Tigercat 635D SKIDDER OPERATOR’S MANUAL SN 6351001 TO 6351500 - PDF DOWNLOAD

635D SKIDDER

OPERATOR’S MANUAL SERIAL NUMBER 6351001 TO 6351500

ISSUE 4.1 NOVEMBER 2013 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat 635D Skidder

Introduction

Tigercat 635D SKIDDER TABLE OF CONTENTS

SECTION INTRODUCTION.....................................................................................................................................v SAFETY...................................................................................................................................................1 CONTROLS AND OPERATION..............................................................................................................2 LUBRICATION AND MAINTENANCE.....................................................................................................3

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

635D Available Literature Operator's Manual, English (This Manual)............................................Part No. 33283A Service Manual, English........................................................................Part No. 33284A Parts Catalog, English...........................................................................Part No. 33672A Vehicle Moving and Transporting Instructions, Multilingual...................Part No. 33545A

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Tigercat 635D Skidder

Introduction

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Tigercat 635D Skidder

Introduction

Tigercat 635D 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 635D Skidder.

Serial numbers:635D

6351001 to 6351500.

The 635D Skidder is designed for skidding trees in selective felling and clear felling applications in plantations and natural stands.

The operator's manual will assist the operator with the techniques of proper and safe operation of the 635D Skidder. The service manual contains safety and servicing procedures and a preventive maintenance schedule to assist in repair and to ensure optimum machine performance. For manual part numbers, see the title page in each manual.

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

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.

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Tigercat 635D 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.

PROTECTIVE STRUCTURES CERTIFICATION

Tigercat Industries Inc.

FOR USE ON ALL Tigercat 600 SERIES MACHINES THIS OPERATOR ENCLOSURE MEETS THE FOLLOWING PROTECTIVE STRUCTURE STANDARDS: ISO 8082:2003 (Roll Over) Maximum Machine Mass 23 360kg / 51,500lb ISO 8083:2006 (Falling Object) Drop Energy Level: 11,600J ISO 8084:2003 (Operator) TO MAINTAIN OPERATOR PROTECTION AND PROTECTIVE STRUCTURES CERTIFICATION • All damaged protective structures must be replaced, not repaired.

• Any alterations must be approved by manufacturer.

MANUFACTURED BY

Tigercat Industries Inc. Brantford, Ontario, Canada 30590AUNI R1

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Tigercat 635D 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.

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Tigercat 635D Skidder

Introduction

viii

Tigercat 635D Skidder SECTION 1 - SAFETY

AUGUST 2013

Read and understand this Safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 ARTICULATION LOCK................................................................................................... 1.30 BATTERY DISCONNECT SWITCH............................................................................... 1.10 BATTERY SAFETY.......................................................................................................... 1.8 CAB EXITS....................................................................................................................... 1.9 CAB SAFETY CABLE.................................................................................................... 1.14 CAB SUPPORT BRACE................................................................................................ 1.14 COOLING SYSTEM....................................................................................................... 1.13 EMERGENCY CAB EXITS............................................................................................... 1.9 EXHAUST FUMES......................................................................................................... 1.16 FIRE PREVENTION....................................................................................................... 1.22 DRY CHEMICAL CLEANUP PROCEDURES............................................................. 1.26 FIRE PREVENTION GUIDELINES............................................................................. 1.22 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED..................................... 1.25 WHAT TO DO TO PREPARE FOR A MACHINE FIRE............................................... 1.23 WHAT TO DO WHEN A MACHINE FIRE OCCURS................................................... 1.24 FIRST AID........................................................................................................................ 1.6 FLUID INJECTION INJURY........................................................................................... 1.17 FLUID LEAKS................................................................................................................ 1.13 GREASE INJECTION INJURY....................................................................................... 1.18 HYDRAULIC PRESSURE HAZARD.............................................................................. 1.13 LIGHTNING SAFETY AWARENESS............................................................................. 1.19 LOOSE CLOTHING HAZARD........................................................................................ 1.14 NOISE LEVEL INSIDE CAB............................................................................................. 1.3 PARKING THE MACHINE.............................................................................................. 1.10 PROTECTIVE CLOTHING............................................................................................... 1.4 SAFETY LABELS........................................................................................................... 1.27 SAFETY PRECAUTIONS, GENERAL............................................................................. 1.4 SAFETY PRECAUTIONS, OPERATING.......................................................................... 1.9 SAFETY PRECAUTIONS, SERVICING......................................................................... 1.12 SAFETY SYMBOLS......................................................................................................... 1.4 SIGNAL WORDS.............................................................................................................. 1.4 VIBRATION LEVELS INSIDE CAB.................................................................................. 1.3 WELDING, PRIOR TO................................................................................................... 1.12 WORKING WITH OIL....................................................................................................... 1.6

Tigercat 635D Skidder

Safety

1.2

Tigercat 635D Skidder

Safety

VIBRATION AND NOISE LEVEL INSIDE CAB

Noise Level Inside Cab dB (mean)

As per Tigercat test ETR00131 Microphone direction: Left Right Driving max speed 83 82 Driving low speed 76 75

Vibration Level - Whole-body

As per Tigercat test ETR00074 & ISO 2631-1:1997(E) Weighted rms acceleration (m/s2) SeatSeat-buttocks Health Comfort back Driving max speed (Highest motor speed) 0.2590 x-axis (back-to-chest) 0.5990 0.2510 y-axis (right-to-left) 0.3070 0.4280 z-axis (buttocks-to-head) 0.3320  0.6610 0.5597 0.3880 Wear suitable hearing protective device such as Driving max speed (Lowest motor speed) earmuffs or earplugs to protect against noise.

0.1050 x-axis (back-to-chest) 0.2280 Prolonged exposure to loud noise can cause 0.1110 y-axis (right-to-left) 0.1090 permanent hearing loss. This machine exceeds 0.2480 z-axis (buttocks-to-head) 0.1170 70dB(A) in the cab and exceeds 85dB(A) when  0.3270 0.2913 0.1420 Noise Level Inside Cab dB (mean) servicing machine engine.

Arch/Boom/Grapple Operation As per Tigercat test ETR00131 0.1070 x-axis (back-to-chest) 0.2240 Microphone direction: Check with your local Safety Left Commission Right0.0912to y-axis (right-to-left) 0.1190 Driving max speed 83 82 determine if hearing protection is required 0.2290at these z-axis (buttocks-to-head) 0.1480 Driving low speed 76 75 levels.  0.3010 0.2687 0.1600

Vibration Level - Whole-body

Vibration Level - Hand/Arm

As per Tigercat test ETR00074 & ISO 2631-1:1997(E) Weighted rms acceleration (m/s2) 2 Weighted rms acceleration (m/s Seat-) PedalSeat-buttocks Health Comfort back foot Seat Control Steering Driving max speed (Highest motor speed)Joystick Panel Wheel 0.2590 x-axis (back-to-chest) 0.5990 0.2660 Driving max speed0.2510 (Highest motor speed) 0.2730 y-axis (right-to-left) 0.3070  0.4280 1.170 0.758 0.355 z-axis (buttocks-to-head) 0.3320 0.4520  0.5597 motor 0.3880 Driving max 0.6610 speed (Lowest speed) 0.2040 Driving max speed (Lowest motor speed)  0.313 0.241 0.608 0.1050 x-axis (back-to-chest) 0.2280 0.0682 Arch/Boom/Grapple Operation 0.1110 y-axis (right-to-left) 0.1090 0.0864  0.2480 0.478 0.189 1.060 z-axis (buttocks-to-head) 0.1170 0.2280  0.3270 0.2913 0.1420 0.0950 Arch/Boom/Grapple Operation 0.1070 x-axis (back-to-chest) 0.2240 0.1630 0.0912 y-axis (right-to-left) 0.1190 0.1210 0.2290 z-axis (buttocks-to-head) 0.1480 0.2060  0.3010 0.2687 0.1600 0.0966

Vibration Level - Hand/Arm

Weighted rms acceleration (m/s2) Seat Control Joystick Panel Driving max speed (Highest motor speed)  1.170 0.758 Driving max speed (Lowest motor speed)  0.313 0.241 Arch/Boom/Grapple Operation  0.478 0.189

Steering Wheel 0.355 0.608 1.060

1.3

Pedalfoot 0.2660 0.2730 0.4520 0.2040 0.0682 0.0864 0.2280 0.0950 0.1630 0.1210 0.2060 0.0966

Tigercat 635D Skidder

Safety

GENERAL SAFETY PRECAUTIONS

SAFETY SYMBOLS

Remember that safety is a prime responsibility of all.

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

This safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

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.

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

Understanding Signal Words

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

Follow all instructions from safety inspector and supervisors.

WARNING

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.

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

Do not let an untrained person operate the machine.

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

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

1.4

Tigercat 635D Skidder

Safety

GENERAL SAFETY PRECAUTIONS continued

WARNING

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 good condition. Repair or replace damaged labels.

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

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

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

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

Prolonged exposure to loud noise can cause permanent hearing loss.

Always use the handrails and steps provided when mounting and dismounting from the machine.

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

No attempt should be made to walk on angled steel surfaces or surfaces that are irregular in shape.

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

Do not jump off the machine at any time.

These anti-slip surfaces should be maintained on a regular basis. If the surface shows signs of wear, the anti-slip material must be replaced immediately.

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

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

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

1.5

Tigercat 635D Skidder

Safety Check all fluid levels.

GENERAL SAFETY PRECAUTIONS continued

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

To reduce the risk of fire, 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, always shut off engine before cleaning machine.

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.

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

Machine should be washed completely at every major service.

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

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

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.

Working with oil Direct contact with oil implies a risk of skin complaints (example: eczema). Strict hygiene should always be observed.

Check window and door guards for damage.

Check protective windows for cracks, a damaged window has reduced strength to stop flying objects. All damaged windows must be replaced with original equipment.

Some advice which should be observed: •

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.

•

• • • • • •

Oils used in this machine may be hot enough to cause serious burns.

Avoid contact with oil, particularly heated oil.

Oil on the skin should be washed off immediately with soap and water.

Wear protective gloves. Hands should be clean before putting on gloves. Apply protective cream to the hands to make washing easier.

Don't put oily rags in your pockets.

Oil soiled clothing should be changes as soon as possible.

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

Cuts and abrasions must be attended to immediately. Clean them and apply first-aid.

Avoid breathing in oil fumes.

Wash hands and arms frequently (example: at each meal break or as often as possible).

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).

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

1.6

Tigercat 635D Skidder

Safety 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.

GENERAL SAFETY PRECAUTIONS continued The following procedures are recommended when inspecting equipment that has been subjected to high temperatures such as fire: •

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).

•

If the machine must be transported, make sure that it is adequately secured to the transporting vehicle. Refer to TRANSPORTING INSTRUCTIONS in SECTION 2 of the OPERATOR'S MANUAL. Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components.

Reduce engine speed to LOW IDLE and let run for approximately 5 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.

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.

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

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

Be aware when performing service and maintenance tasks that surfaces and grab handles in and around the engine and cooling system may become very hot when the engine has been running. Contact with hot surfaces may cause injury.

Safety Hazards - Operating 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.

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

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.

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

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.

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.

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.

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.

Do not move any part of the machine or load within 10 feet (3m) plus 2 times line insulator length of any electric lines.

1.7

Tigercat 635D Skidder

Safety

GENERAL SAFETY PRECAUTIONS continued

Avoid Injury from Backover Accidents Before moving machine, be sure all persons are clear of the area.

WARNING

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

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

Wash hands after handling.

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

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

To avoid backover accidents:

Do not attempt to charge a frozen battery; it can explode.

•

•

Disconnect battery before working on electrical systems. Remove ground terminal first when disconnecting. Connect ground terminal last when reconnecting.

•

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

• •

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

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

•

1.8

Always look around before you back up. Be sure that everyone is clear.

Keep reverse warning alarm in working condition. The reverse warning alarm must sound when the machine is moving in reverse.

Use a signal person when backing up if view is obstructed. Always keep the signal person in view.

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

Keep windows, mirrors and lights in good condition.

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

Tigercat 635D Skidder

Safety CAB EXITS

OPERATING SAFETY PRECAUTIONS

There are three ways to exit the cab in case of an emergency.

1. Left hand cab door, one of the two main points of entry.

2. Right hand cab door, one of the two main points of entry.

3. Sliding windows in the cab doors, this is a third cab exit for use if the cab doors become blocked.

It is important that the operator of the machine be familiar with these emergency exits and how to use them.

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

All three exits should be checked to make sure that they are operational and will function in an emergency.

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

IMPORTANT !

Unlock both doors before operating machine to allow opening from the outside in case of an emergency. Make sure that the doors are operational, open the doors twice, once using the exterior handle and once using the interior latch handle.

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

Sound the machine horn before starting the machine.

The operator's seat is equipped with a lap belt. Use this restraint system at all times when operating the machine.

For additional information, refer to EMERGENCY EXITS in SECTION 3 of the OPERATOR'S MANUAL. Secure loose items in cab.

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.

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

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

Never use a liquid staring aid to start an engine.

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

1.9

Tigercat 635D Skidder

Safety When parking the machine:

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

WARNING

•

Park on level ground ONLY and engage parking brake

•

Do not park on a hillside or incline.

