the engine.

CAUTION

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

• After engine has started, keep engine speed low until engine oil pressure registers on gauge. If it does not register within 10 seconds, stop engine and investigate cause. Note that later machines (6350135 TO 6350499 only ) are equipped with an automatic engine shutdown system which stops the engine immediately if engine oil pressure is below 10 psi.

NOTE: The engine will not turn over unless the parking brake is ON. 3. Set throttle control to LOW IDLE, and set parking brake ON. Push the main pump unloading valve switch ON. This will remove some of the load from the engine and improve starting ability, particularly in cold weather.

4. Earlier Machines (6350101 to 6350134) Turn ignition switch to the START position to crank engine.

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

Later Machines (6350135 TO 6350499) Press and hold the bulb test/engine start switch while turning the ignition switch to the START position to crank engine.

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

Absence of blue or white exhaust smoke during cranking indicates no fuel is being delivered.

5. Earlier Machines (6350101 to 6350134) When engine starts, release ignition key to RUN position.

Later Machines (6350135 TO 6350499) When engine starts, release ignition key to RUN position. When engine oil pressure rises above 10 psi, release the bulb test/ engine start switch.

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

WARNING When starting the engine the drive pedals are deactivated, but the dozer, steer, winch and grapple functions can be activated immediately after start-up by touching the controls.

Do not apply pressure to these controls during start-up as immediate movement of the function(s) will occur.

If engine stalls while operating the machine, turn the ignition key to the OFF position and REPEAT STEPS (1) THROUGH (6).

2.42

Tigercat 635 Skidder RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL If the engine runs out of fuel, the fuel line must be primed:

Controls and operation STARTING IN COLD WEATHER: (WHEN APPLICABLE WITH OPTIONAL STARTING AID KIT) Cold temperatures require the use of the engine block heater and the engine oil pan heater. The use of an optional fuel heater and/ or ether starting aid may also be required.

1. Refill fuel tank completely.

2. Prime the fuel system using the primer pump on the fuel filter/water separator.

3. Bleed the system according to engine manual procedures.

If a (ether) starting aid is being used;

CAUTION

4. Place the main pump unloading valve switch in the ON position and crank the engine until it starts. If it fails to start after 20 seconds, stop and wait for 2 minutes before trying again.

Cold startups can result in pump failure, refer to "APPROVED HYDRAULIC OILS" in SECTION 3 for recommended oil viscosities and temperature ranges.

NOTE: Later Machines (6350135 TO 6350499) only.

It is necessary to press and hold the bulb test/ engine start switch while turning the ignition switch to the START position to crank engine.

Refer to START ENGINE in THIS SECTION.

(a) Move throttle control to the FULL position. (b) Crank engine with starter one or two revolutions before injecting starter fluid.

NOTE: Later Machines (6350135 TO 6350499) only.

It is necessary to press and hold the bulb test/ engine start switch while turning the ignition switch to the START position to crank engine.

Refer to STARTING ENGINE in THIS SECTION.

NOTE: The use of ether to aid in starting the engine is not recommended unless the temperature is below 30°F and only when the engine is COLD.

CAUTION

CAUTION

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.

To prevent damage to starter, do not engage starter motor for more than 15 to 20 seconds.

Wait 2 minutes between each attempt to start the engine.

If engine fails to start, refer to engine manufacturers operator's manual.

If engine fails to start, refer to engine manufacturers operator's manual.

(c) Momentarily depress ETHER push button switch, using short "bursts" while cranking the engine at the same time. Stop injecting fluid after engine starts. If engine begins to die during the first few minutes, inject another "shot" of fluid. (d) Once the engine is running evenly and the engine oil pressure is at NORMAL, move the throttle control to the IDLE position and allow to run for approx. 5 minutes or until the engine coolant temperature gauge begins to register.

If the engine oil pressure does not register on the gauge within 10 seconds stop the engine. (e) Before applying any load to the engine proceed with SYSTEM TEST AND WARM-UP.

2.43

Tigercat 635 Skidder

Controls and operation

SYSTEM TEST AND WARM-UP

(l) Put the parking brake ON.

Before commencing skidding operations, follow steps (a) thru (n) to accomplish the following:

(m) Move the throttle control to the IDLE position.

• Warm up the hydraulic system.

CAUTION

• Test all systems for proper operation.

• Inspect for hydraulic oil leaks.

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

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

If any system fails to respond to the controls, stop the warm-up procedure and call a mechanic, otherwise serious damage to pumps and other components could result.

Ensure that the machine was parked on level ground at last shutdown: (a) Start engine. (b) Ensure gauges and warning lights are indicating normal operating conditions.

(n) Leave the cab and visually check hose connections and cylinders for leaks. Check under the machine for oil leaks.

(c) Check that all personnel are clear of the machine. (d) Increase throttle control to the approximately the MID position. (e) Slowly raise and lower the arch, check for proper operation.

With the grapple and dozer raised slightly off the ground: (f) Operate the grapple arms and check for proper operation. (g) Rotate grapple from stop to stop and check that it is operating correctly. (h) Raise and lower dozer blade (i) Steer the machine to the left and right. (j) When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps (e) "thru" (i) several times. As the hydraulic system warms up, engine speed can be increased gradually to the FULL position. (k) Observe all operations. If any operations are not functioning as they should, take the necessary steps to correct the problem.

After completion of the warm-up and system testing, rest the grapple and dozer blade on the ground.

2.44

Tigercat 635 Skidder STOPPING ENGINE: CAUTION Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components. Follow the stopping procedure outlined below to allow the engine to cool.

1. Park machine on level ground and rest grapple and dozer blade on the ground.

2. Reduce engine speed to LOW IDLE and let run for approx. three 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.

Controls and operation TRAVELLING WITHOUT A LOAD: Raise the grapple and place the dozer blade in the UP position.

(1) Disengage parking brake. NOTE: Machine will not move if the parking brake is not fully off.

(2) Move throttle control to the HIGH IDLE position.

(3) Check the position of the speed control lever.

NOTE: If this lever is pulled all the way back, there will be no pilot pressure to the foot pedals, and therefore the machine will be unable to move forward/backward.

Using the speed control lever the operator is able to set the maximum speed of the machine. This allows the operator to maintain any desired drive speed with full drive pedal operation. Machine speed reduction can still be achieved by not fully depressing the foot pedal.

3. Do not race engine before shut-off.

4. Set parking brake ON. 5. Stop engine by turning ignition switch to the OFF position.

Push the lever fully forward to increase the maximum speed. Pull the lever back to decrease the maximum speed of the machine. This lever can be used while the machine is in motion.

WARNING Before leaving the machine, park it in a safe position on level ground. Engage parking brake and lower the grapple and dozer blade to the ground.

Never work behind, in front of, or below a skidder that has been parked on a grade.

Take additional precautions by placing the wheels against a rock, tree or other secure object.

WARNING When leaving the cab, always lower the dozer blade to the ground, engage the parking brake and turn the ignition switch off.

If leaving the Skidder unattended, also remove the ignition key and switch the electrical disconnect switch to “off”.

(4) Operate the drive foot pedals to move the machine forward or reverse.

(5) This machine is equipped with Variable Ratio Load Sensing Steering. The speed that the vehicle responds to the steering wheel input will vary, depending on the speed that the steering wheel is moved. When operating on the road, a slow movement of the steering wheel will not overcorrect and will steer a straight normal course. Operating in the woods requires quick steering changes and this is produced by a rapid movement of the steering wheel, which will quickly change the vehicles direction.

(6) Use differential locks sparingly and ONLY when additional traction is required.

Never continuously drive the machine with the differential locks on. Serious damage to the axles can result from using the differential locks when they are not needed for additional traction.

Note also: For early machines (6350101 TO 6350134) it is necessary to bring the machine to a complete stop before the rear (bogie) axle differential locks can be engaged.

2.45

Tigercat 635 Skidder

Controls and operation

OPERATING GRAPPLE:

OPERATING WINCH:

DAILY INSPECTION/SERVICE

Place the skidder in a safe, stable location, in line with the load. Apply the parking brake.

Check the Operator’s Manual for your Grapple Lubricate all grease fittings Check all hydraulic fittings Check hoses for wear. Replace as required.

Check for excessive wear at pin points.

Inspect for trash accumulation and clean out.

Check for excessive head swing and tighten the snubber to prevent damage to grapple or arch.

Lower the Grapple and Dozer Blade to the ground to anchor the machine.

Operate the Winch Free Spool Switch.

This will allow the cable to unwind freely from the drum and also disconnects the drive motor from the winch drum.

Make sure the cable is running freely through the fairlead rollers.

Avoid winching at an angle to the skidder.

Pull the cable from the drum and attach to object. Safety gloves should be worn.

To retrieve the cable, deactivate the Winch Free Spool Switch.

Pull and HOLD the Winch Control Lever BACK to wind in the cable. For safety reasons this lever returns to the neutral (centre) position when released and actuates the Pinion Brake, which locks the drum.

635-P04

Later machines are equipped with a WINCH SPEED RANGE switch located on the side instrument panel. This switch is positioned (at the operator's discretion) to either fast speed and low torque for small or no loads, or slow speed and high torque for medium and large loads.

TYPICAL TIGERCAT GRAPPLE

OPERATION Grapple operations should always be performed while seated in the operator’s seat.

The controls will return to neutral automatically when released.

CENTER JOINT:

The Constant Pressure trigger switch on the back of the joy stick will provide a constant closing pressure to the tongs to take up the slack as the logs are lifted and settle together.

This pressure is released when the grapple is opened.

It is very important that the machine not be operated if there is any looseness in the center joint bearings. Refer to MAINTENANCE OF THE CENTER JOINT in SECTION 3 of THIS MANUAL for visual checking procedures. For further information regarding adjustment and maintenance of the center joint refer to CENTER JOINT in SECTION 11 of the SERVICE MANUAL.

Refer to JOYSTICK CONTROL LEVER in THIS SECTION for specific information on grapple operating controls.

2.46

Tigercat 635 Skidder SKIDDING

Controls and operation SKIDDING TECHNIQUE:

For more safety related information see also the Equipment Manufacturers Institute (EMI) Log Skidder Safety Manual for Operators and Mechanics supplied with this machine.

WARNING • Only operate in areas where Skidder will be in a stable condition

SAFETY:

• Avoid felling and bucking areas. Sound your horn when entering.

1. Know all Federal, State/Provincial and local rules which apply to your machine and job site.

• Never travel across a STEEP slope or side hill.

2. NEVER operate this machine while under the influence of drugs or alcohol.

• Never make an uphill turn on a slope • Never approach an unstable log from the downhill side.

3. Know the limitations of your Skidder and Yourself as an operator.

• Do not work below machines that are parked on a hill.

4. Check the work area for HAZARDS, both at ground level and overhead.

• Wear heavy gloves when handing the cables.

5. Always wear and use your seat belt and other Personal Protective Equipment, such as: hard hat, safety shoes, safety glasses and heavy gloves.

• Ensure that the PARKING BRAKE is engaged.

• Operate the winch ONLY FROM THE OPERATOR’S SEAT, never from outside the cab.

6. Rain, snow, ice, loose gravel, soft ground, etc. will change the operating capabilities of your machine.

• Do not winch at a sharp angle. This could cause your machine to tip over.

7. Keep all work surfaces and engine compartment clean and free of oil, grease, snow, ice and debris. Give special care to hand-holds, steps, pedals and floors.

• Overloading can make a machine unstable and create a roll-over condition.