•

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

•

Stop the engine and release pilot system pressure by performing the following steps: 1. Fully apply brake foot pedal 25 times or more to relieve pressure from the brake accumulator.

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

2. Turn ignition switch to the RUN position and operate the differential locks on/off switch on the right hand joystick 10 times or more to relieve pressure from the pilot accumulator. Turn ignition switch OFF.

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

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

Use caution when loosening hydraulic connections.

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

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

Keep the parking brake properly adjusted at all times.

Keep service brakes properly adjusted and check for proper operation of the service brake. Refer to SERVICE BRAKE ~ CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3 of THIS MANUAL. Always rest the grapple and dozer blade on the ground when operation is stopped, regardless if the engine is running or shut off.

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

E625C-111

•

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.

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

WARNING

Do not leave the operator's cab while the winch line is under tension.

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

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

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 out of the operator’s cab for an extended period shut the machine off.

1.10

Tigercat 635D Skidder

Safety

OPERATING SAFETY PRECAUTIONS continued

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.

WARNING

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

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.

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.

Use only prearranged and approved signalling practices.

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

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.

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.

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

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

Read, understand and follow all general safety precautions specified by winch manufacturer and in this manual.

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

NEVER travel across a STEEP slope or side hill: • • • • • • •

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. Refer to also to TIRE PRESSURES in SECTION 3 of THIS MANUAL.

When operating the winch do not work with a damaged cable. Broken wire or strands, or a decrease in the diameter of a cable are warning signs of a damaged cable. Do not anchor a double or two part line to the winch.

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.

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

1.11

Tigercat 635D Skidder

Safety 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.

SERVICING SAFETY PRECAUTIONS

Care must be taken in attaching the welding machine grounding clamp so current does not pass through bearings, especially the centre joint bearing.

Also, turn off the battery disconnect switch and disconnect the positive (+) battery cable from both batteries.

This machine is equipped with sensitive electronic control equipment, prior to welding:-

IMPORTANT

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

24 VOLT

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

ELECTRICAL SYSTEM

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

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE CPU

DISCONNECT 4 PIN ENGINE POWER CONNECTOR

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

620C-81

ENGINE CPU DISCONNECT -LEFT SIDE OF ENGINE

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

This machine may be equipped with an optional variable pitch cooling fan, fan blade pitch is hydraulically varied to control the flow and direction of air through the cooling assembly.

Exercise care when working in this area with the engine running. If the FAN CONTROL SWITCH is in the AUTOMATIC position, the fan could go into CLEAN mode at any time when the engine is running.

DISCONNECT ENGINE GROUND CONNECTION

620C-90

ENGINE GROUND DISCONNECT - RIGHT SIDE OF ENGINE

Disconnect the engine CPU (Central Processing Unit) by unplugging the four pin engine power connector and the two multipin connectors from the left side of the engine.

Always ensure that the fan guard is in place when the engine is running.

Also disconnect the engine ground connection at the chassis.

1.12

Tigercat 635D Skidder

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING

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.

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

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

•

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

•

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

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 the brake accumulator and pilot accumulator (if equipped) before performing work on components, or disconnecting any hoses. For the procedure to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

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

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.

1.13

Tigercat 635D Skidder

Safety

SERVICING SAFETY PRECAUTIONS continued

SAFETY CABLE

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

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

E620C-16

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.

SUPPORT BRACE

E620C-17

WARNING

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE

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. Refer to TILTING THE CAB in SECTION 3 of THIS MANUAL for complete instructions.

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.

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

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

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

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.

1.14

Tigercat 635D Skidder

Safety BOLT ON ACCESS PANELS

SERVICING SAFETY PRECAUTIONS continued

MAINTENANCE ACCESS DOORS

630D-03

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION 620D-210

630D-01

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

ACCESS PANELS RIGHT SIDE

DOOR PROP

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

620D-207

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

MAINTENANCE ACCESS DOOR (RIGHT SIDE SHOWN)

CAUTION Always use the door props provided to safely hold access doors open while in use.

The engine compartment access panels are bolted in place. Whenever bolts are removed panels can fall during the process of removing them from the machine.

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

All handles should be hand tight only at all times.

This is particularly important for easy access to the pressurized water system in the event of a fire or other emergency. Refer also to FIRE PREVENTION in THIS SECTION. 1.15

Tigercat 635D 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.

1.16

Tigercat 635D Skidder

Safety

SERVICING SAFETY PRECAUTIONS continued

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

FLUID INJECTION INJURY Hydraulic and diesel fuel systems on forestry machines operate at very high pressures, often 207 bar (3000 psi) and above. If a loose connection or a defect in a hose should occur, a fine, high velocity stream of fluid will result. Even for systems pressurized to as little as 7 bar (100 psi), this fluid stream can penetrate human skin as if it were a hypodermic needle.

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

• Seek professional medical attention immediately.

As always the best defence against suffering the effects of fluid injection is to prevent the accident from occurring in the first place.

When searching for possible fluid leaks • Never search for leaks with your bare hands.

Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

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

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation.

There is a danger that you will tend to ignore this, thinking that it will get better with time. Most often, it does not! Within a very short time the wound may begin to throb painfully, indicating that tissue damage has already begun.

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

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

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

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

1.17

•

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

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

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

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

• Never grab any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

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

• Never use any hoses that you suspect could be defective.

Tigercat 635D Skidder

Safety

SERVICING SAFETY PRECAUTIONS continued GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS Pneumatic grease guns can deliver grease at pressures from 17 - 400 Bar (246 - 5801 psi).

It takes less than 7 Bar (100 psi) to inject a substance through human skin.

ALWAYS get professional medical treatment immediately after any type of injection injury.

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

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

Prior to using a high pressure pneumatic grease gun perform the following: •

All operators of high pressure pneumatic grease guns MUST be trained in the hazards of its operations and the treatment for such injuries.

•

DO NOT OPERATE a high pressure pneumatic grease gun unless you have been trained in the proper operation and are aware of all safety precautions of such a tool.

•

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

•

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

•

Ensure that protective shrouds are installed on all grease gun nozzles as safety devices.

•

Remove dirt and grease from grease fittings prior to greasing.

•

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

•

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

1.18

Tigercat 635D Skidder

Safety LIGHTNING SAFETY

LIGHTNING SAFETY AWARENESS

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

Loggers can increase their chances of avoiding a lightning strike by following a few simple safety practices.

1. Designate a member of your crew to

WHAT IS A LIGHTNING STRIKE? Lightning is a discharge of the electricity produced by a thunderstorm. As the thunderstorm develops, many small particles of ice within the storm clouds bump together. These collisions create a positive charge at the top of a cloud and a negative charge at the bottom. As this continues a second positive charge builds up on the ground beneath the cloud, concentrated around high objects such as hills, trees, buildings, equipment and even people.

•

Monitor daily weather forecasts

•

Observe local weather conditions

•

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

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

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

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

4. Obey the rule - If you see lightning, Flee. If you hear thunder, Clear.

5. Do not follow the now obsolete guideline to take shelter when the time between seeing lightning and hearing thunder is 30 seconds or less. This does not provide sufficient time to ensure safety. Always follow step 4.

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

Lightning can hit in the same place, many times and often spreads out over 18 m (60 feet) within the soil around the strike point.

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

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

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

Thunder always accompanies lightning. When lightning occurs, the air through which it travels is instantaneously heated to a temperature more than 28,000°C (50,000°F). The air expands rapidly due to this heating, then quickly contracts as it cools. It is this contracting shock wave that we hear as thunder.

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

1.19

Tigercat 635D Skidder

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

LIGHTNING SAFETY AWARENESS continued

If you can, get inside.

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

2. If inside a building:

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

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

•

Don’t watch the lightning storm from open windows or doorways. Stay in inner rooms.

•

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

3. If inside a motor vehicle or fully enclosed ROPS equipment cab:

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

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

Heavy forestry equipment such as a skidder, loader, feller buncher, forwarder, etc. with a fully enclosed rollover protective structure (ROPS) cab take advantage of the skin effect and are therefore safe in electrical storms.

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

Note that the rubber tires on motor vehicles and heavy equipment do not increase safety from lightning strikes. Lightning has already travelled a great distance through the air to strike the vehicle.

In comparison a few inches of rubber in a tire offers absolutely no additional insulation.

1.20

•

Under no circumstances whatsoever step outside of the vehicle or off the equipment to move to another shelter. Very dangerous electrical pathways to ground may go through you.

•

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

•

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

•

Do not touch any metallic objects referenced to the outside of the vehicle.

Do not touch any door and window handles, control levers, foot pedals, steering wheels, cab interior walls and any other inside to outside metal objects.

•

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

Tigercat 635D Skidder

Safety What to do if you feel your skin tingling, your hair stands on end, light metal objects vibrate or you hear a crackling sound.

LIGHTNING SAFETY AWARENESS continued

1. Lightning is probably about to strike. You only have a few seconds to act.

2. Put your feet together. Crouch down like in a baseball catcher’s position. Hold your head down. Cover your ears to protect them against the noise of the thunder.

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

What to do if a co-worker has been struck by lightning.

If you are caught outside and have no where else to go.

1. The victim does not carry any electrical charge. There is no danger to anyone helping this person. You can touch him or her immediately.

1. Avoid wide-open areas where you project above the surrounding landscape.

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

2. Call your local emergency response telephone number immediately.

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

3. If the victim has no pulse, their heart has stopped or they have stopped breathing, start cardiopulmonary resuscitation (CPR) or mouth –to-mouth resuscitation immediately.

Use a portable defibrillator if one is available.

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

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

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

6. Avoid entering any small enclosures or shelters.

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

To further increase your awareness about lightning safety, see the following web sites.

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

National Weather Service Lightning Safety http://www.lightningsafety.noaa.gov National Lightning Safety Institute http://www.lightningsafety.com

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

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

11. Do not use the telephone except for emergencies.

1.21

Tigercat 635D Skidder

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 to a minimum.

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. 2. Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine.

Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 3. Blow off all forest debris and fine organic material 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 when working in logging conditions where large amounts of combustible forest debris are present.

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

Safety 4. 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.

5. Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage. Check for worn or eroded fuel or hydraulic lines before starting up any equipment.

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

7. Steam clean the engine, hydraulic pumps, transmission, brake, fuel and hydraulic tank compartments and all machine belly pans at least once a month or more frequently when working in logging conditions where large amounts of combustible forest debris are present.

8. Use only nonflammable solutions for cleaning the machine and components.

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

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

11. Park the machine at least 15 METERS (50 feet) away from other equipment at the end of each shift.

12. Never leave the machine parked with boom, arch or blade suspended off the ground.

Should their supporting hydraulic hoses burn through during a fire, pressurized hydraulic oil may be injected into the fire and the boom, arch or blade will fall rapidly to the ground.

1.22

Tigercat 635D Skidder

Safety 17. AFTER transporting (trucking) a machine from one job site to the next, open all doors and access panels and blow off any debris that may have repositioned itself onto the engine and exhaust parts due to wind turbulence caused by the journey.

FIRE PREVENTION continued 13. Turn the battery disconnect switch to OFF at shut down to de-energize all electrical circuits.

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

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

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

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

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO LOG, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY OR PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL. WHAT TO DO TO PREPARE FOR A MACHINE FIRE

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

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

1.23

•

Prevent the fire from happening in the first place by ensuring that all machine systems are frequently inspected and always well maintained.

•

Ensure that any hand held fire extinguishers are charged and in working order. Fire extinguishers require routine care. Follow the manufacturer’s instructions for inspection and maintenance shown on the label of the fire extinguisher and in the extinguisher manufacturer's manual.

•

Ensure that any pressurized water systems on the machine (if applicable) are charged and in working order. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of the OPERATOR’S MANUAL.

•

Ensure that you have the proper fire extinguishers on site. Most fires involving mobile forestry equipment will be Class A or B. Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A. Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics, Class B fires occur with flammable liquids such as diesel fuel, oil and grease and Class C fires apply to energized electrical equipment.

Tigercat 635D Skidder

Safety WHAT TO DO WHEN A MACHINE FIRE OCCURS

FIRE PREVENTION continued •

•

•

•

•

•

•

•

Ensure that the nozzle of any hand held extinguisher and pressurized water system available on the machine and at the work site fits within the fire extinguisher access holes in the doors of the machine.

Ensure that your fire detection system* is in working order. Refer to FIRE DETECTION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL. Ensure that your fire suppression system** is charged and in working order. Refer to FIRE SUPPRESSION SYSTEM in SECTION 2 of the OPERATOR’S MANUAL. Ensure that you are familiar with the recommended procedures for fire contained in the emergency action plan of your company.

Ensure that you follow all national, state / provincial and local regulations dealing with fire fighting in effect in your specific geographic region.

Regulations will vary from region to region but most will usually require that: 1. Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

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

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

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

Ensure that after you have received the training as outlined above, that you know how to use the fire extinguisher, the pressurized water system (if

If operating the machine when a fire occurs: 1. Lower all working attachments to the ground.

2. Shut the engine off.

3. Activate the fire suppression system**.

4. Radio or call for help. Be certain to report a fire immediately.

5. Exit the machine taking fire extinguisher and pressurized water system hose (if applicable) with you.

6. 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.

All fires can be very dangerous and life threatening.

7. Only if you can safely do so, turn OFF the battery disconnect switch.

•

applicable) and the fire suppression system** on your machine. There is not enough time available to read instructions during a fire emergency.

Ensure that all information necessary for you to immediately contact all sources of help (local fire department, etc) in the event of a fire emergency is recorded and readily available at all times.

1.24

Before deciding to fight the fire, be certain that: 1. The fire is small and not rapidly spreading.

2. There is always a clear, safe escape route to your back.

3. You have received training in the use of the available fire extinguishing systems and are confident that you can operate them effectively.

4. If in any doubt about whether or not to fight the fire – DON’T. Instead stand well clear of the fire and wait for help to arrive.

5. Be aware that engine coolant , diesel fuel or hydraulic hoses could fail during a fire. If this happens, hot coolant, fuel or oil could possibly be ignited by the fire.

6. If possible a dry chemical fire extinguisher or

fire suppression system** should be used first to fight a machine fire. Then immediately afterwards use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by any debris or hot machine components in the area. The water will cool the area, reducing the chances of reignition.

Tigercat 635D Skidder

Safety WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED

FIRE PREVENTION continued •

•

1. Ensure that the cause of the fire is determined and all appropriate repairs are completed.

Use the PASS method. This is the most effective use of a fire extinguisher.

•

•

•

•

Before returning the machine to work.

2. Ensure that the fire detection system* or the

Pull the pin at the top of the extinguisher that keeps the handle from being pressed. Break the plastic seal as the pin is pulled.

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

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

fire suppression system** is properly serviced and in working order (if applicable).

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

•

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

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

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

**NOTE: Dry chemical fire suppression systems

are offered by Tigercat as an optional installation on some Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

20229A

• • •

• •

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

Place the nozzle of the fire extinguisher into the appropriate fire extinguisher access hole and discharge the extinguisher.

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

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

Ensure that the machine and all components have cooled down sufficiently after a fire so that reignition does not occur.

Remain with the machine until help arrives.

1.25

Tigercat 635D Skidder FIRE PREVENTION continued

Safety 3. In areas exposed to heat during the fire, the dry chemical powder will melt forming a coating that cakes or crusts on all surfaces.

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

DRY CHEMICAL CLEANUP PROCEDURES Both ABC dry chemical fire extinguishers and fire suppression systems discharge a chemical powder to extinguish the fire. The chemical makeup and the small particle size of the powder as well as the force of the discharge all contribute to the fire fighting capability. These same characteristics also permit the powder to penetrate into and fully cover all components in the vicinity of the discharge.

The caked dry chemical when exposed to moisture is also mildly acidic. Therefore when the break down procedure has been completed, follow this immediately with the neutralizing procedure as described in step 2.

The following are recommendations for the cleanup and neutralizing of areas exposed to dry chemical powder.

Workers performing this work should wear protective clothing, safety goggles and a fine particle dust mask to minimize their personal exposure to the dry chemical powder.

Ensure that all electrical systems have been completely de-energized prior to any cleanup.

1. In areas of the machine that remained cool and dry during the fire, the dry chemical will stay in powder form.

Be certain to clean these areas immediately to prevent any settled residual powder from coming into contact with moisture whether through direct contact or humidity in the air.

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

2. In areas exposed to moisture, the dry chemical powder will combine with water to form a paste that is mildly acidic. Note that all surfaces covered by this dry chemical paste including electrical contacts are vulnerable to corrosive attack.

To neutralize the acidic paste on large surfaces, spray or wash these areas with a mixture of 3 parts hot water to 1 part baking soda. Allow this mixture to stand for several minutes before rinsing with warm water. Wash the area with a mild soap and water solution. Rinse thoroughly with water.

Blow-dry to remove all residual water.

Cleaning of electrical contacts should be done using an electrical contact cleaner that has no flash or fire point and is non-corrosive and nonconductive such as CRC Contact Cleaner 2000.

1.26

Tigercat 635D Skidder

Safety NO RIDERS

SAFETY LABELS SAFETY LABELS CAB LABELS The following safety labels are installed in the cab of the Skidder. These labels are located inside the cab in full view of the operator. All labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

EMERGENCY EXIT HAND TIGHTEN ONLY

The sliding windows in the cab doors can be used as a third cab exit. The screens on the outside of these windows can be released by handles both on the inside and the outside of the cab. All handles should be hand tight only at all times.

This will prevent entrapment during an emergency by providing an exit point through the sliding windows if the cab doors are blocked. Refer also to EMERGENCY CAB EXITS in THIS SECTION.

NO RIDERS INSIDE OR OUTSIDE OF THE MACHINE . Do not carry passengers either in the cab or anywhere else on the machine. The vehicle seating accommodation is for one operator only.

Persons riding on the outside of the machine are subject to hazards such as falling off the machine, crush hazards, thrown object hazards and many other hazards WHICH COULD RESULT IN DEATH OR SERIOUS INJURY. If any person attempts to climb onto the machine during operation, STOP THE MACHINE IMMEDIATELY. Do Not Operate the machine until other personnel are a safe distance away from the machine.

1.27

Tigercat 635D Skidder

Safety READ OPERATOR'S MANUAL

SAFETY LABELS USE SEAT BELT

READ OPERATOR'S MANUAL. Always read the operator’s manual before operating the machine.

Pay close attention to WARNINGS and HAZARD identifications.

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

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

1.28

Tigercat 635D Skidder

Safety REMOVE IGNITION KEY BEFORE SERVICING THE MACHINE!

SAFETY LABELS OPERATOR'S MANUAL LOCATION

This label indicates the storage location of the operator's manual.This labelis located on the outside of the operator's manual case inside the cab.

Prior to performing any service work or maintenance on the machine, stop the engine, REMOVE THE IGNTION KEY and store it in a safe place.

1.29

Tigercat 635D Skidder

Safety ARTICULATION LOCK

SAFETY LABELS EXTERIOR LABELS The following safety labels are installed on the exterior of this machine. These labels are located on the machine in the area where the specific safety concern is applicable. Labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

REAR CHASSIS 630D-02

RETAINING PINS

ARTICULATION LOCK STORED POSITION

CRUSH HAZARD This label warns of the crush zone in the center joint area. This can occur when the machine steering is used. DO NOT WORK IN THIS AREA UNTIL THE ARTICULATION LOCK BAR IS INSTALLED!

630D-03

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

Before working in the center joint area, INSTALL THE CHASSIS ARTICULATION LOCK BAR between the chassis and center joint to prevent accidental articulation which could result in death or serious injury.

Refer to ARTICULATION LOCK in SECTION 3 of THIS MANUAL for complete instructions.

630D-01

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

43304BUNI R0

1.30

Tigercat 635D Skidder

Safety ENTANGLEMENT HAZARD

SAFETY LABELS CRUSH HAZARD

This label warns of the crush zone by a down force when the cab is in the partial tilt position.

DO NOT WORK IN THIS AREA UNTIL THE CAB TILT SUPPORT LOCK IS IN PLACE! Before working under the cab when the cab is in the partial tilt position, be sure the CAB TILT SUPPORT LOCK is in place.

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

Refer to TILTING THE CAB in SECTION 3 of THIS MANUAL for complete instructions.

36779BUNI R0

This label warns of an ENTANGLEMENT HAZARD (rotating parts) zone. The label is located on each side of the engine cooling fan which is near the engine serpintine drive belt.

DO NOT PLACE HANDS OR FINGERS IN THIS AREA. Rotating parts such as pulleys, belts and drives can cause entanglement of body parts resulting in serious injury.

KEEP HANDS AND FINGERS CLEAR OF ROTATING BELT, DRIVE OR PULLEY! Before performing any service work on these parts or in this area, shut engine off and wait for rotating parts to come to a complete stop.

1.31

Tigercat 635D Skidder

Safety DO NOT USE WINCH FOR HOISTING

SAFETY LABELS KEEP CLEAR

43225BUNI R0

This label warns of a crush zone by a down force if the winch is used as a hoist.

43424BUNI R0

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

DO NOT use winch for hoisting.

Always keep clear of an operating machine.

The winch on this machine is intended only for use as a retrieval device.

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

Refer to OPERATING MACHINE ~ OPERATING WINCH and SKIDDING ~ CABLE SKIDDING in SECTION 2 of the OPERATOR'S MANUAL for instructions regading the safe use and proper operation of the winch.

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).

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

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

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

1.32

Tigercat 635D Skidder

Safety STORED ENERGY HAZARD

SAFETY LABELS

WARNING

DO NOT LOOSEN CAP UNTIL COOL

• STORED ENERGY HAZARD • THE ACCUMULATOR HAS 3000 PSI OF STORED ENERGY. SERVICING THE ACCUMLATOR BEFORE RELEASING PRESSURE COULD RESULT IN DEATH OR SERIOUS INJURY. • DO NOT SERVICE THE ACCUMULATOR BEFORE RELEASING PRESSURE BY APPLYING BRAKES 25 TIMES WITH ENGINE OFF. 39945BENG R0

This label warns of a STORED ENERGY HAZARD. This label is located on the right side of the front chassis below the cab.

The machine is equipped with an accumulator (located on the underside of the cab). The accumulator has 207 bar (3000 psi) of stored energy. Servicing the accumulator or any hydraulic components before releasing pressure could result in death or serious injury.

33952AUNI R0

This label warns of a PRESSURE AND FLUID SPRAY HAZARD when the the coolant in the radiator is hot.

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

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

DO NOT SERVICE ACCUMULATOR BEFORE RELEASING PRESSURE by applying brakes 25 times with the engine OFF.

1.33

Tigercat 635D Skidder

Safety EXPLOSION HAZARD

SAFETY LABELS

WARNING

FLUID SPRAY HAZARD

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

This label warns of an EXPLOSION HAZARD. This label is located on the end of the air cleaner (air filter housing). The engine is equipped with a heater starting aid, DO NOT USE ETHER to assist in starting the engine.

This label warns of a FLUID SPRAY HAZARD. This label is located above the pressuized water system fill plug .

USING ETHER COULD CAUSE AN EXPLOSION WHICH COULD RESULT IN DEATH OR SERIOUS INJURY.

The machine is equipped with a pressurized water system. A water tank is incorporated into the dozer blade and is pressurized to 60 psi (4 Bar).

Contact with fluid under pressure may cause injury.

DO NOT SERVICE PRESSURIZED WATER SYSTEM until air pressure is fully released by depressing the water system spray nozzle.

Tank fill plug has a cross drilled vent hole. Do not replace with standard plug.

Refer also to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of THIS MANUAL.

1.34

Tigercat 635D Skidder

Safety

SAFETY LABELS CRUSH HAZARD

HAND TIGHT ONLY - ALL HANDLES This indicates that all handles should be hand tight only at all times.

This label is located on the screen protecting the sliding windows on both cab doors. The sliding windows in the cab doors can be used as a third cab exit. The screens on the outside of these windows can be released by handles both on the inside and the outside of the cab. Refer also to EMERGENCY CAB EXITS in THIS SECTION.

This label warns of a CRUSH HAZARD. This label is located in the rear chassis control valve compartment.

Movement of booms and cylinders could result in death or serious injury.

DO NOT perform work on valves or piping until boom and attachment are lowered to the ground and engine is shut off.

This label also located on the storage compartment on the left side of the dozer blade.

1.35

Tigercat 635D Skidder

Safety PRESSURIZED WATER SYSTEM INSIDE HAND TIGHTEN ONLY

SAFETY LABELS FIRE PREVENTION!

This label indicates the location of the pressurized water system and indicates that the compartment handle should be hand tight only at all times.

This label is located on the outside of the pressurized water system compartment on the right side of the dozer blade.

All handles should be hand tight only at all times.

This is particularly important for easy access to the pressurized water system in the event of a fire or other emergency. Refer also to FIRE PREVENTION in THIS SECTION. READ UNDERSTAND AND FOLLOW THE FIRE PREVENTION GUIDELINES IN THIS MANUAL. These guidelines provide all the necessary action required to preventing fires on this machine. DO NOT OPERATE THIS MACHINE until you have read these instructions and have performed any necessary maintenance required that will prevent the potential of a fire from starting on this machine.

It is also important to note that fire prevention inspections and maintenance MUST BE PERFORMED FREQUENTLY (several times per day). A clean combustible free machine as well as frequent inspections of the exhaust components, hydraulic hoses and electrical cables and performing any necessary repairs immediately will help prevent fires.

Maintain a CHARGED fire extinguisher on the machine at all times, know where it is and KNOW HOW TO USE IT! Refer also to FIRE PREVENTION in THIS SECTION.

1.36

Tigercat 635D Skidder

Safety

SAFETY LABELS FIRE EXTINGUISHER ACCESS HOLE

This label indicates the location of each FIRE EXTINGUISHER ACCESS HOLE. The label is installed on each fire extinguisher hole on the engine hood.

Refer also to FIRE PREVENTION in THIS SECTION.