8. Be constantly aware of the location of fellow workers. Especially those on foot.

• Keep load low and close to skidder for best stability.

9. Your Skidder is a one person machine. No riders inside or outside.

• A load of logs will change the handling and stability of the skidder.

10. Be aware of what is happening around you.

Maintain a safe operating distance between your machine and other equipment and workers.

• Always be prepared to dump the load in case of emergency.

11. Know the hand signals that are being used on your job site.

12. Keep skid roads, secondary trails and landing areas clear of debris and in good condition.

2.47

Tigercat 635 Skidder

Controls and operation

GRAPPLE SKIDDING: 1. The timber may be pre-bunched or left for single pick-up. Depending on sizes you may have to single skid or bunch before skidding.

2. Logs should be picked up 3 ft. (1 meter) from the butt end.

3. If you have to add more logs or bunch, place the butt end of the new logs crosswise on top of the load in an “X” pattern. Place the Grapple over the logs where they cross and pick up the complete load.

4. The articulation feature in the Skidder increases the reach to the left and right and increases the range of pick-up for the grapple.

5. When pushing or backing up with a load, you must have the logs lined up with the Skidder and backup in a straight line, since you are using the butt pan to push the logs.

6. The articulation feature allows decking the logs from both sides of the pile.

7. Timber can be piled using the grapple or the dozer blade, depending on conditions.

8. The Dual Arch Skidder has the added ability to reach below ground level. This feature can be used to get the machine unstuck.

Do not drop the load as it helps to support the weight of the machine. Pull the load up close to the butt pan and lower the grapple downwards to solid ground. This process will push the back end of the Skidder upward and forward. Continue to repeat this process until the Skidder is on solid ground.

2.48

Tigercat 635 Skidder

Controls and operation

CABLE SKIDDING: 1. Locate the skidder so that the winch cable will lay in a fairly straight line.

2. Lower the Dozer and Grapple to the ground to anchor the machine. Set the parking brake.

Grapple may have to be raised, depending on winching angle and land terrain.

3. Chokers should be attached close to the butt end of the log.

4. If skidding multiple logs, attach furthest log away, to end of main cable, with closer logs ahead of it.

5. Winch in a straight line to prevent tip over problems.

6. Draw the logs in as close as possible to the butt pan and as high as stability will permit.

7. Raise the Grapple to a safe height and raise the dozer to its full height.

8. If you encounter soft ground or steep hills it may be necessary to drop the load “on the move” and allow the winch to “free spool” without stopping the Skidder. Once on solid ground or on top of the hill, stop the Skidder, lower the dozer, set the parking brake and winch the load back into the butt pan.

9. Adjust your speed to the terrain, ground conditions and the load your skidding.

2.49

Tigercat 635 Skidder

Controls and operation

CARE OF THE MACHINE

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

1. Ensure that all fluid levels are always at the proper level. Use the preventative maintenance schedule in SECTION 3 of this manual .

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

3. Apply grease to all lubrication points at required intervals.

4. Do not apply load to a cold engine.

5. Close and secure all doors and access covers.

6. Do not allow branches, twigs, leaves or pine needles to build up around radiator intake doors or anywhere else on the machine.

Clean frequently but at least once daily.

Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in THIS SECTION. 7. Be sure that the grapple and dozer blade are resting on the ground before servicing or parking the machine.

CLEANING INSTRUCTIONS FOR LEXAN WINDOWS

284-10A

CLEANING LEXAN WINDOWS

To remove wet paint, glazing compound or grease, rub lightly (not in direct sunlight) with a good grade of VM&P naphtha, isopropyl alcohol or butyl cellosolve (2-Butoxy Ethanol), then wash and rinse thoroughly. DO NOT USE GASOLINE, Gasoline or oil will cause uncoated LEXAN to become opaque.

MARGARD coated lexan will start to become opaque around the edges and creep in.

1. Rinse with lukewarm water.

2. Using a soft cloth or sponge, gently wash the sheet with a mild solution of soap or detergent and lukewarm water. DO NOT scrub or use brushes or squeegees.

3. Rinse with clean lukewarm water.

4. Dry thoroughly with a chamois or moist cellulose sponge to prevent water spotting.

SIDE WINDOW SCREENS

Removing Hairline Scratches

The side window screens can be removed to clean the windows. Screens are provided for the personal protection of the operator and must be reinstalled immediately after cleaning the windows.

Scratches and minor abrasions can be removed or minimized by using a mild automobile polish. Three such products that tend to polish and fill scratches are Johnson Paste Wax, Novus Plastic Polish #1 & #2, and Mirror Glaze Plastic Polish. It is suggested that a test be made on a sample of LEXAN sheet with the product selected and that the polish manufacture's instructions be followed.

WINDOW SCREEN HANDKNOB

•• 173-25

SIDE WINDOW SCREEN

2.50

Tigercat 635 Skidder

Controls and operation

SOME IMPORTANT DON’TS DO NOT use abrasive or highly alkaline cleaners on LEXAN sheet products.

Never scrape LEXAN sheet products with squeegees, razor blades or other sharp instruments.

Benzene, gasoline, oil, acetone or carbon tetrachloride should never be used on LEXAN sheet products.

DO NOT clean LEXAN sheet products in hot sun or at elevated temperatures.

Compatible Cleaning Agents - Aqueous Solutions of Soaps and Detergents Formula 409

Top Job

Freon T.F.

VM&P grade Naphtha

Joy

Windex with Ammonia D

Palmolive Liquid GRAFFITI REMOVAL (A) Butyl Cellosolve (For removal of paints, marking pen inks, etc.) The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

(B) 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. GASOLINE SHOULD NOT BE USED.

2.51

Tigercat 635 Skidder

Controls and operation

CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR The A/C condenser core is located on the right side of the machine and is mounted directly in front of the oil cooler and radiator. The cross-flow fan is mounted on the left side of the machine facing outward. The cross-flow fan draws air from the right side of the machine through the door screen, the A/C condenser, the oil cooler and the engine radiator blowing it out of the left side of the machine.

A/C CONDENSER SWINGS DOWN FOR CLEANING PROCEDURE: 302-19

1. Swing out the top screen door and lift out the bottom screen panel on the right and left sides of the rear engine area, in front of the cab.

2. The A/C condenser swings down to access the back-side of the condenser and the front of the oil cooler and radiator for cleaning. It is held in place by two wingnuts while the machine is operating.

302-21

This cooling assembly must be checked daily for debris and may have to be thoroughly cleaned on a weekly or monthly basis, depending on operating conditions. Compressed air or water may be used for cleaning. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

RIGHT SIDE - A/C CONDENSER AND OIL COOLER

CAUTION

290-11

Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

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

Always use personal protective equipment to guard against flying debris

LEFT SIDE - CROSS-FLOW FAN

The A/C condenser core, engine radiator and oil cooler should be manually checked every 8 hours (every shift) or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. All engine enclosure doors must also be checked

CAUTION Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

2.52

Tigercat 635 Skidder

Controls and operation

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine. For more information on fire prevention refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL. If an oil leak has occurred in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed. The presence of oil will cause dust and dirt to cling to surfaces impair the reversible fan's ability to remove dust and dirt particles. Care must be taken when cleaning this assembly, as the components can be damaged by careless handling and cleaning.

USING THE FAN PURGE FUNCTION TO REMOVE DEBRIS DURING OPERATION The hydraulic engine fan has a PURGE function for use in cleaning debris from the radiator, oil cooler, A/C condenser and air intake door screens during operation. By “reversing” the flow of the fan, air flow is propelled in the opposite direction, thereby forcing dust and debris off the radiator, oil cooler, A/C condenser and air intake door screens. Ensure that there are no personnel standing directly to the right of the machine when performing this operation, as dust and debris will fly out. Refer to FAN CONTROL LEVER (EARLIER DESIGN) or FAN CONTROL SWITCH (LATER DESIGN) in THIS SECTION for more information.

USING THE FAN CONTROL SWITCH (LATER DESIGN) IN THE EVENT OF AN ENGINE COOLANT AND/OR HYDRAULIC OIL TEMPERATURE ALARM. In the event of an engine coolant temperature and/or hydraulic oil temperature alarm: 1. Stop the machine.

2. Place the fan control switch in the FULL ON position until cooling is achieved.

3. If necessary use the PURGE function to reverse fan flow and clean debris from the radiator, oil cooler, A/C condenser and air intake door screens.

4. In severe operating conditions manual cleaning of debris may be required.

FAN CONTROL SWITCH

• FAN CONTROL LEVER (EARLIER DESIGN)

FAN CONTROL SWITCH (LATER DESIGN) 630-D36

303-6

5. If the problem persists check engine coolant and/or hydraulic oil levels. Refer to OPERATING MACHINE ~ PRESTART CHECKS in THIS SECTION. 6. Return the fan control switch to AUTOMATIC and check for proper operation of the fan. In the event of a problem with the automatic control system the fan control switch should be placed in the FULL ON position while the machine is operating until the fan control can be properly repaired.

USING THE FAN CONTROL LEVER (EARLIER DESIGN) IN THE EVENT OF AN ENGINE COOLANT AND/OR HYDRAULIC OIL TEMPERATURE ALARM. In the event of an engine coolant temperature and/or hydraulic oil temperature alarm: 1. Stop the machine.

2. Check the fan control lever to ensure that the fan has been operating in the forward position.

3. Push the fan control lever fully forward to increase fan speed until cooling is achieved.

4. If necessary use the fan control lever to reverse fan flow and clean debris from the radiator, oil cooler, A/C condenser and air intake door screens. Return the fan control lever to the fully forward position.

5. In severe operating conditions manual cleaning of debris may be required.

6. If the problem persists check engine coolant and/or hydraulic oil levels. Refer to OPERATING MACHINE ~ PRESTART CHECKS in THIS SECTION.

2.53

Tigercat 635 Skidder

Controls and operation

ARTICULATION LOCK

TRANSPORTING INSTRUCTIONS

1. Position machine on level ground and steer machine into a straight ahead position.

The skidder may be transported with the wheels on or off. If the wheels are removed the machine must be blocked so that the center joint is one inch or more above the truck bed.

2. Lower grapple and dozer blade to the ground, apply parking brake, stop engine and remove ignition key.

CAUTION Do not use the centre joint to chain the machine to the truck. This can damage the center joint

ARTICULATION LOCK

•

•

••

The dozer blade must be down on the truck bed.

RETAINING PINS

The grapple must be closed and lowered to the truck bed.

REAR CHASSIS

635-P05

The articulation lock bar must be installed.

ARTICULATION LOCK STORED POSITION

The machine must be cross chained (side to side) using the two axles.

3. Remove both retaining pins from the articulation lock. Relocate articulation lock between front and rear chassis. Line up holes at each end of articulation lock with holes in chassis’ and secure in place with both retaining pins.

285-14

Chains must be attached to the grapple to prevent movement.

Additional chains may be installed on the two tow lugs (front of unit) and on the cab access steps.

Note: Chains must be installed to prevent forward, reverse and side movement.

ARTICULATION LOCK IN LOCKED POSITION

4. After work is completed, relocate articulation lock into storage position on rear chassis and hold in place with retaining pins.

2.54

Tigercat 635 Skidder

Controls and operation

TOWING INSTRUCTIONS

STEERING CYLINDERS

STEERING CYLINDERS

A malfunction of the machines equipment may make towing necessary.

Towing is only recommended over short distances. It is always better to make repairs at the point where the machine is parked whenever possible.