1.37

Tigercat 635D Skidder

Safety

1.38

Tigercat 635D Skidder SECTION 2 - CONTROLS & OPERATION

NOVEMBER 2013

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 ACCESS PANELS AND DOORS...................................................................2.90 ARTICULATION LOCK..................................................................... 2.121, 2.122 BATTERY DISCONNECT SWITCH...............................................................2.93 CAB CONTROLS...........................................................................................2.10 BRAKE PEDAL ROTATING SEAT & JOYSTICK STEERING...........................................2.10 STATIONARY SEAT & STEERING WHEEL.......................................... 2.11 COMPUTER DISPLAY...............................................................................2.22 CONTROL PANEL A/C HEATER CONTROLS - AIR CONDITIONER...................................2.20 A/C HEATER CONTROLS - AIR SOURCE.............................................2.20 A/C HEATER CONTROLS - FAN CONTROL.........................................2.21 A/C HEATER CONTROLS - TEMPERATURE........................................2.20 AUX (OPTIONAL)...................................................................................2.16 DIFFERENTIAL LOCK SELECTOR SWITCH.........................................2.19 FAN CONTROL SWITCH, COOLING.....................................................2.16 HORN, SAFETY ALERT - SWITCH........................................................2.19 IGNITION SWITCH (6351191-6351500).................................................2.21 LIGHTS - SWITCH..................................................................................2.16 MAXIMUM SPEED CONTROL DIAL STATIONARY SEAT & STEERING WHEEL.......................................2.21 PARKING BRAKE SWITCH....................................................................2.18 WINCH CONTROL LEVER.....................................................................2.20 WINCH SELECT SWITCH......................................................................2.19 DIFFERENTIAL LOCK SELECTOR SWITCH............................................2.19 DIFFERENTIAL LOCK(S) ON/OFF SWITCH.............................................2.14 DIRECTION SELECTION SWITCH ROTATING SEAT & JOYSTICK STEERING...........................................2.12 DOZER BLADE CONTROL LEVER...........................................................2.15 ENGINE SPEED CONTROL, RIGHT JOYSTICK TRIGGER.....................2.15 ENGINE SPEED/TRAVEL PEDALS ROTATING SEAT & JOYSTICK STEERING...........................................2.10 STATIONARY SEAT & STEERING WHEEL.......................................... 2.11 FOOT PEDALS, FORWARD FACING AND REAR FACING ROTATING SEAT & JOYSTICK STEERING................................. 2.10, 2.11 BRAKE PEDAL....................................................................................2.10 TRAVEL/ENGINE SPEED PEDAL......................................................2.10 HORN, SAFETY ALERT - SWITCH............................................................2.19 IGNITION SWITCH (6351001-6351190).................................................................................2.22 (6351191-6351500).................................................................................2.21 INSTRUMENT PANEL................................................................................2.22 ALARM LIGHT........................................................................................2.22 AUXILIARY POWER OUTLET................................................................2.22 COMPUTER DISPLAY............................................................................2.22

Tigercat 635D Skidder Tigercat 635D Skidder

Controls and operation

SECTION 2 - CONTROLS & OPERATION COMPUTER USB PLUG.........................................................................2.22 ENGINE DIAGNOSTICS CONNECTION................................................2.23 IGNITION SWITCH (6351001-6351190).................................................2.22 LIGHTER.................................................................................................2.22 MASTER ALARM....................................................................................2.22 STORAGE COMPARTMENT..................................................................2.22 LEFT HAND JOYSTICK (ROTATING SEAT & JOYSTICK STEERING) DIRECTION SELECTION SWITCH........................................................2.12 MAXIMUM SPEED CONTROL...............................................................2.13 STEERING..............................................................................................2.12 MAXIMUM SPEED CONTROL ROTATING SEAT & JOYSTICK STEERING...........................................2.13 STATIONARY SEAT & STEERING WHEEL..........................................2.21 PARKING BRAKE LEVER.......................................................................... 2.11 RIGHT HAND JOYSTICK ARCH AND BOOM CONTROLS.............................................................2.14 BOOM AND ARCH CONTROLS.............................................................2.14 DIFFERENTIAL LOCK(S) ON/OFF SWITCH.........................................2.14 GRAPPLE CONSTANT PRESSURE SWITCH.......................................2.14 GRAPPLE OPEN/CLOSE.......................................................................2.15 GRAPPLE ROTATE CONTROLS...........................................................2.14 TRIGGER SWITCH, ENGINE SPEED CONTROL.................................2.15 ROTATING SEAT KICK LEVER..................................................................2.24 SEAT...........................................................................................................2.25 SEAT, ROTATING SEAT KICK LEVER.......................................................2.24 STEERING JOYSTICK...............................................................................................2.12 STEERING WHEEL................................................................................2.13 TRAVEL/ENGINE SPEED PEDALS ROTATING SEAT & JOYSTICK STEERING...........................................2.10 STATIONARY SEAT & STEERING WHEEL.......................................... 2.11 WARNING MESSAGES....................................................... SEE COMPUTER WINCH CONTROL LEVER........................................................................2.20 WINCH SELECT SWITCH..........................................................................2.19 CAB VENTILATION AIR VENTS.................................................................................................2.85 FILTER, FRESH AIR...................................................................................2.85 FILTER, RECIRCULATING AIR, A/C UNIT.................................................2.85 CARE OF THE MACHINE............................................................................ 2.116 CARE OF POLYCARBONATE WINDOWS.............................................. 2.116 CAUTIONS............................................................................................ 2.118 CLEANING INSTRUCTIONS................................................................ 2.118 CONCEALING HAIRLINE SCRATCHES.............................................. 2.118 FIRE PRECAUTIONS........................................................................... 2.119 GRAFFITI REMOVAL............................................................................ 2.119 INSPECTION AND MAINTENANCE..................................................... 2.117 RESISTANCE TO CHEMICALS............................................................ 2.117 RESISTANCE TO WATER.................................................................... 2.117 CENTER JOINT........................................................................................... 2.111 CLEANING A/C CONDENSER AND COOLING ASSEMBLY......................2.120 COLD IDLE OPERATION.............................................................................2.104 COLD IDLE SPEED ADJUSTMENT............................................................2.105 2.2

Tigercat Tigercat 635D635D SkidderSkidder

Controls and operation

SECTION 2 - CONTROLS & OPERATION COMPUTER...................................................................................................2.26 ADJUSTMENT MENU EXAMPLE ~ ADJUSTMENT MENU NAVIGATION.................................2.36 ADJUSTMENT MENU - ENGINE SETTINGS............................................2.33 AUTO RPM.............................................................................................2.33 COLD IDLE SPEED................................................................................2.33 ADJUSTMENT MENU - FAN SETTINGS (IF EQUIPPED).........................2.34 CLEAN DURATION.................................................................................2.34 CLEAN FREQUENCY.............................................................................2.34 FAN AUTO CLEAN..................................................................................2.34 ADJUSTMENT MENU - SERVICE SETTINGS..........................................2.34 FRONT TIRE SIZE..................................................................................2.35 HYDRAULIC OIL GRADE.......................................................................2.34 PROGRAM MODE..................................................................................2.35 STEER ADJUST (JOYSTICK STEERING ONLY)...................................2.35 STEER INVERT (JOYSTICK STEERING ONLY)...................................2.35 COMPUTER CONTROL SYSTEM.............................................................2.27 COMPUTER CONTROL SYSTEM COMPONENTS..................................2.27 ENGINE COOLANT TEMPERATURE GAUGE..........................................2.31 ENGINE MENU - ENGINE FUNCTIONS.......................................... 2.29, 2.30 BOOST....................................................................................................2.32 CHARGE AIR TEMPERATURE..............................................................2.32 COOLANT TEMPERATURE...................................................................2.31 ENGINE HOURS.....................................................................................2.32 ENGINE SPEED.....................................................................................2.31 ENGINE VOLTAGE.................................................................................2.32 ENG % TORQUE....................................................................................2.31 OIL PRESSURE......................................................................................2.31 ENGINE MENU - FUEL INFORMATION....................................................2.30 FUEL RATE.............................................................................................2.30 TOTAL FUEL USED................................................................................2.30 TRIP AVERAGE FUEL RATE..................................................................2.30 TRIP FUEL USED...................................................................................2.30 ENGINE TACHOMETER GAUGE..............................................................2.31 FUEL GAUGE................................................................................... 2.30, 2.40 HYDRAULIC OIL TEMPERATURE GAUGE...............................................2.39 INFORMATION MODE MENU....................................................................2.38 DRIVE MOTOR SPEED..........................................................................2.39 DRIVE PRESSURE FORWARD.............................................................2.39 DRIVE PRESSURE REVERSE..............................................................2.39 HYDRAULIC OIL TEMPERATURE.........................................................2.39 HYDROSTATIC CIRCUIT TEMPERATURE............................................2.39 MACHINE HOURS..................................................................................2.39 MACHINE VOLTAGE..............................................................................2.40 TRAVEL SPEED.....................................................................................2.40 INFORMATION MODE MENU - FUEL INFORMATION.............................2.40 FUEL RATE.............................................................................................2.40 TOTAL FUEL USED................................................................................2.40 TRIP AVERAGE FUEL RATE..................................................................2.40 TRIP FUEL USED...................................................................................2.40 MAIN MENU...............................................................................................2.28 MAIN MENU PAGE.....................................................................................2.41 2.3

Tigercat 635D635D SkidderSkidder Tigercat

Controls and operation

SECTION 2 - CONTROLS & OPERATION MAIN MENU PAGE - ADJUST MENU........................................................2.42 MAIN MENU PAGE - INFO MENU.............................................................2.48 LOGS......................................................................................................2.49 MODULES...............................................................................................2.49 MAIN MENU PAGE - MEASURE MENU....................................................2.43 MAIN MENU PAGE - PREFERENCES MENU...........................................2.44 DATE/TIME ADJUSTMENT....................................................................2.46 DISPLAY ADJUSTMENT........................................................................2.45 LANGUAGE ADJUSTMENT...................................................................2.48 MD3 COMPUTER.......................................................................................2.26 MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY.........................2.26 MD3 COMPUTER MAIN MENU.................................................................2.28 MESSAGES AND WARNINGS...................................................................2.50 ALERT MESSAGES (YELLOW).............................................................2.65 CRITICAL MESSAGES (RED)...............................................................2.51 ERROR MESSAGES (RED)...................................................................2.61 INFORMATION MESSAGES (BLUE).....................................................2.80 MESSAGES AND WARNINGS - ALERT DRIVE CHARGE FILTER BYPASSED....................................................2.68 DRIVE CHARGE SYSTEM PRESSURE LOW.......................................2.70 DRIVE MOTOR SPEED SENSOR NO MOTOR SPEED........................2.69 ENGINE AIR INTAKE FILTER RESTRICTED.........................................2.67 ENGINE FAULT CODE MESSAGES - ALERT........................................2.76 ENGINE VOLTAGE HIGH.......................................................................2.75 ENGINE VOLTAGE LOW........................................................................2.75 FUEL LEVEL LOW..................................................................................2.67 FUEL - WATER IN FUEL.........................................................................2.71 HARDWARE FAILURE - COUT..............................................................2.74 HARDWARE FAILURE - DIN..................................................................2.73 HARDWARE FAILURE - DOUT..............................................................2.74 HARDWARE FAILURE - VIN..................................................................2.73 HARDWARE FAULT - MD3.....................................................................2.71 HARDWARE FAULT - XA2......................................................................2.72 HARDWARE FAULT - XS2......................................................................2.72 MACHINE VOLTAGE HIGH....................................................................2.69 MACHINE VOLTAGE LOW.....................................................................2.68 MODULE HIGH SUPPLY VOLTAGE - ALERT........................................2.78 MODULE HIGH TEMPERATURE - ALERT.............................................2.77 MODULE LOW SUPPLY VOLTAGE - ALERT.........................................2.79 SERVICE BRAKE PRESSURE LOW.....................................................2.70 MESSAGES AND WARNINGS - CRITICAL DRIVE MOTOR CLUTCH PRESSURE LOW.........................................2.52 DRIVE MOTOR OVERSPEED................................................................2.53 ENGINE COOLANT LEVEL LOW...........................................................2.58 ENGINE COOLANT TEMPERATURE HIGH..........................................2.58 ENGINE FAULT CODE MESSAGES - CRITICAL...................................2.60 ENGINE OIL PRESSURE LOW..............................................................2.59 ENGINE STOP........................................................................................2.55 HARDWARE FAULT - ENGINE...............................................................2.56 HARDWARE FAULT - MD3.....................................................................2.56 HARDWARE FAULT - XA2......................................................................2.57

2.4

Tigercat 635D635D SkidderSkidder Tigercat

Controls and operation

SECTION 2 - CONTROLS & OPERATION HARDWARE FAULT - XS2......................................................................2.57 HYDRAULIC OIL LEVEL LOW................................................................2.52 HYDRAULIC OIL TEMPERATURE HIGH...............................................2.54 INTAKE MANIFOLD TEMPERATURE HIGH..........................................2.59 INTERLOCK SYSTEM............................................................................2.55 MESSAGES AND WARNINGS - ERROR CURRENT OUTPUT ERROR (COUT)...................................................2.64 DIGITAL INPUT ERROR (DIN)...............................................................2.64 DIGITAL OUTPUT ERROR (DOUT).......................................................2.64 MODULE NO CONTACT ERROR..........................................................2.62 MODULE VREF ERROR........................................................................2.63 VOLTAGE INPUT ERROR (VIN).............................................................2.64 MESSAGES AND WARNINGS - INFORMATION MACHINE STEERING INVERT DISABLED...........................................2.84 SETUP MODE - DRIVE MOTOR SETUP...............................................2.81 SETUP MODE - DRIVE PUMP POR SETUP.........................................2.81 SETUP MODE - DRIVE PUMP REGULATION SETUP..........................2.81 SETUP MODE - ENGINE HP TEST........................................................2.81 SETUP MODE - FUNCTION SETUP......................................................2.81 SETUP MODE - MAX CURRENT SETUP MODE..................................2.81 DOORS AND ACCESS PANELS...................................................................2.90 ENGINE AIR CLEANER AIR CLEANER............................................................................................2.94 AIR CLEANER UNLOADER VALVE...........................................................2.95 AIR PRECLEANER....................................................................................2.94 ENGINE FAULT CODE MESSAGES - ALERT...............................................2.76 ENGINE FAULT CODE MESSAGES - CRITICAL..........................................2.60 FIRE EXTINGUISHER, PORTABLE..............................................................2.87 FIRE PREVENTION FIRE EXTINGUISHER, PORTABLE...........................................................2.87 PRESSURIZED WATER SYSTEM.............................................................2.93 FUEL TANK....................................................................................................2.92 FUSE AND RELAY PANELS CAB............................................................................................................2.88 ELECTRICAL BOX.....................................................................................2.89 GRAPPLE, OPERATING.............................................................................. 2.110 HYDRAULIC FILTERS...................................................................................2.96 HYDRAULIC HAND FILL PUMP....................................................................2.97 HYDRAULIC OIL TANK..................................................................................2.96 MOVING INSTRUCTIONS....................................... SEE SEPARATE BOOKLET OPERATING MACHINE.................................................................................2.98 CENTER JOINT........................................................................................ 2.111 COLD IDLE OPERATION.........................................................................2.104 COLD IDLE SPEED ADJUSTMENT.........................................................2.105 OPERATING GRAPPLE........................................................................... 2.110 OPERATING WINCH................................................................................ 2.111 PRE-START CHECKS................................................................................2.98 2.5

Tigercat 635D635D SkidderSkidder Tigercat

Controls and operation

SECTION 2 - CONTROLS & OPERATION RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL...................2.108 STARTING ENGINE.................................................................................2.102 STARTING IN COLD WEATHER..............................................................2.103 STOPPING ENGINE.................................................................................2.108 SYSTEM TEST AND WARM-UP..............................................................2.107 TRAVELLING WITHOUT A LOAD............................................................2.109 OPERATOR’S SEAT......................................................................................2.25 PARKING BRAKE LEVER.............................................................................. 2.11 PARKING BRAKE SWITCH...........................................................................2.18 PICTOGRAM DESCRIPTIONS........................................................ 2.7, 2.8, 2.9 PRE-START CHECKS...................................................................................2.98 RADIO, AM/FM CD.........................................................................................2.86 RADIO, CB (IF EQUIPPED)...........................................................................2.86 RETRIEVAL POINTS...................................................................................2.123 ROTATING SEAT KICK LEVER.....................................................................2.24 SKIDDING.................................................................................................... 2.112 CABLE SKIDDING.................................................................................... 2.115 EFFECT OF ARCH/BOOM GEOMETRY ON WEIGHT DISTRIBUTION............................................................... 2.113 GRAPPLE SKIDDING.............................................................................. 2.114 SAFETY.................................................................................................... 2.112 SKIDDING TECHNIQUE.......................................................................... 2.112 STARTING ENGINE.....................................................................................2.102 STEERING JOYSTICK STEERING...............................................................................2.12 STEERING WHEEL....................................................................................2.13 STEREO, AM/FM CD.....................................................................................2.86 STOPPING ENGINE....................................................................................2.108 SYSTEM TEST AND WARM-UP..................................................................2.107 SYSTEM WARNING MESSAGES........................................... SEE COMPUTER TILT CAB....................................................................................SEE SECTION 3 TOWING INSTRUCTIONS...........................................................................2.126 TRANSMISSION DIPSTICK...........................................................................2.93 TRANSMISSION OIL FILL LOCATION..........................................................2.93 TRANSPORTING INSTRUCTIONS.............................................................2.124 LIFTING POINTS......................................................................................2.125 TIE DOWN POINTS..................................................................................2.125 WINCH, OPERATING.................................................................................. 2.111

2.6

Tigercat 635D Skidder

Controls and operation

PICTOGRAM DESCRIPTIONS Diagrams in pictorial form are used to represent machine function operation. Some of the symbols are signs, characters, figures, or any components related to the operation of the machine. They are a simple universal language of symbols or pictograms that illustrate a function or component without the use of words. Pictograms are installed on or in close proximity to the switch or device used to activate or deactivate the machine function or they may be a sign used on a warning or indicator light of a function that is operating or advising of an alarm condition.

Examples of these pictograms are the turtle speed such as SLOW =

or FAST =

and the rabbit

that are often used to describe

.

The pictograms used on this machine are as follows: = Boom UP

= Adjustment Menu Icon OR

= Air Conditioner ON

= Brake

=Cigarette Lighter, 24 Volt

= Air Conditioner OFF

= Air Source, Fresh Air

= Control lever, multidirectional

= Air Source, Recirculate

= Control lever, dual direction

= Alert Message Symbol

= Critical Message Symbol

= Arch IN

= Differential Locks (ON/OFF)

= Arch OUT

= Differential Lock, Front

= Auxiliary Power Outlet 12 V

= Differential Locks, Front and Rear

= Battery CONNECT = Differential Lock, Rear = Battery DISCONNECT = Dozer Blade DOWN = Boom DOWN = Dozer Blade UP

2.7

Tigercat 635D Skidder PICTOGRAM DESCRIPTIONS CONTINUED

Controls and operation

= Fuel Reset

= Engine Cold Idle = Engine Coolant Temperature

= Grapple CLOSE

= Engine Fan, Variable Pitch, Full On

= Grapple Constant Pressure = Grapple OPEN

= Engine Fan, Variable Pitch, Auto

= Engine Fan, Variable Pitch, Clean

= Grapple Rotate Clockwise

= Engine Menu Icon

= Grapple Rotate Counter Clockwise

= Engine Run

= Hand tighten only = Horn

= Engine Start

= Hydraulic oil level

= Engine Stop

= Engine Speed Control

= Hydraulic Oil Temperature

= Engine speed/travel

= Imperial/Metric Toggle Symbol

= Engine Wait to start = Information Menu Icon = Error Message Symbol = Information Message Symbol = Foot Pedal Control = Lights, Work = Fuel Information, Computer = Maximum speed control

= Fuel = Fuel Diesel 2.8

Tigercat 635D Skidder PICTOGRAM DESCRIPTIONS CONTINUED = OFF

Controls and operation

= Travel FORWARD

= ON

P

= Travel FORWARD (Seat Forward Facing)

= Parking Brake = Speed FAST or HIGH

= Travel FORWARD (Seat Rear Facing)

= Speed SLOW or LOW = Travel REVERSE = Steer Left = Travel REVERSE (Seat Forward Facing)

= Steer Left (Seat Forward Facing)

= Travel REVERSE (Seat Rear Facing)

= Steer Left (Seat Rear Facing)

= Ventilation Blower Fan

= Steer Right

= Volume, FULL = Steer Right (Seat Forward Facing) = Volume, EMPTY = Steer Right (Seat Rear Facing) = Winch = Temperature

= Winch Brake (Dynamic)

= Winch Freespool

= Travel Direction

= Winch IN = Travel Direction (Seat Forward Facing)

= Travel Direction (Seat Rear Facing) 2.9

Tigercat 635D 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.

CAB CONTROLS 2

1 2

E625C-23

FORWARD FACING FOOT PEDALS (SEAT FACING FRONT OF MACHINE)

E625C-22

1. TRAVEL/ENGINE SPEED PEDAL (ROTATING SEAT & JOYSTICK STEERING) Press the foot pedal to drive in the direction selected on the direction selection switch on the left hand joystick.

The position of the foot pedal is directly proportional to the travel/engine speed of the machine.

NOTE: A backup alarm will sound when travelling in reverse based on the position of the operator's seat.

Refer also to LEFT HAND JOYSTICK ~DIRECTION SELECTION SWITCH in THIS SECTION. 2. BRAKE PEDAL (ROTATING SEAT & JOYSTICK STEERING) Press 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.

NOTE: As a safety precaution before working on or around the machine; After the engine has been shut off, depress this pedal 25 or more times to relieve any pressure that may be stored in the hydraulic system.

1

REAR FACING FOOT PEDALS (SEAT FACING REAR OF MACHINE)

BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3 of THIS MANUAL. FORWARD FACING PEDALS AND REAR FACING PEDALS (ROTATING SEAT & JOYSTICK STEERING) The rotating seat cab is equipped with two sets of pedals one set forward facing and the other set rear facing.

Note that control of machine travel is automatically transferred by the computer control system from the forward facing travel/engine speed pedal to the rear facing travel/engine speed pedal based on the position of the operator's seat. Both brake pedals operate regardless of seat position.

For safe operation of all controls the operator's seat must be locked in either the forward facing or rear facing position. Refer also to ROTATING SEAT KICK LEVER in THIS SECTION. FRONT AND REAR ORIENTATION NOTE: The dozer blade is considered to be at the front of the machine. The attachment is considered to be at the rear of the machine. Therefore in the forward facing position the operator's seat is facing the dozer blade and in the rear facing position the operator's seat is facing the attachment.

Check service brake for proper operation daily.

Refer to SERVICE BRAKE ~ CHECKING 2.10

Tigercat 635D Skidder

Controls and operation

3 4

635D-56A

PARKING BRAKE ~ ENGAGED POSITION

620C-92

PARKING BRAKE ~ DISENGAGED POSITION 5. PARKING BRAKE LEVER (IF EQUIPPED) 635D-56

PULL up on handle to ENGAGE parking brake.

3.

PUSH down on the handle to DISENGAGE parking brake.

TRAVEL/ ENGINE SPEED PEDALS (STATIONARY SEAT & STEERING WHEEL)

This parking brake operates a disc brake calliper on the transmission.

Press the RIGHT foot pedal to drive FORWARD.

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

Press the LEFT foot pedal to drive in REVERSE. The position of the foot pedal is directly proportional to the travel/engine speed of the machine.

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

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

A limit switch is attached to the brake lever housing. When the brake lever is in the ON position the limit switch is activated. When the brake lever is in the fully OFF position the limit switch is de-activated. The signal is sent to the computer control system.

4. BRAKE PEDAL (STATIONARY SEAT & STEERING WHEEL) 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.

Keep the brake properly adjusted at all times.

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.

Refer to PARKING BRAKE ADJUSTMENT in SECTION 9 of the SERVICE MANUAL.

NOTE: As a safety precaution before working on or around the machine; After the engine has been shut off, depress this pedal 25 or more times to relieve any pressure that may be stored in the hydraulic system.

Note that some machines are equipped with a parking brake switch. Refer to PARKING BRAKE SWITCH in THIS SECTION.

Check service brake for proper operation daily. Refer to SERVICE BRAKE ~ CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3 of THIS MANUAL.

2.11

Tigercat 635D Skidder 6a

Controls and operation 6b

FORWARD FACING SEAT

REAR FACING SEAT E625C-11

Operating in the woods requires quick steering changes and this is produced by a rapid movement of the steering control, which will quickly change the vehicle's direction.

LEFT HAND JOYSTICK

6. LEFT HAND JOYSTICK

(ROTATING SEAT & JOYSTICK STEERING)

For safe operation of all controls the operator's seat must be locked in either the forward facing or rear facing position. Refer also to ROTATING SEAT KICK LEVER in THIS SECTION.

Steering Move the joystick to the RIGHT* to articulate the machine to the RIGHT* .

Move the joystick to the LEFT* to articulate the machine to the LEFT* .

6a. DIRECTION SELECTION SWITCH (ROTATING SEAT & JOYSTICK STEERING)

*NOTE: Steering control is automatically adjusted by the computer control system based on the position of the operator's seat. Therefore LEFT articulation and RIGHT articulation as described above are considered to be left and right as viewed by the operator either from the forward facing seat position or the rear facing seat position.

This switch selects the direction of travel for the travel/engine speed pedal in use (either forward facing or rear facing).

This is a three position switch.

Place switch in the forward position to travel in a FORWARD* direction .

Place switch in the center position for neutral.

It should also be noted that the machine steering invert function can be disabled.

Refer to COMPUTER ~ MESSAGES AND WARNINGS - INFORMATION ~ MACHINE STEERING INVERT DISABLEd and COMPUTER ~ ADJUSTMENT MENU - SERVICE SETTINGS ~ STEER INVERT (JOYSTICK STEERING ONLY) in THIS SECTION.

Place switch in the rear position to travel in a REVERSE* direction . *NOTE: Control of machine travel is automatically transferred by the computer control system from the forward facing travel/ engine speed pedal to the rear facing travel/ engine speed pedal based on the position of the operator's seat. Therefore FORWARD and REVERSE as described above are considered to be forward and reverse as viewed by the operator either from the forward facing seat position or the rear facing seat position.

This machine is equipped with variable ratio load sensing steering. The speed that the vehicle responds to the steering control input will vary, depending on the speed at which the steering control is moved.

Refer also to FOOT PEDALS, FORWARD FACING AND REAR FACING ~TRAVEL/ ENGINE SPEED PEDAL and ROTATING SEAT KICK LEVER in THIS SECTION.