1. To facilitate towing, the transmission must be placed in NEUTRAL, this will disconnect the wheels from the hydraulic motors.

The transmission disconnect lever is accessed from the right side, between the cab and heat exchanger assembly. A short bar is placed through the hole in the lever and pulled upwards to put the transmission into neutral.

SM47

Ensure a vehicle of equal power and size is used for towing.

When going downhill, be sure to use a holdback vehicle as the machine is now without any effective braking.

5. When towing is completed, reconnect steering cylinder hoses in proper location.

CAUTION

DISCONNECT LEVER

Before towing, the transmission must always be placed in NEUTRAL. Never tow a machine in gear. If the machine is subjected to hard pulling while in gear, the extremely high forces created will cause significant damage to the components of the hydrostatic drive system and the transmission.

Never tow the machine at over 2 mph. This will cause significant damage to the transmission.

Never press the forward or reverse pedals while the transmission is in neutral. This will cause significant damage to the transmission.

•

342-1

HOSES ON ONE CYLINDER CROSS CONNECTED FOR TOWING

4. The machine will be towed from the front, making use of the towing lugs at front of machine behind the dozer blade.

2. Raise the grapple and dozer blade off the ground and turn off the engine.

3. To allow the machine to steer while towing and prevent damage to the steering cylinders, cross hydraulic hoses on one of the steering cylinders. This will allow trapped oil to flow freely between the two steering cylinders, providing ease of turning with some dampening effect.

NORMAL HOSE CONNECTIONS

TRANSMISSION DISCONNECT LEVER SHOWN IN NEUTRAL

2.55

Tigercat 635 Skidder

Controls and operation

2.56

Tigercat 635 Skidder SECTION 3 - LUBRICATION & MAINTENANCE SEPTEMBER 2003

CONTENTS - SECTION 3 AIR CLEANER MAINTENANCE ............................................................................... 3.16 AIR CONDITIONING SYSTEM, CHECKING ............................................................ 3.22 APPROVED HYDRAULIC OILS ................................................................................. 3.7 CENTER JOINT LUBRICATION ....................................................................................................... 3.27 MAINTENANCE ..................................................................................................... 3.27 EMERGENCY EXITS, CHECK MONTHLY ................................................................. 3.3 FILTERS AXLE RETURN FILTERS ...................................................................................... 3.15 CHARGE PRESSURE FILTER - DRIVE PUMP .................................................... 3.13 CHARGE PRESSURE FILTER - FAN DRIVE PUMP ............................................ 3.13 ENGINE AIR INTAKE ............................................................................................ 3.16 FUEL FILTER/WATER SEPARATOR ................................................................... 3.10 FUEL TANK STRAINER ........................................................................................ 3.11 HYDRAULIC OIL DOUBLE FILTERS .................................................................... 3.12 HYDRAULIC TANK BREATHER FILTER .............................................................. 3.15 FIRE PREVENTION .................................................................................................... 3.3 GENERAL MAINTENANCE ........................................................................................ 3.3 GRAPPLE SNUBBER MAINTENANCE .......................................................... 3.18, 3.19 HOUR METER ~ MAINTENANCE .............................................................................. 3.2 LUBRICATION AND SERVICE POINTS .................................................................... 3.9 NEW MACHINE MAINTENANCE ...............................................................................

FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT ...............................

INITIAL PRE-DELIVERY INSPECTION ...................................................................

TIGHTENING POINTS .............................................................................................

3.2 3.2 3.2 3.2

OIL LOST FROM LEAKAGE ....................................................................................... 3.2 PRESSURIZED WATER SYSTEM MAINTENANCE ................................................ 3.20 REAR (BOGIE) AXLE ................................................................................................

BOGIE HOUSINGS (2 FILLING POINTS) .............................................................

DIFFERENTIAL (1 FILLING POINT) ......................................................................

DRAINING AND REFILLING BOGIE AXLE ...........................................................

PLANETARY DRIVES (4 FILLING POINTS) .........................................................

REPLACING THE ENGINE SERPENTINE BELT ....................................................

3.28 3.29 3.28 3.28 3.29 3.32

SCHEDULED MAINTENANCE ................................................................... 3.4, 3.5, 3.6 FREQUENTLY ......................................................................................................... 3.4 8 HOURS ................................................................................................................. 3.4 48 HOURS ............................................................................................................... 3.5 125 HOURS ............................................................................................................. 3.5 250 HOURS ............................................................................................................. 3.5 500 HOURS ............................................................................................................. 3.5 1000 HOURS ........................................................................................................... 3.6 SERVICE AND LUBRICATION POINTS .................................................................... 3.9 SPEED CONTROL LEVER ADJUSTMENT .............................................................. 3.33 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE .................................... 3.30 TILTING THE CAB .................................................................................................... 3.24 TORQUE CHART ...................................................................................................... 3.34 TORQUE CHART, GENERAL ................................................................................... 3.35 WHEELS, INSTALLING .............................................................................................. 3.2 WINCH LUBRICATION - LANTEC ONLY ................................................................. 3.26

Tigercat 635 Skidder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 635 SKIDDER NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBERS 5281 AND 5283; "PDI AND 50-100 HOUR INSPECTION REPORT"

*FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBERS 5281 AND 5283; "PDI AND 50-100 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 50-100 HOUR TIME FRAME. *IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY, THIS REPORT MUST BE COMPLETED AND RETURNED TO Tigercat Industries Inc. WARRANTY DEPARTMENT.

TIGHTENING POINTS FOR:-

IMPORTANT!

THE FIRST 50-100 HOUR INSPECTION REPORT:~

WHEELS: When installing wheels, ensure that all paint has been removed from the mating surfaces of both the wheel disc and the flange of the axle to ensure metal to metal contact.

All hydraulic connections Hose clamps Center joint pin securing bolts

For more complete instructions also refer to section 8 of the service manual.

Transmission securing bolts Engine mounting bolts Pump drive gearbox securing bolts

HOUR METER ~ MAINTENANCE:

Axle mounting bolts

Check the hour meter on a regular basis to determine your scheduled maintenance times.

Wheel retaining bolts

The intervals and times on the scheduled maintenance chart in this manual are for normal operating conditions.

Cab securing bolts Pin retainers Any other loose nut, bolt or fitting

If your machine is being operated in difficult or severe conditions, you should service your machine at shorter intervals.

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

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

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

3.2

LOST 0IL (GALLONS) PER PER PER DAY MONTH YEAR 0.112 3.36 40.0 0.225 6.75 81.0 1.125 33.75 405.0 3.75 112.5 1,350.0 24.00 720.0 8,640.0

Tigercat 635 Skidder

Lubrication and Maintenance

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

Clean around filler caps before checking or adding fluids Release hydraulic pressures and clean around hydraulic fittings before breaking connection.

Plug or cap immediately Clean up spills as soon as possible Always 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 Top up diesel fuel AT END OF Each shift to reduce contamination by condensation Clean up oil spills on walking surfaces and top of engine enclosure immediately Before welding on machine be sure master switch is disconnected When welding secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires Always have a fire extinguisher at hand For safety; when leaving the cab or leaving machine unattended or during service, always lower grapple and dozer blade to the ground For safety, always block or support grapple and dozer blade when working under them.

CHECK EMERGENCY EXITS MONTHLY~ Two alternate exit routes are provided: right hand cab door and the sliding windows in the cab doors.

These are only to be used if the left hand cab door cannot be opened.

It is therefore essential that these emergency exits be checked at least once per month to ensure they are fully operational.

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

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

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

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

3. Read the fire suppression system manual and have the system serviced regularly by qualified personnel.

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

Also refer to the SAFETY section of this manual for additional information on how to prevent fires from starting on the machine.

3.3

Tigercat 635 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE FREQUENTLY:~

cartridge lip seals and grease fittings. Later axles have face seals and do not require manual lubrication. Refer to diagram to determine which axles apply to your machine.

• Operate the reversible fan to clear debris from the engine cooling air intake door screens. It may also be necessary to manually check for possible restriction depending upon operating conditions in your area.

• Lubricate mid drive shaft, 1-fitting, purge

EVERY 8 HOURS (EVERY SHIFT):~

• Lubricate rear drive shafts: front bearing, 1-fitting, purge intermediate bearing, 1-fitting, purge differential yoke, 1-fitting, purge

Note: Lubrication of mid drive shaft slip joint should be done with machine fully articulated.

• Perform "frequently" maintenance check,

• Lubricate center joint bearings, 2-fittings, purge

And in addition:~ • Check engine coolant level

• Lubricate steering cylinder ends, 4-fittings, purge

• Check engine oil level • Drain fuel/water separator

• Lubricate arch cylinders and pivots, 12-fittings, purge

• Check air intake precleaner, clean as required • Check air cleaner unloader valve

• Lubricate dozer blade cylinders and pivots, 6-fittings, purge

• Check engine air filter restriction indicator • Check hydraulic oil level

Clean:~ • Potentially damaging limbs or sticks from machine

• Check pump drive gearbox oil level with dipstick

• A/C condenser, oil cooler, radiator refer to CLEANING A/C Condenser, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR'S MANUAL.

• Check transmission oil level with dipstick • Check winch sump oil level • Lubricate front axle pivot, 2-fittings, purge • Lubricate front axle - outer bearings ‡ 1-fitting; 2-places; lubricate until grease flows out past the outer seals.

Check:~ • For leakage around hydraulic components and flexible hoses. See "Oil lost from leakage" chart.

Note: Do not use a power greaser as it will damage the seals.

• For loose nuts, bolts and fittings

‡ In submerged or snow conditions perform the following every shift (otherwise every 125 hrs)

• Condition and tension of fan belts.

• Water pressure (60 psi) for pressurized water system.

Note: Manual lubrication of outer axle bearings applies only to earlier axles with CARTRIDGE LIP SEAL

GREASE FITTING

••

••

If the water system has been operated, refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION for refilling and charging instructions.

FACE SEAL

•

• Conduct an overall visual inspection.

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

EARLIER AXLES

M724D-15

LATER AXLES 3.4

Tigercat 635 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 48 HOURS:~ • Check the center joint for looseness. Refer to CENTER JOINT MAINTENANCE in THIS SECTION for instructions. If a problem is found corrective action should be taken immediately. Refer also to CENTER JOINT in SECTION 11 of the SERVICE MANUAL for more detailed checking and adjustment procedures.

Visually check for damage to:• Arch and pivot linkage • Front and rear frame • Center joint area • Attachment Make repairs immediately Visually inspect for:• Frayed electrical wiring and hydraulic hose • Wear in any other components

EVERY 125 HOURS:~ • Perform "frequently" maintenance

Clean/replace:• Air conditioner re-circulation filter • Cab fresh air filter

• Perform 8 hour maintenance

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

And in addition:~ • Check fuel tank filler screen • Lubricate front drive shaft, 1-fitting, purge • Lubricate front axle - outer bearings 1-fitting; 2-places; lubricate until grease flows out past the outer seals.

EVERY 250 HOURS:~ • Perform "frequently" maintenance

Note: Do not use a power greaser as it will damage the seals. ‡ In submerged or snow conditions perform the following every shift (otherwise every 125 hrs) Note: Manual lubrication of outer axle bearings applies only to earlier axles with cartridge lip seals and grease fittings. Later axles have face seals and do not require manual lubrication. Refer to diagram to determine which axles apply to your machine.