When operating on the road, a slow movement of the steering control will not overcorrect and will steer a straight normal course.

2.12

Tigercat 635D Skidder

Controls and operation

6b. MAXIMUM SPEED CONTROL (ROTATING SEAT & JOYSTICK STEERING)

rapid movement of the steering wheel, which will quickly change the vehicle's direction.

The maximum speed control allows the operator to set the maximum travel speed of the machine to maintain a given travel speed without having to feather the drive pedal.

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 center of the steering wheel.

Push control forward to increase the maximum travel speed.

QUICK STEER VALVE (OPTIONAL)

Pull control back to decrease the maximum travel speed of the machine.

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 angle the steering wheel is turned. Turning the steering wheel ±50° results in controlled flow, from zero to full steering flow.

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

Caution: Setting the maximum speed control to the minimum setting lowers maximum travel speed only, it will NOT prevent the machine from travelling when the forward or reverse travel controls are used.

When operating on the road, turning the steering wheel only a few degrees in either direction will result in slower steering, not overcorrect and will steer a straight normal course.

Operating in the woods requires quick steering changes and this is produced by fully turning the steering wheel (± 50°), which will fully lock steering and quickly change the vehicle’s direction.

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

7

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

139-3

7. STEERING WHEEL

(STATIONARY SEAT & STEERING WHEEL) METERED STEER VALVE 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 at which 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 2.13

Tigercat 635D Skidder

Controls and operation 8b

8a

8c

8d

8. RIGHT HAND JOYSTICK

8e

NOTE: Standard dual arch grapple skidder controls are shown. Non-standard machines or machines modified after shipment may use this joystick to control some other functions.

Always verify all functions before operating this machine.

635C-02

Boom Move the joystick BACK to RAISE boom.

8

RIGHT HAND JOYSTICK

8c Differential Locks ON/OFF - One push button (Top right - RIGHT BUTTON)

the

This switch activates differential locks in the front, rear or both axles depending on the position of the differential lock selector switch on the control panel. Axle(s) are locked to provide torque to both wheels.

Move the joystick FORWARD to LOWER the boom.

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

Press button to activate differential lock(s).

Push button a second time to deactivate.

Move the joystick to the LEFT to tilt arch IN .

This machine is equipped with a 10 minute AUTO-OFF feature which automatically deactivates the differential lock(s) after 10 minutes have passed.

8a Grapple Rotate - Two push buttons (Top left) Push LEFT BUTTON to rotate grapple COUNTER CLOCKWISE .

Refer also to CAB CONTROLS ~ CONTROL PANEL ~ DIFFERENTIAL LOCK SELECTOR SWITCH in THIS SECTION.

Push RIGHT BUTTON to rotate grapple CLOCKWISE .

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

8b Constant Pressure (grapple) - One push button (Top right - LEFT BUTTON) Push this button and release it to maintain a constant pressure HOLD on the grapple load and help prevent slipping. Constant pressure is released when the grapple is opened.

FRONT When the differential lock selector switch is in the FRONT position the front differential locks can be engaged or disengaged while the machine is in motion.

The grapple constant pressure icon on the main menu of the computer display will be illuminated when the grapple constant pressure switch is activated.

The front differential lock icon on the main menu of the computer display will be illuminated when front differential lock is engaged.

Also refer to GRAPPLE, OPERATING in THIS SECTION.

2.14

Tigercat 635D Skidder

Controls and operation

FRONT AND REAR LOCATED TO THE RIGHT OF THE JOYSTICK ON THE RIGHT ARM REST

When the differential lock selector switch is in the FRONT AND REAR position the front differential locks can be engaged or disengaged while the machine is in motion.

The rear differential locks will engage only when drive motor rpm falls below 125 rpm.

The rear differential locks can be disengaged while machine is in motion.

The front and rear differential lock icon on the main menu of the computer display will be illuminated when both the front and rear differential locks are engaged.

REAR When the differential lock selector switch is in the REAR position the rear differential locks will engage only when drive motor rpm falls below 125 rpm. The rear differential locks can be disengaged while machine is in motion.

E625C-12

DOZER BLADE CONTROL LEVER

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

the dozer

Push the lever FORWARD to LOWER dozer blade.

The rear differential lock icon on the main menu of the computer display will be illuminated when rear differential lock is engaged.

the

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

8d Grapple open/close - Two push buttons (Bottom)

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

Push LEFT BUTTON to CLOSE grapple

.

Push RIGHT BUTTON to OPEN grapple

.

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

8e. Engine Speed Control - Trigger Pull this trigger to increase engine speed when performing machine functions which do not require machine travel. Release trigger to return to engine idle speed.

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 battery disconnect switch to the OFF position .

Refer also to COMPUTER ~ ADJUSTMENT MENU - ENGINE SETTINGS ~ AUTO RPM in THIS SECTION.

2.15

Tigercat 635D Skidder

Controls and operation 3

2

1

5 E625C-27X

6

4

7

11

8

12

13

9

14

10

15

CONTROL PANEL (6351001 TO 6351190)

CONTROL PANEL

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

1. LIGHTS FRONT - SWITCH This switch turns on working lights.

2. LIGHTS REAR - SWITCH This switch turns on working lights.

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

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

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

5. FAN CONTROL - SWITCH (IF EQUIPPED - VARIABLE PITCH FAN) This is a three position switch, labeled / / (FULL ON/ AUTOMATIC/ CLEAN).

This switch controls the operation of the optional Flexxaire® cooling fan.

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

The Flexxaire® cooling fan blade pitch is hydraulically varied to control the flow and direction of air through the cooling assembly

The auto clean cycle is adjustable through the computer control system menu (ADJUSTMENT MENU ~ FAN SETTINGS).

Refer also to COMPUTER ~ ADJUSTMENT MENU - FAN SETTINGS in THIS SECTION.

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

2.16

Tigercat 635D Skidder 16

1

15 54827B

Controls and operation 3

2

6

4

7

11

8

12

13

9

14

10

5

CONTROL PANEL (6351191 TO 6351500)

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

engine enclosure to eliminate potential overheating and poor machine performance caused by overheating. Ensure that there are no personnel standing directly to the sides of the machine when performing this operation, as dust and debris will fly out.

FULL ON Position - When the switch is in the FULL ON position, the computer control system is overridden and the fan will run at FULL air flow (blades pitched to 100%), for cooling regardless of charge air, engine coolant or hydraulic oil temperatures.

Normally the fan control switch is placed in the AUTOMATIC position for optimal cooling.

The FULL ON position is intended for use in the event of a temporary failure of the control system.

The auto clean cycle is adjustable through the computer control system menu (ADJUSTMENT MENU ~ FAN SETTINGS).

Refer also to COMPUTER ~ ADJUSTMENT MENU - FAN SETTINGS in THIS SECTION.

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

It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in THIS SECTION.

CLEAN Position - Momentarily pressing the switch to the CLEAN position will manually start the automatic clean cycle, reversing the flow of air (there is no need to hold the switch down). The pitch of the fan blades is changed and the direction of airflow through the engine enclosure is reversed. This change in airflow blows debris from the machines 2.17

Tigercat 635D Skidder

Controls and operation 3

2

1

6

5 E625C-27X

4

7

11

12

8

13

9

14

10

15

CONTROL PANEL (6351001 TO 6351190)

6. PARKING BRAKE SWITCH (IF EQUIPPED)

Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ INTERLOCK SYSTEM in THIS SECTION.

P

This is a three position switch which operates a driveline brake.

The parking brake must be kept properly adjusted at all times and should be serviced every 500 hours during normal operating conditions. Refer to PARKING BRAKE ADJUSTMENT in SECTION 9 of the SERVICE MANUAL. For later machines refer to PARKING BRAKE (6351191 to 6351500) ~ PARKING BRAKE ADJUSTMENT in SECTION 3 of THIS MANUAL.

Momentarily press the top of this switch (ON) to ENGAGE the parking brake. The parking brake icon on the main menu of the computer display will be illuminated when the parking brake is engaged. The switch will spring return to the center position.

Momentarily press the bottom of this switch (OFF) to DISENGAGE the parking brake. The switch will spring return to the center position.

Note that some machines are equipped with a parking brake lever. Refer to PARKING BRAKE LEVER in THIS SECTION.

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

SWITCH

ACTUATOR ON DOOR

NOTE ALSO: The interlock system prevents the machine from being driven and function controls from being operated while the parking brake is ENGAGED. As part of the interlock system this machine automatically engages the parking brake whenever a cab door is open. This prevents accidental or improper operation of the controls from anywhere but the operator's seat.

E625C-108

2.18

INTERLOCK SWITCHES ON CAB DOORS

Tigercat 635D Skidder 16

1

Controls and operation 4

7

6

15 54827B

3

2

11

8

12

13

9

14

10

5

CONTROL PANEL (6351191 TO 6351500) 9. WINCH SELECT SWITCH

7. HORN, SAFETY ALERT - SWITCH

This is a three position switch, O / I /

This is a two position "momentary" switch.

Press and hold this switch to sound the safety alert horn.

Place this switch in the O (OFF) position to de-activate the winch control lever and prevent accidental operation of the winch.

Always use this horn prior to starting the engine and to alert other personnel in the area of your presence.

Place this switch in the I (ON) position to activate the winch control lever. The winch icon on the main menu of the computer display will be illuminated when the winch selector switch is in the I (ON) position.

8. DIFFERENTIAL LOCK SELECTOR SWITCH This is a three position switch,

/

/

.

.

Place this switch in the (FREESPOOL) position to disconnect the drive motor from the drum in the winch and allow the cable to be freely pulled from the spool. Free spool must be turned off to activate a pull with the winch. The winch freespool icon on the main menu of the computer display will be illuminated when the winch selector switch is in the position.

Placing this switch in the (FRONT) position selects the front axle differential locks for activation via the differential lock switch on the right hand joystick.

Placing this switch in the (FRONT AND REAR) position selects both the front and rear axle differential locks for activation via the differential lock switch on the right hand joystick.

Refer also to WINCH CONTROL LEVER in THIS SECTION .

Placing this switch in the (REAR) position selects the rear axle differential locks for activation via the differential lock switch on the right hand joystick.

Refer also to CAB CONTROLS ~ DIFFERENTIAL LOCK(S) ON/OFF SWITCH in THIS SECTION. 2.19

Tigercat 635D Skidder

Controls and operation 3

2

1

6

5

4

7

11

12

8

13

9

14

10

15

CONTROL PANEL (6351001 TO 6351190)

E625C-27X

10. WINCH CONTROL LEVER

12. AIR SOURCE

Place the winch select switch (to the left of the lever) in the I (ON) position. Push and hold the winch control lever FORWARD to release the dynamic brake (if equipped) for a controlled release of cable. The control lever will return to the center neutral position when released.

This is a two position rocker switch used to add fresh air to the cab.

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

Refer also to CAB VENTILATION in THIS SECTION.

In the cab.

In the position air from the cab is recirculated along with fresh air.

13. TEMPERATURE CONTROL This is a variable, rotary control used to adjust the temperature of air in the cab for heating or 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.

Place the winch select switch (to the left of the lever) in the I (ON) position. Pull and hold the winch control lever BACK to wind in the winch cable . The control lever will return to the center neutral position when released.

Placing the winch select switch (to the left of the lever) in the (FREESPOOL) position permits the cable to unwind freely. The cable can then be pulled from the drum by the operator.

If the hot water shut off valve is closed the temperature control will have no effect on cab air temperature for heating or cooling.

During times when cab heating is not required the HOT WATER SHUT OFF VALVE, on the heater hose from the engine, may also be closed to prevent hot water from seeping through the heater unit, thereby reducing the cooling effect.

Refer also to WINCH SELECT SWITCH in THIS SECTION. 11. AIR CONDITIONER This is a two position rocker switch used to turn the air conditioner ON or OFF. In the

position the air condition is ON.

In the

position the air conditioner is OFF.

position fresh air is brought into the

2.20

Tigercat 635D Skidder 1

16

15

Controls and operation 3

2

6

4

7

11

8

12

13

9

14

10

5

CONTROL PANEL (6351191 TO 6351500)

54827B

Turn the dial to the left to decrease the maximum travel speed of the machine.

ENGINE

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

SHUT-OFF VALVE

Caution: Turning the maximum speed control dial completely to the left (minimum setting) lowers maximum travel speed only, it will NOT prevent the machine from travelling when the forward or reverse travel pedals are used.

HOSE TO A/C HEATER UNIT

E620C-13

16. IGNITION SWITCH - 3 POSITION (6351191-6351500)

HOT WATER SHUT OFF VALVE

STOP position - All electrical power fed through the ignition switch is turned "OFF"

14. FAN CONTROL This is a rotary, four position switch (0/1/2/3).

When the switch is in the 0 position the cab air fan is OFF. When the switch is in the 1, 2 or 3 position the fan is activated at one of three fan speeds.

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.

15. MAXIMUM SPEED CONTROL DIAL (STATIONARY SEAT & STEERING WHEEL)

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

The maximum speed control dial allows the operator to set the maximum travel speed of the machine to maintain a given travel speed without having to feather the drive pedals.

Refer also to STARTING ENGINE in THIS SECTION.