• Perform 8 hour maintenance • Perform 125 hour maintenance And in addition:~ • Replace engine oil and change oil filter • Replace engine fuel filter • Replace fuel/water separator filter • Replace air intake primary element • Replace oil in pump drive gearbox • Replace oil in transmission

Check:~ • Fluid level in batteries unless maintenance free

• Check oil level in bogie axle differentials • Check oil level in bogie axle housings, 2 places

• Engine rpm.

• Check oil level in bogie axle planetary drives, 4 places

• All hydraulic pressures • Hydraulic pump and motor securing bolts

• Lubricate bogie axle slewing rings, 12-fittings; 2-places

• Torque tightening points as per new machine maintenance

Note: Do not use a power greaser as it will damage the seals.

• Proper operation of pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

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

3.5

Continued on page 8

Tigercat 635 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE Continued from page 7

SEASONAL:~

EVERY 500 HOURS:~

• Drain and refill hydraulic oil tank and front axle with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION also see SECTION 8 of the SERVICE MANUAL for front axle draining procedure.

• Perform "frequently" maintenance • Perform 8 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance

• Drain and refill bogie axle differential, housings and planetary drives. Refer to REAR (BOGIE) AXLES in THIS SECTION. Refer also to bogie axle service and repair manual for recommended gear oils and service intervals.

And in addition:~ • Replace air intake safety element • Drain oil from the hydraulic tank breather filter (later machines only) • Replace charge pressure filter-drive pump †

• Replace hydraulic hand fill pump filter. †

• Replace charge pressure filter-cooling fan pump †

• Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

• Replace hydraulic oil double element filters (2 elements) † 1 white, high performance element.

1 blue, water absorbing element.

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

EVERY 1000 HOURS:~ • Perform "frequently" maintenance • Perform 8 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance And in addition:~ • Replace air cleaner unloader valve • Check center joint preload with a dial indicator.

Refer to CENTER JOINT ~ CHECKING CENTER JOINT PRELOAD in SECTION 11 of the SERVICE MANUAL. If a problem is found corrective action should be taken immediately, refer to CENTER JOINT PRELOAD ADJUSTMENT in SECTION 11 of the SERVICE MANUAL. • Replace oil in winch sump • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

† Use only Genuine Tigercat replacement hydraulic oil filters.

3.6

Tigercat 635 Skidder

Lubrication and Maintenance

APPROVED HYDRAULIC OILS In addition to providing the vehicle with its normal operational functions, hydraulic oil is also used to fill the front axle assembly, apply brakes and operate front differential locks.

Wet disk brakes in the front axle require oil with specific properties to ensure reduced chatter and ensure proper lubrication of mechanical components.

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

HYDRAULIC OIL THE FLUID USED TO FILL OR REPLENISH THE HYDRAULIC SYSTEM OF THIS MACHINE MUST MEET JOHN DEERE SPECIFICATIONS TYPE J20C (SUMMER) OR J20D (WINTER).

THE FOLLOWING ARE APPROVED BY Tigercat FOR USE IN THIS MACHINE:

®

CHEVRON CITGO IMPERIAL/ESSO SHELL SUN JOHN DEERE

TRACTOR HYDRAULIC FLUID (SUMMER) TRACTOR HYDRAULIC FLUID (33-310) (SUMMER) HYDRAUL 56 (SUMMER) HYDRAUL 50 (LOW VISC) WINTER) DONAX TD (SUMMER) DONAX TDL (WINTER) SUNFLEET TH FLUID (SUMMER) TYPE J20C (HYGARD) (SUMMER) 11514A R1 TYPE J20D (HYGARD) WlNTER)

3.7

Tigercat 635 Skidder

Lubrication and Maintenance

20

REAR DRIVE SHAFTS 23 3 FTG/8

OUTER AXLE BEARINGS 18 2 FTG/8

4

10

3

12

19

11

GRAPPLE YOKE 28

4 FTG/8

13 GRAPPLE ROTATOR 28 3 FTG/125 5 SHOTS GRAPPLE SNUBBERS 28 4 FTG /8

GRAPPLE PINION GEAR 28 1 FTG/250 5 SHOTS

BOGIE AXLE SLEWING RINGS 22 24 FTG/250

NOTE: REMOVE PIPEPLUG TO ACCESS

ARCH

12 FTG/8 29

STEER CYLINDERS

4 FTG/8

30

AXLE - PIVOT 25

2 FTG/8

17

DOOR HINGES 26

8 FTG/500

5

15

1

7 8

DOZER

6

6 FTG/8

CENTER JOINT

GRAPPLE 28

8 FTG/8

21

24

2 FTG/8

MID DRIVE SHAFT 23

1 FTG/8

FRONT DRIVE SHAFT 23 1 FTG/125

16

14

9

LEGEND *

ANTIFREEZE SOLUTION MUST MEET GM 6038M SPECIFICATIONS - SEE MANUFACTURERS MAINTENANCE MANUAL

**

LUBRICATE UNTIL GREASE FLOWS OUT PAST OUTER SEALS. DO NOT USE POWER GREASERS AS IT WILL DAMAGE THE SEALS. SEVERE CONDITIONS (DEEP MUD, WATER OR SNOW) LUBRICATE EVERY 8 HOURS. NORMAL CONDITIONS LUBRICATE EVERY 125 HRS. STEER MACHINE FULLY BEFORE GREASING MID DRIVE SHAFT SLIP YOKE.

*** ****

2 FTG/125

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2 FTG) AND HOURS BETWEEN SERVICING (125 ). JOINT TO BE PURGED. USE LITHIUM BASED GREASE CONTAINING MOLYBDENUM DISULFIDE.

†

Use only Genuine T igercat replacement Hydraulic oil filters.

12804BR5

3.8

CHK REP DRN D/R LUB

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

27

Tigercat 635 Skidder

Lubrication and Maintenance

Tigercat® Model 635 SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

1

COOLING SYSTEM

CHK

2

ENGINE OIL/FILTER CUMMINS C SERIES FUEL FILTER (ENGINE) FUEL/WATER SEPARATOR FUEL TANK FILLER SCREEN AIR INTAKE PRECLEANER AIR INTAKE PRIMARY ELEMENT AIR INTAKE SAFETY ELEMENT

CHK

3 4 5 6 7

CHANGE COOLANT EVERY 2 YEARS REP

40

10.6

18.9

5

REP REP

DRN CHK CHK

REP REP

60/40 ANTIFREEZE * SEE ENGINE MANUFACTURERS MAINTENANCE MANUAL 1 1 1 1 1 1

CLEAN AS REQUIRED CHECK FILTER RESTRICTION INDICATOR WITH ENGINE RUNNING

1

REFER TO SECTION 3 IN MANUAL

1

DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE (SEE HYDRAULIC OIL CHART)

8

AIR CLEANER UNLOADER VALVE

CHK

9

HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10 11

HYDRAULIC TANK BREATHER FILTER HYDRAULIC FILTER, FULL FLOW, INCLUDES:1 BLUE WATER ABSORBING ELEMENT* 1 WHITE HIGH PERFORMANCE ELEMENT

DRN REP †

12

CHARGE PRESSURE FILTER (DRIVE PUMP)

13

CHARGE PRESSURE FILTER (FAN DRIVE PUMP)

14

PUMP DRIVE GEARBOX CHECK LEVEL WITH DIPSTICK

CHK

D/R

3

0.8

1

15

TRANSMISSION

CHK

D/R

6

1.6

1

FRONT AXLE - (EARLIER AXLE WITH GREASE LUBRICATED OUTER BEARINGS)

28

7.4

1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10Fº(-23ºC) USE 75W-90 UP TO 100ºF(38ºC) USE 80W-90 ABOVE 100ºF(38ºC) USE 85W 140 D/R WITH SEASONAL OIL CHANGE

FRONT AXLE - (LATER AXLE WITHOUT GREASE LUBRICATED OUTER BEARINGS)

31

8.2

1

D/R WITH SEASONAL OIL CHANGE

16

CAST

17

FRONT AXLE - PIVOT

LUB LUB ***

18

FRONT AXLE-OUTER BEARINGS EARLIER AXLE WITH GREASE LUBRICATED OUTER BEARINGS

19 20 21 22

23

REP

DESCRIPTION

QTY

USG

LITERS

500

250

125

8

ITEM

CAPACITY

1000

SERVICE POINT NO.

SERVICE EVERY

95

25

2

REMOVE FILTER, DRAIN AND REINSTALL *NOTE: MUST USE 1 OF EACH TYPE OF FILTER ELEMENT.

REP †

1

CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW

REP †

1

LUB ***

PURGE

2

LITHIUM BASE EP2 GREASE

** SEE NOTE

2

LITHIUM BASE EP2 GREASE

FRONT AXLE OUTER BEARINGS LATER AXLE THERE ARE NO LUBRICATION FITTINGS, AXLE OUTER BEARINGS ARE LUBRICATED WITH OIL FROM "SERVICE POINT NO. 16" BOGIE AXLE - DIFFERENTIAL (LATER CHK 22.5 6 1 REFER TO BOGIE AXLE SERVICE AND REPAIR MANUAL FOR RECOMMENDED BOGIE AXLE - HOUSINGS CHK 35 9.2 2 GEAR OILS BOGIE AXLE - PLANETARY DRIVES BOGIE AXLE - SLEWING RINGS FRONT DRIVE SHAFT MID DRIVE SHAFT REAR DRIVE SHAFTS: BEARING FRONT BEARING INTERMEDIATE DIFFERENTIAL YOKE

CHK LUB LUB

5 1.3 PURGE PURGE PURGE

4 24 LITHIUM BASE EP2 GREASE 1 1

LUB LUB LUB

PURGE PURGE PURGE

1 1 1

PURGE

2

LUB

CENTER JOINT

LUB

24

CENTER JOINT BEARING PRELOAD

25 26 27 28 29

STEERING CYLINDERS DOUBLE ARCH CYLINDER & PIVOTS DOZER BLADE CYLINDER & PIVOTS GRAPPLE, Tigercat WINCH LANTEC

CHK 48 LUB LUB LUB CHK

30

PRESSURIZED WATER SYSTEM

CHK

635LUBCHARTMOD0903.XLS/PDF

CHK

TEST

LITHIUM BASE EP2 GREASE

LITHIUM BASE EP2 GREASE

REFER TO SECTION 3 OF THE MANUAL FOR DETAILS 4 LITHIUM BASE EP2 GREASE PURGE 12 LITHIUM BASE EP2 GREASE PURGE 6 LITHIUM BASE EP2 GREASE PURGE SEE LUBRICATION POINTS DIAGRAM D/R 18 4.7 SEE WINCH MANUFACTURER'S MAINTENANCE MANUAL D/R 52 13.7 SEASONAL DRAIN AND REFILL

3.9

Tigercat 635 Skidder

Lubrication and Maintenance

FILTERS

Changing the filter: 1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to the ground, stop engine, pull parking brake ON and block wheels.

IMPORTANT Failure to service and replace filters at the proper intervals specified in the manufacturer's manuals, could cause damage to the machine and result in the product warranty becoming NULL and VOID. Check Tigercat parts catalog for replacement filters.

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

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

4. Wearing face protection (in case of a fuel spray) unscrew the old filter.

FUEL FILTER/WATER SEPARATOR This is a combination unit, with a replaceable fuel filter and a removable water sediment bowl on the bottom of the unit. The water sediment bowl is only replaced if it becomes damaged or non-functional. For service and replacement intervals see SERVICE AND LUBRICATION POINTS in THIS SECTION.

5. Remove and discard the small 1” I.D. gasket from the threaded extension on the filter head.

6. Remove the water sediment bowl from the bottom of the old filter. Discard this gasket also. Dispose of old filter and any fuel properly.

7. Clean the water sediment bowl.

8. Check the seating area for the gaskets on the filter head and the water sediment bowl and wipe clean.

••

FUEL WATER SEPARATOR

PRIMER PUMP

••

WATER SEPARATOR BOWL

9. Lubricate gasket for bottom of filter and water sediment bowl with clean engine oil and carefully hand tighten the water sediment bowl onto the new filter. It is plastic and will break if over tightened. Close the water drain valve.

10. Lubricate the new 1” I.D. gasket with clean engine oil and install onto the threaded extension on the filter head.

11. Lubricate the gasket on top of the new filter with clean engine oil and pre-fill the filter with clean fuel.

• •

DRAIN TAP

12. Screw the new filter on to the filter head until the gasket makes contact with the seat and then hand tighten an additional 3/4 turn only.

13. Start the engine and check for leaks.

270-9A

FUEL WATER SEPARATOR

3.10

Tigercat 635 Skidder

Lubrication and Maintenance

FUEL TANK STRAINER This is a stainless steel fuel strainer, screwed on to the inlet pipe of the engine fuel feed line inside at the bottom of the fuel tank.

Changing or cleaning the strainer: NOTE: This should only be required if excessive quantities of foreign material has built up inside the tank.

1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to the ground , stop engine, pull parking brake ON and block wheels.

2. Drain the fuel tank. (plug in bottom) 3. Remove the round fuel tank cover plate and “O” ring from the access hole.

4. Before removing the strainer, clean any debris from the bottom of the tank and wipe it clean.

5. Remove the fuel strainer using the hex on the end of strainer. Carefully clean the strainer (it may be damaged by rough handling).

6. Check for a buildup of foreign materials where the strainer threads on to the pipe and elbow.

7. Reinstall the strainer using the hex on end.

8. Reinstall fuel tank cover plate with “O” ring.

9. Refuel and check for leaks. Start the engine and check for leaks again.

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

3.11

Tigercat 635 Skidder

Lubrication and Maintenance

HYDRAULIC OIL DOUBLE ELEMENT FILTERS The hydraulic oil cooling circuit contains a double filter head with a built in restriction indicator and a 25 psi bypass valve. In the event of a clogged filter element or thicker oil on cold starts, this bypass filter will open and redirect oil around the filter element. When the filter elements become restricted, the Red pop-up indicator will show RED, indicating that the elements must be changed. It is recommended that all machines use two different filter elements:

• •

GASKET

•

SQUARE SECTION GASKET INSTALLATION

Square Section Gasket Remove used gasket and clean groove in head.

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Pre-fill filter with clean oil before installation. Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

1 blue, Tigercat water absorbing, full flow hydraulic oil filter element.

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS SECTION. Changing the filters:

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

DOUBLE ELEMENT FILTER

•

FILTER ELEMENT

FILTR_SEALS

1 white, Tigercat high performance, full flow hydraulic oil filter element

••

FILTER HEAD

•

•• •

• BLUE ELEMENT

•

DRIVE PUMP CHARGE PRESSURE FILTER FILTR_SEALS

630-D38

FILTER HEAD

HYDRAULIC FILTERS

1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to ground, stop engine, pull parking brake ON and block wheels.

z

FILTER ELEMENT

'O' RING GASKET INSTALLATION

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

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Pre-fill filter with clean oil before installation. Screw on new filter until gasket makes contact.

Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact)

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

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

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

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

GASKET

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

6. Start the engine and check for leaks.

3.12

Tigercat 635 Skidder IMPORTANT HYDRAULIC FILTER SERVICING GUIDELINES NEVER PRE-FILL ANY HYDRAULIC FILTERS ON 200, 700, 800 AND 1000 SERIES MACHINES NEVER PRE-FILL CHARGE PRESSURE FILTERS ON 600 SERIES SKIDDERS Tigercat generally 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 valves, pumps and motors. The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

ALWAYS PRE-FILL DUAL HEAD HYDRAULIC FILTERS ON 600 SERIES SKIDDERS

Lubrication and Maintenance CHARGE PRESSURE FILTERSDRIVE PUMP AND FAN DRIVE PUMP The drive pump charge circuit contains a single element, full flow Tigercat hydraulic filter with a restriction indicator sending unit and a 50 psi third port bypass valve. The restriction indicator sending unit turns on the filter bypass warning light when an oil flow restriction in excess of 50 psi is encountered at the filter head. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the drive circuit.

The fan drive circuit contains a single element, full flow Tigercat hydraulic filter with a restriction indicator sending unit and a 50 psi third port bypass valve. The restriction indicator sending unit for this filter is not connected to a warning light.

When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the fan drive circuit.

Continued on page 14

Dual head hydraulic filters on 600 series skidders must always be pre-filled with clean oil as noted specifically in the manuals for each of these machines.

All 600 series hydraulic circuits direct oil from the dual head filters to the main and drive pump inlets. Air must not be allowed to enter the inlets of these pumps. Entry of air directly into pump inlets can cause significant and costly damage to pumps. In this particular case the risk of damage to pumps caused by entry of air into the circuit is considered to be greater than the risk of damage caused by unfiltered oil.

Prefiltering of any hydraulic oil used to pre-fill these filters is strongly recommended to eliminate the risk of damage caused by unfiltered oil.

DOUBLE ELEMENT FILTER

•

• •

•

DRIVE PUMP CHARGE PRESSURE FILTER

BLUE ELEMENT

630-D38

HYDRAULIC FILTERS LEFT SIDE BELOW COOLING FAN

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

333-3

3.13

FAN DRIVE CHARGE PRESSURE FILTER

Tigercat 635 Skidder

Lubrication and Maintenance

Continued from page 13

Changing a pressure filter:

IMPORTANT

1. Park machine on level ground, install articulation lock bar, lower dozer blade to ground, stop engine, pull parking brake ON and block wheels.

HYDRAULIC FILTER SERVICING GUIDELINES NEVER PRE-FILL ANY HYDRAULIC FILTERS ON 200, 700, 800 AND 1000 SERIES MACHINES

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

NEVER PRE-FILL CHARGE PRESSURE FILTERS ON 600 SERIES SKIDDERS

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

4. Wearing face protection (in case of an oil spray), unscrew the filter.

5. Drain filter and dispose of any oil properly.

6. Check the seating area on the filter head and wipe it clean.

7. This filter has an o-ring gasket. Replace o-ring as required and apply hydraulic oil to the gasket surface.

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

Tigercat generally 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 valves, pumps and motors. The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

ALWAYS PRE-FILL DUAL HEAD HYDRAULIC FILTERS ON 600 SERIES SKIDDERS

DO NOT PRE-FILL THE NEW PRESSURE FILTER. 9. Turn filter an additional 1/2 turn by hand to tighten.

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only 10. Start the engine and check for leaks.

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

3.14

Dual head hydraulic filters on 600 series skidders must always be pre-filled with clean oil as noted specifically in the manuals for each of these machines.

All 600 series hydraulic circuits direct oil from the dual head filters to the main and drive pump inlets. Air must not be allowed to enter the inlets of these pumps. Entry of air directly into pump inlets can cause significant and costly damage to pumps. In this particular case the risk of damage to pumps caused by entry of air into the circuit is considered to be greater than the risk of damage caused by unfiltered oil.

Prefiltering of any hydraulic oil used to pre-fill these filters is strongly recommended to eliminate the risk of damage caused by unfiltered oil.

Tigercat 635 Skidder AXLE RETURN FILTERS (LATER MACHINES)

Lubrication and Maintenance HYDRAULIC TANK BREATHER FILTER (LATER MACHINES) HYDRAULIC TANK BREATHER FILTER

•

635-P07

FRONT AXLE RETURN FILTER

Later machines are equipped with a front axle return oil filter in the drain line of the front axle.

The axle return oil filter requires changing only when repairing a leaking or failed John Deere or Tigercat High Flotation axle.

630-D44

HYRAULIC TANK BREATHER (LATER MACHINES)

Later machines are equipped with a hydraulic tank breather filter. Refer to SCHEDULED MAINTENANCE or SERVICE AND LUBRICATION POINTS for correct service interval.

Draining the filter: 1. Park machine on level ground, install articulation lock bar, lower dozer blade to ground, stop engine, pull parking brake ON and block wheels.

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

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

4. Wearing face protection (in case of an oil spray), unscrew the filter.

5. Drain filter and dispose of any oil properly.

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

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

8. Tighten until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact).

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only 9. Start the engine and check for leaks.

3.15

Tigercat 635 Skidder

Lubrication and Maintenance

AIR CLEANER MAINTENANCE ENGINE AIR PRECLEANER

AIR CLEANER

•

•

SENDING UNIT FOR WARNING LIGHT IN CAB

FILTER RESTRICTION INDICATOR

ENGINE AIR CLEANER

•

•• ••

291-3

ENGINE AIR CLEANER

303-8

EXHAUST PORT AREA

ENGINE AIR CLEANER

AIR CLEANER The air cleaner on this machine uses two filter elements, a primary element and a safety element accessible from the right side of the engine compartment.

284-25A

REAR VIEW OF PRECLEANER

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

ENGINE AIR PRECLEANER The engine air precleaner cleans engine air before it reaches the air cleaner filter elements. It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance. However, it should be checked periodically to make sure that foreign materials have not plugged the intake area or the exhaust port area.

A warning light on the cab instrument panel will come ON when the elements in the engine air cleaner become excessively clogged with dust causing air intake restriction.

In addition, a filter restriction indicator is mounted to the output side of the filter, this should show green when the engine is running at high RPM. Service is required if the indicator shows red.

UNLOADER VALVE AS THE AIR SPINS, CENTRIFUGAL FORCE SEPARATES FOREIGN MATERIALS FROM THE CLEAN AIR

CONTAMINANTS ARE BLOWN OUT OF SPECIAL DISCHARGE PORTS BY HIGH VELOCITY, AIR POWERED ROTOR

•

• 303-7

• • •

THE TURBO II PRECLEANER HAS SPECIALLY DESIGNED BLADES THAT CAUSE THE INCOMING AIR TO SPIN TURBO 3

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

TURBO II PRECLEANER OPERATION

AIR CLEANER UNLOADER VALVE

AIR CLEANER UNLOADER VALVE This rubber valve on the tube of the air cleaner housing should be checked at the beginning of every shift. (8 hours) If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective. The valve should suck closed at 1/3 throttle.

This valve should be replaced every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. Check and clean the valve. A good valve should be soft and flexible. If it is 3.16

Tigercat 635 Skidder

Lubrication and Maintenance

plugged, be sure to check the filter elements as they may need replacing as well. Reattach the valve to the tube.

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

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS 1. Release the cover latch gently to reduce the amount of dust dislodged.

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

In addition to the SCHEDULED MAINTENANCE, the following instructions should also be noted.

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

The most common and damaging servicing problems are:

4. Always clean the inside of the outlet tube and filter housing.

PRIMARY ELEMENT

OUTLET TUBE

•

SAFETY ELEMENT

••

NOTE: Filter elements should never be cleaned and reused. 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.

•

ENGINE AIR PRECLEANER

171-18A

5. Check your old filter, It can help you detect foreign material on the sealing surface that is causing leakage.

AIR FILTER ELEMENTS

OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that looks 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 engine manufacturer's guidelines, should a filter be replaced.

6. Inspect the new filter for damage.

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

8. Check connections and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points Leaks here send dust directly to the engine.