Turn the dial to the right to increase the maximum travel speed.

2.21

Tigercat 635D Skidder 1

2

Controls and operation 3

4

6

5

7

8

9

INSTRUMENT PANEL (63501001 TO 6351030) 4. MASTER ALARM INSTRUMENT PANEL This alarm will sound to alert the operator that 1. IGNITION SWITCH - 3 POSITION an alarm condition has been detected and (6351001-6351190) should be dealt with immediately. All warning STOP position - All electrical power fed messages can be viewed on the computer through the ignition switch is turned "OFF" display on the instrument panel. Refer to the COMPUTER ~ MESSAGES AND RUN position - Connects the battery to all WARNINGS in THIS SECTION. functions. Used for normal machine operation.

E625C-26

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

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

5. LIGHTER 24V Cigarette lighter is supplied.

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

6. AUXILIARY POWER OUTLET 12 V A 12 volt outlet is provided for portable devices such as cell phones.

Refer also to STARTING ENGINE in THIS SECTION.

7. STORAGE COMPARTMENT

2. COMPUTER DISPLAY The computer display is the operator interface with the computer control system.

9

Refer to COMPUTER in THIS SECTION for complete operating details.

8

3. ALARM LIGHT This light flashes to alert the operator that an alarm condition has been detected and should be dealt with immediately. All warning messages can be viewed on the computer display on the instrument panel.

E625C-106

IN STORAGE COMPARTMENT

8. COMPUTER USB PLUG Plug in a laptop with appropriate IQAN software for software updates, diagnostics and some adjustments.

Refer to the COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION.

2.22

Tigercat 635D Skidder

Controls and operation 3

2

1

4

5

6

8

7

9

INSTRUMENT PANEL (6351031 TO 6351190)

46071B

3

2

4

5

6

8

7

9

INSTRUMENT PANEL (6351191-6351500) Refer also to COMPUTER in THIS SECTION 8 and SECTION 6 of the SERVICE MANUAL for more information.

56583BUNI

9

9. ENGINE DIAGNOSTICS CONNECTION Plug a remote electronic diagnostic device into this connection such as a laptop computer with appropriate engine manufacturer's programming to perform engine performance analysis and tuning.

NOTE: This operation can only be performed by a trained service technician.

630D-04X

2.23

REMOVE COVER TO ACCESS

Tigercat 635D Skidder ROTATING SEAT KICK LEVER

Controls and operation STEERING INVERT DISABLEd and COMPUTER ~ ADJUSTMENT MENU - SERVICE SETTINGS ~ Steer Invert (Joystick steering only) in THIS SECTION.

(ROTATING SEAT & JOYSTICK STEERING)

FRONT AND REAR ORIENTATION NOTE: The dozer blade is considered to be at the front of the machine. The attachment is considered to be at the rear of the machine. Therefore in the forward facing position the operator's seat is facing the dozer blade and in the rear facing position the operator's seat is facing the attachment.

E625C-18

ROTATING SEAT KICK LEVER

This lever releases the seat to rotate between forward facing position and the rear facing position.

To rotate from the forward facing position to the rear facing position kick the left side of the lever and rotate the seat to the right until the seat locks in the rear facing position.

To rotate from the rear facing position to the forward facing position kick the right side of the lever and rotate the seat to the left until the seat locks in the forward facing position.

For safe operation of all controls the operator's seat must be locked in either the forward facing or rear facing position. A limit switch located in the seat pedestal sends a signal to the computer control system indicating the position of the operator's seat.

Note that control of machine travel is automatically transferred by the computer control system from the forward facing pedal to the rear facing pedal based on the position of the operator's seat. Both brake pedals operate regardless of seat position.

Refer also to FOOT PEDALS, FORWARD FACING AND REAR FACING ~TRAVEL/ENGINE SPEED PEDAL and LEFT HAND JOYSTICK ~DIRECTION SELECTION SWITCH in THIS SECTION. Note that steering control is automatically adjusted by the computer control system based on the position of the operator's seat. Refer also to LEFT HAND JOYSTICK ~ STEERING in THIS SECTION. It should also be noted that the machine steering invert function can be disabled. Refer to COMPUTER ~ MESSAGES AND WARNINGS - INFORMATION ~ MACHINE 2.24

Tigercat 635D Skidder OPERATOR’S SEAT - AIR RIDE ADJUSTMENTS

Controls and operation SEAT ADJUSTMENTS

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

LUMBAR HORIZONTAL ADJUSTMENT (NOT SHOWN)

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 in between, provide a total height adjustment of 3".

BACK ANGLE ADJUSTMENT KNOB

To raise the seat Firmly lift up on the height adjustment lever and partially lift your body weight from the seat. When the seat rises to the desired height, FIRMLY PUSH DOWN on the lever into the locking position (a click should be heard).

To lower the seat Firmly lift up on the height adjustment lever and add body weight to the seat until the seat is at the desired height. FIRMLY PUSH DOWN on the lever into the locking position (a click should be heard).

RIDE ADJUSTMENT KNOB 720E-001

NOTE: Later machine seats may be equipped with a fixed (bolted) two position height adjustment. The second position provides a total height increase of 1". Four bolts are used to reposition the seat for height adjustment.

HEIGHT ADJUSTMENT LEVER FORE/AFT SLIDE LEVER

LUMBAR HORIZONTAL ADJUSTMENT

AIR RIDE ADJUSTMENT PROCEDURES After adjusting the seat height, the ride adjustment can be made by pulling or pushing the air ride control valve knob.

To stiffen the air ride For a stiffer ride push on the air ride adjustment knob to increase the air pressure in the suspension air bag.

332-6

To soften the air ride For a softer ride, pull on the air ride adjustment knob to decrease the air pressure in the suspension air bag.

VIEW FROM RIGHT REAR OF SEAT

ARMREST ADJUSTMENT

SEAT - HORIZONTAL POSITION Move and hold fore/aft slide leaver. Roll seat forwards or backward to the desired position relative to the foot pedal controls.

2-WAY ADJUSTABLE LUMBAR To increase lumbar support pressure, turn lumbar adjustment knob clockwise. To decrease lumbar support pressure, turn lumbar adjustment knob counterclockwise

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

BACKREST - ANGLE ADJUSTMENT Rotate backrest angle adjustment knob to place backrest at the desired angle.

2.25

Tigercat 635D Skidder

Controls and operation MD3 COMPUTER

COLOUR DISPLAY

MD3 COMPUTER, ELECTRONIC CONTROL AND DISPLAY

635D-28A

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY

MD3 COMPUTER USB PLUG

ALARM MD3 COMPUTER LIGHT

MASTER ALARM

The MD3 computer, electronic control and display is the operator interface with the electronic control system. The MD3 is the central unit in the control system which works as both a master controller and a display unit. It has a backlit colour graphic transflective display for reading system information.

The front of the MD3 consists of a control panel with a display and nine buttons. The buttons are arranged on the bottom and right hand side of the display.

• F1 through F4 function buttons

,

INSTRUMENT PANEL

,

Pushing this button equals ’enter’. Saves the value or confirms the selection you have made.

, .

Programmed buttons that are configured by program software to bring up a display page, bring up an adjustment group or act as an input.

• Up and down arrow buttons

,

• Menu button .

Always brings up the Menu page. It is not programmable.

.

• ’Esc’ or BACK button

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

Navigation buttons that are used to scroll through selections on a menu page. The buttons are configured by program software to bring up a display page, bring up an adjustment group or act as a virtual input.

• OK button

.

.

2.26

Tigercat 635D Skidder MD3 COMPUTER MODULE

Controls and operation

9 PIN ENGINE DIAGNOSTIC CONNECTOR 615C-001

XA2-A1* EXPANSION MODULE FRONT CHASSIS 2 (IF EQUIPPED)

XS2 EXPANSION MODULE CAB

XA2-A0 EXPANSION MODULE FRONT CHASSIS

* IF EQUIPPED ENGINE ELECTRONIC CONTROL MODULE

COMPUTER CONTROL SYSTEM COMPONENTS

COMPUTER CONTROL SYSTEM The MD3 computer control system is part of a network of components (shown above). The system is made up of the following components: •

MD3 Computer and Display Module

•

XS2 Expansion Module (Cab)

•

XA2-A1 Expansion Module (Front Chassis 2) (if equipped*) XA2-A0 Expansion Module (Front Chassis) Engine Electronic Control Module Various controls, switches, sensors and valves not shown.

• • •

LOCATED ON LEFT SIDE OFCAB

E625C-109

XS2-A0 MODULE - CAB (6351001 TO 6351030)

LOCATED IN CAB BEHIND LEFT KICK PANEL

The MD3 computer is the main controller in the system. The MD3 computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

The engine electronic control module provides electronic information to the MD3 computer via the J1939 CAN BUS link. This information is displayed on the computer display.

630D-14

XS2-A0 MODULE - CAB (6351031 AND UP)

LOCATED UNDER CAB, RIGHT REAR - REMOVE COVER TO ACCESS MODULES

NOTE: The computer control system is softwarebased. This software may be updated after the machine is in service as a part of on-going product improvement programs and service newsletters. The information contained in this manual is accurate at the time of printing.

Improvements to the machine and/or software are on-going and may not be covered. In these cases contact your Tigercat dealer for appropriate information.

XA2-A0 FRONT CHASSIS

XA2-A1 FRONT CHASSIS 2 (*IF EQUIPPED)

615C-007

2.27

XA2 MODULES

Tigercat 635D Skidder 1

2A 2B

Controls and operation 3

4A

4B

5

14

13 12 6

7

8

9

10

11

MAIN MENU

635D-28

MD3 COMPUTER MAIN MENU 1. ** PARKING BRAKE - ENGAGED/DISENGAGED

10. INFORMATION MENU - Press F3 to select

2A. ** REAR DIFFERENTIAL LOCK - ENGAGED/DISENGAGED

12. HYDRAULIC OIL GRADE INDICATOR

11. ALARM INDICATORS - Press F4 to select 13. HYDRAULIC OIL TEMPERATURE GAUGE

2B. ** FRONT DIFFERENTIAL LOCK - ENGAGED/DISENGAGED

14. FUEL LEVEL GAUGE

3. *GRAPPLE CONSTANT PRESSURE ON/OFF

* When the icon is illuminated, function is ON.

4A. * WINCH ON/OFF (

** When the icon is illuminated, function is ENGAGED.

)

4B. * WINCH FREE SPOOL (

)

5. * COLD IDLE ON/OFF 6. ENGINE TACHOMETER GAUGE 7. ENGINE MENU - Press F1 to select 8. ADJUSTMENT MENU - Press F2 to select 9. ENGINE COOLANT TEMPERATURE GAUGE

2.28

Tigercat 635D Skidder

Controls and operation

ENGINE MENU

ENGINE FUNCTIONS (EARLIER PROGRAMS) Press the F1 button to select the fuel information display.

From the main menu press the F1 button to select the engine display.

Press the F2 button to toggle the cold idle function ON/OFF. Refer to COLD IDLE OPERATION and COLD IDLE SPEED ADJUSTMENT in THIS SECTION.

When selected the engine menu icon is on display and the engine functions will also be displayed.

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

Press the back button to return to the main menu.

The engine functions on display are as follows: • • • • • • • •

Engine Speed - rpm Engine Torque - % Coolant Temperature - °F or °C Engine Oil Pressure - psi or bar Turbocharger Boost Pressure - psi or bar Charge Air Temperature - °F or °C Voltage - V Engine Hours - h

2.29

Tigercat 635D Skidder

Controls and operation

ENGINE FUNCTIONS (LATER PROGRAMS)

FUEL INFORMATION (EARLIER PROGRAMS) Press the F1 button to reset the trip average fuel rate and trip fuel used functions.

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

Press the F2 button to toggle between imperial and metric units of measure.

Press the F2 button to toggle the cold idle function ON/OFF. Refer to COLD IDLE OPERATION and COLD IDLE SPEED ADJUSTMENT in THIS SECTION.

Press the back button to return the engine display.

Press the back button to return to the main menu.

Press the back button again to return to the main menu.

1. Fuel Rate - US gph or L/h (instantaneous) This display indicates the current rate of fuel consumption in gallons per hour.

2. Total Fuel Used - US gal or L This display indicates the total fuel used during the life of the machine.

3. Trip Average Fuel Rate - US gph or L/h This display indicates the average fuel consumption rate for the machine since last reset.

4. Trip Fuel Used - US gal or L This display indicates the total fuel used since last reset.

FUEL GAUGE The fuel level gauge is shown on the main menu.

2.30

Tigercat 635D Skidder

Controls and operation

1. Engine Speed (rpm)

3. Coolant Temperature - °F or °C

This display indicates engine speed in rpm.

This display indicates the current engine coolant temperature.

Maintaining Correct Engine RPM

If temperature rises above the recommended temperature, alarm will sound, check the following:

It is important that the engine speeds be correct at all times: Cummins QSB Series Engine: Low Idle 950 RPM (No Load) High Idle 2230 RPM (No Load)*

• Plugged air intake access panel screens • Plugged radiator.

NOTE: The above values are measured with the hydraulic and engine oil at normal operating temperatures and no functions activated.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in THIS SECTION. NOTE: Coolant temperature can also be monitored using the engine coolant temperature gauge shown on the main menu.