NOTE: This does not apply to oil filters.

IMPROPER SERVICING Engine exposure to dust during servicing is the largest single reason for engine damage due to dust.

Abrasive dust can easily enter the intake system once the air cleaner cover and protective filter element is removed for replacement. The safety element does reduce this risk but it should also be replaced at every third primary element change.

3.17

Tigercat 635 Skidder

Lubrication and Maintenance

GRAPPLE SNUBBER MAINTENANCE

QUADCO MODEL 300 SNUBBER USED ON TIGERCAT GRAPPLES

IMPORTANT

In this model the snubbers are independent of the link. Separate snubbers provide snubbing action in two directions. There 1 grease fitting on each snubber for daily lubrication of the sleeves and housings. Grapple installations use 4 model 300 snubbers depending on the type of grapple and yoke used. Be sure to lubricate all the grapple snubbers on your machine.

All service points on snubbers must be greased every shift (8 hours) to ensure a long service life.

QUADCO MODEL 500 SNUBBER USED ON TIGERCAT GRAPPLES In this model the snubbers are independent of the link. Separate snubbers or pairs of snubbers provide snubbing action in two directions. There are 3 grease fittings on each snubber for daily lubrication of the sleeves and housings. Grapple installations use 2 or 3 model 500 snubbers depending on the type of grapple and yoke. Be sure to lubricate all the grapple snubbers on your machine.

ADJUSTING SNUBBER TENSION Tension is adjusted by tightening the end cap bolt.

Tighten the end cap bolt only 1/2 turn at a time until the desired tension is achieved.

Note: Overtightening may result in grapple stiffness and reduced friction sleeve life. Applying too much pressure may press the spring washer flat causing all tension to be lost.

ADJUSTING SNUBBER TENSION Tension is adjusted by tightening the end cap bolt.

Tighten the end cap bolt only 1/2 turn at a time until the desired tension is achieved.

Note: Overtightening may result in grapple stiffness and reduced friction sleeve life. Applying too much pressure may press the spring washer flat causing all tension to be lost.

GREASE FITTINGS (1 PER SNUBBER)

•

LINK

GREASE FITTINGS (3 PER SNUBBER)

LINK

• SPRING WASHER

GREASE FITTINGS (3 PER SNUBBER)

••

•

FRICTION SLEEVE

••

FRICTION SLEEVE SPRING WASHER

•• END CAP BOLT

•

CY045

END CAP BOLT

• CY023

QUADCO MODEL 500 SNUBBER 3.18

QUADCO MODEL 300 SNUBBER

Tigercat 635 Skidder

Lubrication and Maintenance CROSS GROOVE POSITION LINED UP WITH WEAR BLOCK

FRICTION SLEEVE REPLACEMENT QUADCO MODEL 300 AND 500 SNUBBERS 1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to ground, stop engine, pull parking brake ON and block wheels.

2. Remove the snubber end cap bolt, end cap, bearing, spring washer and housing.

SPRING WASHER

•

•

END CAP

•

3. Remove the friction sleeve from the core assembly using a pry bar on each side to loosen it. Note: Loctite® is used for friction sleeve installation. Heat may be required to loosen the sleeve for removal.

•

••

••

•• •• CORE ASSEMBLY FRICTION SLEEVE

HOUSING BEARING

END CAP BOLT

4. Clean the core assembly to remove any Loctite® residue.

CY044

QUADCO MODEL 500 SNUBBER CROSS GROOVE POSITION LINED UP WITH WEAR BLOCK

5. Apply a thin coat of Loctite® 620 retaining compound (or equivalent) to the core assembly and to the inner side of the new friction sleeve.

6. Position the friction sleeve so that the cross groove will be lined up with the wear block (Models 500) or wear slot (Model 300) as shown. Push the friction sleeve onto core assembly.

••

WEAR BLOCK

WEAR SLOT

END CAP

•

Check again to be sure the friction sleeve is positioned correctly as shown. Correct positioning of the cross groove is required to ensure proper snubber lubrication and long service life.

• CY045

7. Apply moly-based grease to the outer friction sleeve surface. Use a generous amount of grease.

8. Reinstall the housing, spring washer, bearing, end cap and end cap bolt.

9. Allow the Loctite® to cure for at least 30 minutes before operating the machine.

3.19

• ••

•

SPRING WASHER

••

• ••

•

CORE ASSEMBLY FRICTION SLEEVE

HOUSING BEARING

END CAP BOLT

QUADCO MODEL 300 SNUBBER

Tigercat 635 Skidder

Lubrication and Maintenance SYSTEM TEST

PRESSURIZED WATER SYSTEM MAINTENANCE •

WATER TANK PRESSURE GAUGE

•

•

•

This system should be tested once every month by turning the shut-off valve ON and expelling water from the hose end nozzle. A very forceful discharge of water should be obtained. If the water does not come out with force (with pressure gauge reading 60 psi) the system needs to be PURGED. Refer to PURGING PRESSURIZED WATER SYSTEM in THIS SECTION.

DOZER BLADE

•

WATER SHUT-OFF VALVE

After testing, the tank must be refilled and pressurized to 60 psi. Refer to the following FILL AND CHARGE procedure. This FILL AND CHARGE procedure should be carried out yearly.

HOSE STORAGE COMPARTMENT

PRESSURIZED WATER SYSTEM

630-D46

A water tank is incorporated into the dozer blade and is pressurized to 60 psi. A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade.

Tank capacity is 13.7 US gallons (52 litres).

FILL & CHARGE PRESSURIZED WATER SYSTEM 1. Open water shut off valve and completely discharge all water and compressed air from the tank via the hose end nozzle.

CAUTION

The control valve incorporates an air charge valve, a pressure gauge and a relief valve on the outlet side of the valve. A ball valve is installed on the outlet side of the valve and is used to shut off the water supply to the hose. This ball valve should be in the OFF position when the system is not in use.

The pressure gauge on the valve should read 60 psi check system pressure daily.

Never remove fill plug before depressurizing tank or injury may result. This fill plug incorporates a vent hole to release air pressure from the tank before the threads disengage. Do not replace this fill plug with any substitute.

2. Slowly unscrew fill plug two full turns. Any remaining air in the tank will be heard expelling from the special fill plug. Do not remove fill plug until all air has been expelled.

WATER SHUT-OFF VALVE (SHOWN OFF) PRESSURE GAUGE

WATER TANK

• •

•

FILL PLUG

OUTLET CONNECTION

•

•

AIR CHARGE VALVE 150-1A

•

WATER CONTROL VALVE

Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL.

• 150-8A

DOZER BLADE

PRESSURIZED WATER SYSTEM

3. Close water shut off valve.

4. Fill tank with clean water. Tank capacity is approximately 13.7 USgallons (52 litres).

When temperatures below 32°F are anticipated, use a 60/40 solution of Nontoxic R. V. Antifreeze or other suitable antifreeze.

Antifreeze solution must meet GM 6038M specifications.

3.20

Tigercat 635 Skidder NOTE: Most Nontoxic R.V. Anti freeze solutions contain corrosion and algae inhibitors, it is therefore suggested that this solution be added to the water on a continual basis regardless of temperature conditions.

5. Install fill plug in tank.

NOTE: This is a special plug designed to withstand pressurization of the water tank.

Do not substitute.

Lubrication and Maintenance PURGING PRESSURIZED WATER SYSTEM Purging should be carried out whenever the flow of water does not forcefully discharge from the end of the hose with the pressure gauge reading 60 psi.

1. Open water shut off valve and completely discharge all water and compressed air from the tank via the hose end nozzle.

6. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

CAUTION Never remove fill plug before depressurizing tank or injury may result. This fill plug incorporates a vent hole to release air pressure from the tank before the threads disengage. Do not replace this fill plug with any substitute.

7. Open the water shut off valve.

8. Discharge about 1/2 gallon (2 litres) of fluid into an empty antifreeze jug or other suitable container.

There will be significant foaming as the fluid is discharged into the jug. Continue until a very forceful flow is obtained and any contamination that may have been in the tank is flushed from the system.

9. Check fluid in the jug for contamination. If fluid is dirty dispose of it properly.

2. Slowly unscrew fill plug two full turns. Any remaining air in the tank will be heard expelling from the special fill plug. Do not remove fill plug until all air has been expelled.

3. Close the water shut off valve and add 2 gallons (8 litres) of CLEAN water to the tank.

4. Install the fill plug

10. Close the water shut-off valve.

NOTE: This is a special plug designed to withstand pressurization of the water tank.

Do not substitute.

11. Release pressure and fluid from the hose.

12. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

13. Return the hose to the hose compartment.

5. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

6. Open the shut off valve and completely discharge all the water in the tank via the hose end nozzle.

7. Discharge all the water into an empty antifreeze jug or other suitable container.

There will be significant foaming as the fluid is discharged into the jug. Continue until a very forceful flow is obtained and any contamination that may have been in the tank is flushed from the system.

8. If a forceful discharge was not achieved, repeat the purging procedure. If a second purging does not work, remove lines and check for an obstruction.

9. After the purging operation, fill and charge the system as described in FILL & CHARGE PRESSURIZED WATER SYSTEM in THIS SECTION.

3.21

Tigercat 635 Skidder

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

IMPORTANT

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant only. PAG (polyalkeylene glycol) oil should be present in the system and must be used on 'O' ring fittings during assembly.

It is recommended that during cold weather when the A/C system is not in use, that it be run for a period of 5 minutes every 2 weeks.

This will circulate oil to all components of the A/C system.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

3 LBS. 0 OZ.

7 OZ.

The compressor and charge valves are accessed from the right side engine compartment. The receiver drier is accessed from the compartment behind the right door, on the outside. The evaporator core is accessed on the right hand side of the machine just inside the cab door.

Use this checklist to maintain system between service intervals.

302-19

a. Check and adjust compressor drive belt tension.

CAUTION

b. Check air intake filters and clean as required.

Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

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

Always use personal protective equipment to guard against flying debris

c. Check the condenser core for dirt and debris. Clean as required. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR'S MANUAL. d. Check the evaporator core and the inside of the A/C housing for dirt and debris.

Clean as required.

CAUTION

e. Run air conditioning system for 3 - 5 minutes. f.

CHECK A/C CONDENSER CORE

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

Check to see that compressor clutch will engage.

3.22

Tigercat 635 Skidder

Lubrication and Maintenance FRESH AIR FILTER

•

•

•

ENGINE

SHUT-OFF VALVE

HOSE TO A/C HEATER UNIT

• 303-20

274-5

HOT WATER SHUT OFF

HOT WATER SHUT OFF VALVE During times when cab heating is not required the HOT WATER SHUT OFF VALVE, on the heater hose from the engine, should also be closed to prevent hot water from seeping through the A/C unit, thereby reducing the cooling system effect.

RECIRCULATING AIR FILTER

•

FRESH AIR FILTER

FILTER - FRESH AIR When the control switch is in the FRESH AIR position , outside air is drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. To reduce dust in the cab area, use the FRESH AIR option with the A/C on.

This pressurizes the cab, forcing dust out and reducing dust coming in. The FRESH AIR filter is accessible from outside of the cab, at the back between the lights. It should be cleaned or replaced every 125 hours. This is done by removing 6 bolts (3/8”) and removing the air inlet cover. Next remove two nuts (1/4”) and remove the filter box cover. This will allow access to the filter.

WARNING - These filters may require cleaning or replacement more frequently under extreme operating conditions.

151-9

VENTS BEHIND SEAT - 2

•

TEMPERATURE CONTROL

FILTER, RECIRCULATING AIR - A/C UNIT Air in the cab is drawn into the A/C-HEATER unit via this filter and recirculated. The filter is located at the base of the A/C unit. It should be cleaned or replaced every 125 hours. This is done by removing two thumb screws in the filter box cover.

350-4A

A/C-HEATER CONTROL PANEL

HEAT - VARIABLE/TEMPERATURE CONTROL This is a variable, rotary dial to adjust the amount of heated air for the cab. Make sure this control is off or at the coolest setting (full counterclockwise), when using the air conditioning. Refer also to HOT WATER SHUT OFF VALVE.

3.23

Tigercat 635 Skidder

Lubrication and Maintenance

TILTING THE CAB WARNING Before tilting the cab, ensure that the machine is parked on level ground. Lower the dozer blade and grapple on to the ground.

Engage the parking brake and turn the ignition switch off.

5. Remove the left side Cab Locking Pins. (2 pins) This is done by first removing the locking bolts. (2 bolts) 6. Open the lower compartment door in left hand step below the cab door to access the cab tilt hand pump.

PUMP HANDLE

RAISING THE CAB

••

•

1. Position the Skidder on level ground.

PUMP

•

2. Lower the Grapple and Dozer to the ground.

3. Apply parking brake and turn ignition off.

4. Remove the sweep mounting bolts at the cab.

(4 bolts)

PUMP HANDLE STORAGE BRACKETS

•

HAND PUMP FOR CAB TILT

302-14

7. Turn the lever on the pump manifold to RAISE (pointing in).

PUMP HANDLE

CANOPY SWEEP BOLTS

•

•

PUMP LEVER SHOWN IN "RAISE" POSITION

•

PUMP LEVER SHOWN IN "LOWER" POSITION

•

• 303-14 138-8AX

PUMP CONTROL LEVER

8. Insert handle into pump and pump in a steady manner to raise the cab to the tilt position.

The pump handle is stored on the inside of the battery access door located below the test port compartment.

CAUTION Keep hands away from the locking pin area.

As the cab passes "top dead centre" it will slowly move on its own to the full extent of the safety cable. DO NOT PUMP BEYOND LIMIT OF SAFETY CABLE.

303-M2

•

303-12

•

9. Insert CAB SUPPORT BRACE for partial tilt.

Secure brace at each end with the cab locking pins. Full tilt is limited to the length of the safety cable and is beyond centre of gravity.

The cab will stay at this limit provided Skidder is on level ground.

CAB LOCKING PINS

3.24

Tigercat 635 Skidder

Lubrication and Maintenance

LOWERING THE CAB CAB SUPPORT BRACE (3291B).

MUST USE CAB & CHASSIS LUGS SHOWN

1. Clear the area under the cab of obstructions and secure all lines and wires.

2. If the Cab Support Brace was used, you may have to take the weight off of it by slightly raising the cab before removing it.

•

SAFETY CABLE

CAB LOCKING PINS

3. Turn the lever on the pump manifold to LOWER (pointing out) 4. Pump the handle on the pump to lower the cab.

•

•

5. Watch closely for pinching of hydraulic lines 302-16

•

PARTIAL TILT WITH CAB SUPPORT BRACE

CAUTION Keep hands away from the locking pin area as the cab is being lowered. and wires.

6. When fully lowered, insert Cab Locking Pins and tighten locking bolts (2 pins) (2 bolts) 7. Turn the lever on the pump manifold inwards and store the pump handle on the lower door.

8. Close and lock the lower door.

9. Replace the Canopy Sweep Bolts. (4 bolts)

•

WARNING

Before working under cab; Machine must be parked on level ground.

Cab must be fully tilted with safety cable completely tight, or cab support brace must be installed.

CAB SAFETY CABLE (3361B)

302-13

CAB AT FULL TILT SUPPORTED SUPPORTED BY SAFETY CABLE

WARNING If cab support brace is damaged or lost, it must be replaced immediately with Tigercat brace PART NO. 3291B. DO NOT attempt to work under a raised cab supported only by the hydraulic cylinder or a substitute device.

WARNING

311-13

CAB SUPPORT BRACE STORED UNDER SEAT

If cab safety cable is damaged or lost, it must be replaced immediately with Tigercat PART NO. 3361B. DO NOT attempt to work under a raised cab supported only by the hydraulic cylinder or a substitute device.

3.25

Tigercat 635 Skidder

Lubrication and Maintenance

WINCH LUBRICATION - LANTEC ONLY

MAIN FILLER/BREATHER PLUG

Refer to the manufacturer's maintenance and service manual for information on your winch.

•

The sump holds 4.7 U.S. Gal. (18 litres). Tigercat recommends the use of tractor hydraulic fluid for the lantec winch. Refer to approved hydraulic oils in this section.

348-21

•

Oil should be changed 1000 hours, depending on use.

OIL LEVEL SIGHT GAUGE

The oil level should be checked every day (if the winch is being used) before starting the machine.

The oil level should be up to the oil level sight glass on the left side of the winch.

348-22

LANTEC WINCH - LEFT SIDE

ADDING OIL-LANTEC MODEL 40 WINCH 1. To avoid underfilling the lantec model 40 winch it is necessary to fill first the right side of the winch and then the left side.

2. Remove the auxiliary level plug located on the right side of the winch. Fill the right side of the winch until the oil level reaches the auxiliary level plug. Replace the auxiliary level plug.

•

3. Remove the main filler/breather plug, the top plug on the left side of the winch. Fill the left side of the winch until the oil level reaches the oil level sight glass. Replace the main filler/ breather plug.

AUXILIARY LEVEL PLUG

348-23

3.26

LANTEC WINCH - RIGHT SIDE

Tigercat 635 Skidder

Lubrication and Maintenance

CENTER JOINT MAINTENANCE OF CENTER JOINT Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint grease fittings to purge the pivot bearings of debris and water. Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint pivot for looseness every 48 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

1. Have operator lift the dozer blade off the ground and then rapidly raise and lower blade several times to "bounce" machine.

2. As machine bounces, check for motion between the front and rear chassis frame lugs. Also check for a "clunking" sound at the center joint area.

3. Movement between front and rear chassis lugs or clunking of the pivot indicates a loose joint and preload must be checked.

Refer SECTION 11 of the SERVICE MANUAL for more information.

REAR CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

DIG-003

FRONT CHASSIS

CENTER JOINT PRE-LOAD CHECK

3.27

Tigercat 635 Skidder

Lubrication and Maintenance

REAR (BOGIE) AXLE

DIFFERENTIAL (1 FILLING POINT)

The bogie axle has 7 separate oil reservoirs.

Each reservoir must be filled separately to get the proper level of lubrication in the bogie axle.

Note: The volume of oil required for the differential case has been increased from the previously recommended level. Checking the increased fill level requires the installation of a dipstick kit per PSB 1373. Refer to SERVICE AND LUBRICATION POINTS CHART in THIS SECTION for correct volume.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

1. Remove the DIPSTICK from the TOP BREATHER PORT.

DRAINING AND REFILLING BOGIE AXLE •

Park the machine on level ground.

•

Stop the engine and place the parking brake in the ON position.

•

The bogie axle must be level in order to drain and refill it properly.

•

Note that it will be necessary to reposition the wheel hubs when draining and refilling the planetary drives.

•

The oil must be warm before draining and refilling.

•

Clean around all fill, level and drain plugs before removing them.

2. Remove the DIFFERENTIAL DRAIN PLUG and drain the oil into a suitable container for disposal.

3. Clean any filings from the magnet on the oil drain plug.

4. Re-install the DIFFERENTIAL DRAIN PLUG. 5. Refill the differential with new oil until the level reaches the first flat section at the end of the DIPSTICK. Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

6. Re-install the DIPSTICK in the TOP BREATHER PORT.

DIFFERENTIAL DRAIN PLUG (1 PLACE)

BOGIE HOUSING LEVEL PLUG (4 PLACES)

•

TOP BREATHER PORT (DIPSTICK 1 PLACE)

•

•

•

•• BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

• •

BM041

BOGIE HOUSING FILL PLUG (2 PLACES)

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

3.28

•

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

Tigercat 635 Skidder

Lubrication and Maintenance

PLANETARY DRIVES (4 FILLING POINTS)

19. Clean any fillings from the four drain plugs.

7. Position the wheel hub for draining the planetary, with the drain plug in the lowest possible position as shown.

20. Re-install the four drain plugs.

21. Remove the BOGIE HOUSING LEVEL PLUGS (2 per housing).

8. Remove the PLANETARY FILL PLUG.

22. Refill the housing through the BOGIE HOUSING FILL PLUG, using first the reusable portion of the oil drained from the bogie housing and then new oil, until the oil level reaches the bottom of the BOGIE HOUSING OIL FILL PLUG.

9. Remove the PLANETARY DRAIN/LEVEL PLUG and drain the oil into a suitable container for disposal.

10. Reposition the wheel hub for filling the planetary, with the PLANETARY DRAIN/ LEVEL PLUG at 9 o’clock and the fill plug at 1 o’clock as shown.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

11. Refill the planetary with new oil until the level reaches the bottom of the PLANETARY DRAIN/LEVEL PLUG. (Note: To get a correct filling level the wheel hub must be in the planetary fill position as shown.)

23. Re-install the BOGIE HOUSING FILL PLUG and BOGIE HOUSING LEVEL PLUGS. 24. Repeat steps 12 to 23 for the second bogie housing.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

AFTER DRAINING AND REFILLING 25. Check all drain, fill and level plugs for leaks.

12. Repeat steps 7 to 11 for each of the four planetary drives.

BOGIE HOUSINGS (2 FILLING POINTS) 13. Note that the bogie housing must be level to drain and refill it properly.

14. Before draining the oil from the bogie housings, the axle should sit for at least 30 minutes so that contaminants in the oil can settle in the oil pan.

15. Remove the BOGIE HOUSING FILL PLUG. 16. A portion of the oil drained from the housing can be reused. To drain the reusable oil remove the BOGIE HOUSING DRAIN PLUGS (2 per housing – upper plugs) and drain the oil into a clean container, as this part of the oil can be reused.

17. Set aside the reusable oil.

18. The remaining oil is contaminated and must be discarded. To drain the contaminated oil remove the BOGIE HOUSING CONTAMINATED OIL DRAIN PLUGS (2 per housing – lower plugs) and drain the remaining oil into a second container for disposal.

3.29

Tigercat 635 Skidder

Lubrication and Maintenance

STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE This procedure should be followed: •

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.

•

Loosen plug on the outside of the main pump.

•

PRE-STARTUP AND FILLING LOOSEN PLUG OUTSIDE OF MAIN PUMP

1. Ensure all filters are in place.

Pre-fill only the new hydraulic oil double element filters.

Do not pre-fill the new charge pressure filters.

Refer to FILTERS in THIS SECTION. 2. Check oil levels in the engine, the pump drive gearbox and the transmission.

630-D30

•

Loosen plugs on both motors.

3. Check coolant level in the radiator.

LOOSEN PLUGS ON BOTH MOTORS

4. Do a final inspection of all fittings and clamps to make sure they are tight and will not leak.

••

5. Install the articulation lock bar and apply the parking brake.

6. Turn both differential lock switches to OFF. 7. Do not start engine. Purge air from hydraulic system by adding oil as follows: •

•

•

Prepare the hand fill pump on the machine to add hydraulic oil. Clean the fill line pipe, remove cap on end of pipe and insert pipe into oil supply drum.

Pre-fill the cases of the hydrostatic pump and any other components that have been drained of oil.

•

630-D31

•

Loosen plug in port 'N' on top of fan pump.

'N' PORT PLUG

Loosen plug on the top center of hydrostatic drive pump servo

••

LOOSEN PLUG ON TOP CENTER OF HYDROSTATIC DRIVE PUMP SERVO

•

SOME HOSES REMOVED FOR CLARITY 333-7

630-D35

3.30

FAN DRIVE PUMP

Tigercat 635 Skidder

Lubrication and Maintenance

•

Operate the hand fill pump at medium speed, using a steady motion.

•

Watch for oil leaking from each plug previously loosened and tighten each plug when oil leaks out.

•

Continue pumping slowly and watch the oil sight gauge on the reservoir. Continue pumping slowly until the hydraulic tank is full.

NOTE: If the axles were drained of oil, refer to FILLING THE AXLES in SECTION 8 of THE SERVICE MANUAL

11. Top up the radiator with clean coolant. With cylinders fully retracted, top up the hydraulic oil reservoir with clean hydraulic oil.

NOTE: If the machine was on wheels, the steer and drive functions were not properly purged or flushed. Remove the articulation lock bar and at LOW IDLE, slowly operate the steer function right and left a few times. With the parking brake released and at LOW IDLE, slowly operate the drive function forward and reverse a few times.

NOTE: If possible, allow the machine to stand for 4 to 6 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.

MACHINE STARTUP Before beginning this procedure, perform the PRE-STARTUP AND FILLING steps.

1. Ensure the articulation lock bar is installed.

CAUTION Machine operator must ONLY take directions from the person doing the set-up.

2. Disconnect red and white wires on injector pump solenoid (prevents engine starting).

3. Crank engine for 10 seconds, wait for 10 seconds. Repeat 6 times to pump oil into pumps.

4. Reconnect wires on injector pump solenoid.

Do not start engine.

5. Install a 0-1000 psi. gauge on drive pump to check charge pressure at ‘G’ ( TEE fitting).

Watch gauge closely during startup.

6. Start engine. If charge pressure does not rise within 5 to 10 seconds, TURN ENGINE OFF. If charge pressure is between 260 and 450 psi., run engine at IDLE for 20 minutes.

Check engine oil pressure in cab. Do not operate any functions. Remove gauge from 'G'.

7. With engine at IDLE, parking brake ON, hold foot brake down, bleed brakes in front axle.

8. Turn both differential locks ON and run engine at IDLE for 30 minutes to purge air and fill axles with oil (axles fill with leakage from diff. locks). If wheels have been removed, operate forward and reverse pedals very slowly to fill axles with oil.

9. Set throttle to IDLE and run each function for 2 minutes to purge air from circuit.

10. Set throttle to FULL and run each function again for 2 minutes to flush circuit.

3.31

Tigercat 635 Skidder

Lubrication and Maintenance

REPLACING THE ENGINE SERPENTINE BELT A/C COMPRESSOR BELT

In order to replace the engine serpentine belt it is necessary to disassemble the fan drive pump coupling.

BELT GUARD BOLT LOCATIONS

••

•

1. Park the machine on level ground. Parking brake ON, grapple and dozer down and engine off.

2. Remove the belt guard (4 bolts).

3. Remove the A/C compressor belt.

•

•

4. Remove the fasteners that hold the pump drive coupler together (8 bolts - 1/4"). Note the engine will have to be 'jogged' to access all of the bolts.

•

5. Carefully slide the black rubber section of the coupler towards the fan pump. This will provide enough clearance to replace the serpentine belt.

•

SERPENTINE BELT

•

COUPLER

6. Replace the serpentine belt. Ensure that all of the ribs on the serpentine belt align with the grooves on the engine pulleys.

••

FAN DRIVE PUMP

7. Reassemble the pump drive coupler, using the original bolts. Use loctite 242 (temporary) or equivalent. Torque all bolts to 8-10 lbf-ft using an opposing torque pattern.

SHOWN WITH FAN AND SOME HOSES REMOVED FOR CLARITY

8. Reinstall, align and tension the A/C compressor belt.

314-24

BELT GUARD

9. Reinstall the belt guard.

CAUTION Always install belt guard before running the engine.

FAN DRIVE PUMP BOLTS

COUPLER

• •• •

•

COUPLER 1/4" BOLTS

SHOWN WITH FAN AND SOME HOSES REMOVED FOR CLARITY

314-12

3.32

FAN DRIVE PUMP BOLT LOCATIONS

Tigercat 635 Skidder

Lubrication and Maintenance

SPEED CONTROL LEVER ADJUSTMENT The friction setting on the speed control lever is variable and can be adjusted to allow proper operation.

SPEED CONTROL LEVER

CONTROL PANEL

••

The friction setting on the speed control lever may reduce over time, during normal operation, and not maintain the set position of the lever, especially at maximum throw.

•

••

PROCEDURE Before starting work, read and follow all servicing safety precautions in SECTION 1 of THIS MANUAL.

PROTECTIVE RUBBER 'BOOT'

630-D36

1. Park machine on level ground, apply park brake, lower dozer blade and grapple to ground, shut off engine.

2. Position the speed control lever in the neutral position (pointing straight up).

3. Raise the protective rubber ‘boot’ from the speed control valve body, located on the side instrument panel.

4. Locate the adjustable friction set screw.

5. Tighten the adjustable friction set screw as required (2.5mm hex key) 6. Replace the protective rubber ‘boot’ over the speed control valve body.

SPEED CONTROL LEVER

•• PROTECTIVE RUBBER BOOT

RIGHT HAND SIDE OF MACHINE

• ADJUSTABLE FRICTION SET SCREW

• •

630B-31

CONTROL PANEL

SPEED CONTROL LEVER FRICTION SET SCREW LOCATION 3.33

SPEED CONTROL LEVER

Tigercat 635 Skidder

Lubrication and Maintenance

TORQUE CHART LOCATION Cylinders Pin bolts Piston nut, steer cylinder Piston nut, arc/boom cylinder Piston nut, dozer cylinder Gland, steer cylinder Keeper plate bolts Keeper plate bolts

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

3/4" UNC 1 3/8" UNF 1 3/4" UNF 1 3/8" UNF 3/4" UNC 5/8" UNC

282-310 1100 1750 1260 550 282-310 159-175

393-420 1491 2372 1708 745 393-420 216-237

Cab pin keeper plate bolts

3/4" UNC

282-310

393-420

Center joint bearing Bearing retaining bolts Pin retaining bolts

1/2" UNC 3/4" UNC

80-88 282-310

109-119 393-420

Engine mounting Bolts Bolts, brkt. to bell hsg.

7/8" UNC M12

450 80

610 108

Pump drive gearbox Drive plate to flywheel Bell housing to engine Engine mounting bracket

3/8" UNC 10 x 1.5 5/8" UNC

33-36 32 159-175

45-49 43 216-237

1 1/4" x 18 UNEF 3/4" UNC

475-525 282-310

640-711 393-420

1/2" UNF

120-132

163-179

1/2" UNF

120-132

163-179

1/2" UNF

120-132

163-179

3/4" UNC 1" UNC M27

300 682-750 1000

406 925-1016 1350

Wheel bolts

7/8" UNF

501-550

679-745

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

5/8"UNC 7/8" UNC

159-175 450

216-237 610

Drive shafts Yoke retaining nut, rear shaft Pillow block retaining bolts Rear drive shaft assembly universal joint bolts Mid. drive shaft universal joint bolts Front drive shaft universal joint bolts Axle mounting bolts Front Axle Rear (Bogie) Axle

REV0 11/2000

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

3.34

Tigercat 635 Skidder

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 COARSE THREADS 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 THREADS 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

DRY LUBRICATED lbf-ft Nm lbf-ft Nm 11 - 12 15 - 16 8 - 10 11 - 13 20 - 28 27 - 38 26 - 30 35 - 40 44 -48 60 - 65 33 - 36 45 - 49 70 - 77 95 - 104 52 - 57 71 - 77 106 - 117 144 - 158 80 - 88 109 - 119 153 - 168 208 - 228 115 - 127 156 - 172 212 - 233 288 - 316 159 - 175 216 - 237 376 - 414 510 - 561 282 - 310 393 - 420 606 - 667 822 - 904 455 - 501 617 - 679 909 - 1000 1233 - 1355 682 - 750 925 - 1016 1288 - 1417 1746 - 1921 966 - 1062 1310 - 1441 1817 - 1999 2464 - 2710 1360 - 1496 1844 - 2027 DRY LUBRICATED lbf-ft Nm lbf-ft Nm 13 - 14 18 - 19 10 - 13 14 - 17 23 - 28 31 - 38 18 - 25 25 - 33 49 - 54 67 - 73 37 - 41 50 - 55 78 - 86 106 - 116 58 - 64 79 - 86 120 - 132 163 - 179 90 - 99 122 - 134 171 - 188 232 - 255 128 - 141 174 - 191 240 - 264 326 - 358 180 - 198 244 - 268 420 - 462 570 - 626 315 - 347 427 - 470 668 - 735 906 - 996 501 - 550 679 - 745 995 - 1096 1359 - 1486 746 - 821 1012 - 1113 1445 - 1590 1960 - 2155 1083 - 1191 1469 - 1613 2012 - 2213 2728 - 2997 1509 - 1660 2046 - 2250

COARSE DRY THREADS lbf-ft Nm 1/4" - 20 7- 8 10 - 11 5/16" - 18 14 - 18 19 - 24 3/8" - 16 31 - 34 42 - 46 7/16" - 14 49 - 54 66 - 73 1/2" - 13 75 - 83 102 - 112 9/16" - 12 109 - 120 148 - 162 5/8" - 11 150 - 165 204 - 223 3/4" - 10 266 - 293 360 - 397 7/8" - 9 394 - 433 535 - 586 1" - 8 591 - 649 802 - 879 1 1/8" - 7 794 - 873 1077 - 1183 1 1/4" - 7 1120 - 1232 1519 - 1670 FINE DRY THREADS lbf-ft Nm 1/4" - 28 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 3/8" - 24 35 - 39 48 - 53 7/16" - 20 55 - 61 75 - 83 1/2" - 20 85 - 94 116 - 127 9/16" - 18 121 - 133 164 - 180 5/8" - 18 170 - 187 231 - 253 3/4" - 16 297 - 327 403 - 443 7/8" - 14 434 - 477 589 - 646 1" - 12 646 - 711 876 - 965 1 1/8" - 12 891 - 980 1208 - 1328 1 1/4" - 12 1240 - 1364 1682 - 1849

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 10 - 15 13 - 20 23 - 25 31 - 34 37 - 41 50 - 55 57 - 63 77 - 85 82 - 90 111 - 122 113 - 124 152 - 168 200 - 220 271 - 298 296 - 326 402 - 441 443 - 489 601 - 663 596 - 656 808 - 889 840 - 924 1139 - 1252 LUBRICATED lbf-ft Nm 9 - 10 12 - 13 16 - 20 21 - 27 26 - 29 35 - 39 41 - 45 56 - 61 64 - 70 87 - 95 91 - 100 124 - 135 128 - 141 174 - 191 223 - 245 303 - 332 326 - 359 442 - 486 484 - 534 657 - 724 668 - 735 906 - 996 931 - 1024 1262 - 1387

METRIC

SIZE

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

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

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

3.35

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

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

Tigercat 635 Skidder

Lubrication and Maintenance

3.36