Engine idle speed defaults to 950 rpm when the engine is started.

Refer to the COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION for more information about the hydraulic oil temperature warning.

NOTE ALSO: Engine speed can also be monitored using the engine tachometer gauge shown on the main menu.

4. Oil Pressure (psi or bar) This display indicates engine oil pressure.

* Refer also to COMPUTER ~ ADJUSTMENT MENU - ENGINE SETTINGS ~ ENGINE HIGH IDLE ADJUST and AUTO RPM in THIS SECTION.

If oil pressure falls too low, an alarm will sound.

Refer to the COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION.

2. Eng % Torque (%) This display indicates the percentage of maximum engine torque being consumed at the current engine rpm level.

With engine speed at IDLE (no load) and hydraulic oil at operating temperature the reading should be: Parking Brake ENGAGED

13-16%

Readings with the parking brake DISENGAGED should be a maximum of 4% higher than the reading with the parking brake ENGAGED. If the readings are outside this range investigate the cause.

NOTE: The above readings are at normal operating temperatures. During cold start-ups it is not unusual for readings to be significantly higher until normal operating temperatures are reached.

2.31

Tigercat 635D Skidder

Controls and operation

5. Boost ( psi or bar)

ADJUSTMENT MENU

This display indicates air intake manifold boost pressure in psi.

6. Charge Air Temperature (°F or °C) This display indicates the charge air cooler temperature reading.

If temperature rises above the recommended temperature, alarm will sound, check the following:

• Plugged air intake access panel screens • Plugged charge air cooler.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in THIS SECTION. Refer also to COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION for more information about the hydraulic oil temperature warning.

From the main menu press F2 button to select the ADJUSTMENT MENU. When selected the adjustment menu icon is on display and all the adjustment selections will also be displayed.

7. Engine Voltage (volts) This display indicates engine voltage levels.

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

If engine voltage goes outside the normal range, an alarm will sound. Refer to COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION. A reading in excess of 30 volts indicates a possible faulty voltage regulator.

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

IMPORTANT 24 VOLT ELECTRICAL SYSTEM 8. Engine Hours - h This display indicates the total number of hours the engine has run.

The adjustment selections are as follows: •

Engine Settings - Shown first by default.

•

Fan Settings - Press F2 to select

•

Service Settings - Press F3 to select Press the back button to return to the main menu.

2.32

Tigercat 635D Skidder

Controls and operation Cold Idle Speed Range 950 to 1500 rpm (1200* rpm) * NOTE: Reset default settings are marked.

Refer to COMPUTER ~ ADJUSTMENT MENU ~ EXAMPLE ~ ADJUSTMENT MENU NAVIGATION for an example of adjustment menu navigation.

Refer also to COLD IDLE OPERATION and COLD IDLE SPEED ADJUSTMENT in THIS SECTION.

ENGINE SETTINGS Press the F1 button to select the Engine Settings Menu from the ADJUSTMENT MENU. The engine settings menu will appear.

Press F1 (Adjust) to adjust engine settings.

Press the back button to return the Engine Settings Menu display.

Press the back button again to return to the main menu.

The adjustable engine settings are: Engine High Idle Adjust Range 1800 to 2200* rpm This parameter allows the operator to adjust engine high idle speed limit, this limit will be in effect whenever the grapple constant pressure function is NOT activated. This function is intended to allow the automatic reduction of the engine high idle speed limit when travelling without a load.

Auto RPM On* or Off When the Auto RPM function is ON engine rpm will automatically increase proportionally with operation of all joystick functions.

When the Auto RPM function is OFF engine rpm must be increased by the operator using the travel/engine speed pedals or the engine speed control trigger on the right hand joystick.

2.33

Tigercat 635D Skidder

Controls and operation

FAN SETTINGS (IF EQUIPPED)

SERVICE SETTINGS

Press F2 button to select Fan Settings Menu from the ADJUSTMENT MENU. Note that this menu is applicable only for machines equipped with the optional variable pitch fan.

Press F3 button to select the Service Settings Menu from the ADJUSTMENT MENU. The service settings menu will appear.

Press F3 (Adjust) to adjust service settings

The fan settings menu will appear.

Press the back button to return the Service Settings Menu display.

Press F2 (Adjust) to adjust fan settings Press the back button to return the Fan Settings Menu display.

Press the back button again to return to the main menu.

Press the back button again to return to the main menu.

The adjustable service settings are: Hydraulic Oil Grade

The adjustable fan settings are:

ISO 22* Petro CAN MV 22 ISO 32 Petro CAN MV 36 ISO 46 Petro CAN MV 60 ISO 68

Fan Auto Clean On* or Off Clean Frequency Range 1 to 420 minutes (*30 minutes) Clean Duration

This information is used by the machine program to adapt hydraulic oil temperature warning messages for the operating range of each Hydraulic Oil Grade.

Range 5 to 20 seconds (*15 seconds) * NOTE: Reset default settings are marked.

Refer to COMPUTER ~ ADJUSTMENT MENU ~ EXAMPLE ~ ADJUSTMENT MENU NAVIGATION for an example of adjustment menu navigation.

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

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

2.34

Tigercat 635D Skidder

Controls and operation

Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HYDRAULIC OIL TEMPERATURE HIGH in THIS SECTION for more information about the hydraulic oil temperature warning.

Steer Adjust (Joystick steering only) Range 50 to 100% (75*%) This setting adjusts the performance of the joystick steering function. A lower setting will result in a slower response. A higher setting will result in a quicker response.

Refer to COMPUTER ~ INFORMATION MODE MENU ~ HYDRAULIC OIL TEMPERATURE in THIS SECTION for hydraulic oil temperature information display.

Steer Invert (Joystick steering only) On* or Off

Front Tire Size

When ON the joystick steering control is automatically adjusted by the computer control system based on the position of the operator's seat. Therefore LEFT articulation and RIGHT articulation are considered to be left and right as viewed by the operator either from the forward facing seat position or the rear facing seat position.

Not Configured 28L 24.5 30.5L 35.5L DH73 This information is used by the machine program to accurately calculate and display machine travel speed.

When OFF the joystick steering invert function is disabled. Steer joystick direction does not change when operator is facing rearward.

Therefore LEFT articulation and RIGHT articulation are considered to be left and right as viewed by the operator from the forward facing seat position regardless of the position of the operator's seat. The machine steering invert disabled information message will be shown each time the machine is started to inform the operator that the steer invert function has been disabled.

Program Mode Normal* Engine HP Test Mode Drive Motor Setup Mode Drive Pump POR Setup Mode Drive Pump Regulation Setup Function Setup Mode Max Current Setup Mode (if equipped) * NOTE: Reset default settings are marked.

Refer to COMPUTER ~ ADJUSTMENT MENU ~ EXAMPLE ~ ADJUSTMENT MENU NAVIGATION for an example of adjustment menu navigation.

IMPORTANT !

Machine must be in the Normal Program Mode to operate normally.

Other program modes are used for service/setup procedures only.

When setup program modes are chosen an information message is shown on the electronic display until the message is acknowledged.

In each program mode some controls are deactivated for safety during setup procedures.

Attempting to use these controls will reactivate the information message.

Refer also to LEFT HAND JOYSTICK ~ STEERING, ROTATING SEAT KICK LEVER and COMPUTER ~ MESSAGES AND WARNINGS - INFORMATION ~ MACHINE STEERING INVERT DISABLED in THIS SECTION.

2.35

Tigercat 635D Skidder

Controls and operation

EXAMPLE ~ ADJUSTMENT MENU:

Press the arrow up or arrow down buttons to scroll to the setting to be adjusted.

From the main menu press F2 button to select the ADJUSTMENT MENU.

Press the F2 button to reset to default setting.

Press F2 (Yes) or F3 (No) to confirm.

The engine settings menu will appear by default.

Press F1 (Adjust) to adjust engine settings

2.36

Tigercat 635D Skidder

Controls and operation

OR

OR

Press the OK button to go to the adjustment display.

To reset to default setting press the F2 button.

Press F2 (Yes) or F3 (No) to confirm.

Press the arrow up or arrow down buttons to make the adjustment.

Press the OK button to confirm the setting.

Press the back button to return to the adjustment menu.

Press the back main menu.

2.37

button again to return to the

Tigercat 635D Skidder

Controls and operation

INFORMATION MODE MENU

EARLIER PROGRAMS

Press the F3 button to access the information menu.

When selected the information menu icon is on display and the information functions will also be displayed.

The information functions on display are as follows: •

Hydraulic Oil Temp -°F or °C

•

Drive Pressure Forward - psi or bar

•

Drive Pressure Reverse - psi or bar

•

Drive Motor Speed - rpm

•

Hydrostatic Circuit Temperature -°F or °C

•

Machine Hours - h

•

Machine Voltage - V

•

Travel Speed - mph or km/h

LATER PROGRAMS Press the F1 button to toggle between imperial and metric units of measure.

Press the F2 button to select the fuel information display (if applicable) Press the back button to return to the main menu.

2.38

Tigercat 635D Skidder

Controls and operation Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge.

Operating outside the recommended operating range will shorten hydraulic component life.

Refer to COMPUTER ~ ADJUSTMENT MENU - SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in THIS SECTION for hydraulic oil grade selection settings information.

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HYDRAULIC OIL TEMPERATURE HIGH in THIS SECTION for more information about the hydraulic oil temperature warning.

INFORMATION FUNCTIONS 1. Hydraulic Oil Temperature (°F or °C) This display indicates the current hydraulic oil temperature registered in the main hydraulic tank.

2. Drive Pressure Forward - psi or bar This display indicates forward drive pressure.

If the temperature rises above the recommended operating range for the type of hydraulic oil in use, alarm will sound, check the following: • • • • • •

3. Drive Pressure Reverse - psi or bar This display indicates reverse drive pressure.

4. Drive Motor Speed - rpm

Plugged oil cooler Malfunction in a hydraulic system High loads on the hydraulic system Malfunction of the cooling fan Low hydraulic oil level Correct Hydraulic Oil Grade Selection

This display indicates the drive motor speed in rpm.

5. Hydrostatic Circuit Temperature -°F or °C (if equipped) This display indicates the hydrostatic circuit temperature as read by the temperature sensor located on the drive pump.

If hydraulic oil temperature rises above the recommended operating range DO NOT continue to operate the machine.

6. Machine Hours - h This display indicates the total number of hours the machine has run.

NOTE ALSO: Hydraulic oil temperature can also be monitored using the hydraulic oil temperature gauge shown on the main menu.

The alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main menu of the computer display, together with the operating range chart in SECTION 3 to prevent damage to the hydraulic system.

2.39

Tigercat 635D Skidder

Controls and operation

7. Machine Voltage - V This display indicates voltage levels in the electrical system.

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

If voltage goes outside the normal range, an alarm will sound. Refer to COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION. A reading in excess of 30 volts indicates a possible faulty voltage regulator.

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

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

FUEL INFORMATION (LATER PROGRAMS)

8. Travel Speed - mph or km/h

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

This display indicates machine travel speed.

Note that front tire size information is used by the machine program to accurately calculate and display machine travel speed. Refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ FRONT TIRE SIZE to check or update front tire size settings.

Press the F2 button to reset the trip average fuel rate and trip fuel used functions.

Press the back button to return the information display.

Press the back button again to return to the main menu.

1. Fuel Rate - US gph or L/h (instantaneous) This display indicates the current rate of fuel consumption in gallons per hour.

2. Total Fuel Used - US gal or L This display indicates the total fuel used during the life of the machine.

3. Trip Average Fuel Rate - US gph or L/h This display indicates the average fuel consumption rate for the machine since last reset.

4. Trip Fuel Used - US gal or L This display indicates the total fuel used since last reset.

FUEL GAUGE The fuel level gauge is shown on the main menu.

2.40

Tigercat 635D Skidder

Controls and operation

MAIN MENU PAGE From any menu page.

Press the menu button to go to the main menu page.

The main menu page displays the following selections: •

Adjust - Press F1 to select

•

Measure - Press F2 to select

•

Preferences - Press F3 to select

•

Info - Press F4 to select Press the back button to return to the page which was displayed when the main menu page was selected.

OR Press the menu button again to return to the page which was displayed when the main menu page was selected.

2.41

Tigercat 635D Skidder ADJUST MENU

Controls and operation ENGINE ADJUST GROUP*

FAN ADJUST GROUP* (IF EQUIPPED)

From the main menu page press the F1 button (Adjust) to access the adjust menu.

SERVICE ADJUST GROUP*

The following menu items can be selected: •

Engine Adjust Group*

•

Fan Adjust Group* (if equipped)

•

Service Adjust Group*

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection. *NOTE: Marked menu items can also be accessed from the main menu. Refer to COMPUTER ~ ADJUSTMENT MENU in THIS SECTION for more information.

NOTE ALSO: Service technicians may have access to more options through this menu. Refer to SECTION 6 of the SERVICE MANUAL for more information.

Press the back button (or F1) to return to the main menu page.

2.42

Tigercat 635D Skidder MEASURE MENU

Controls and operation

The following menu items can be selected.

From the main menu page press the F2 button (Measure) to access the measure menu.

• • • • • • • • • •

Voltage Inputs Digital/Frequency Inputs Digital Outputs Current Outputs J1939 Parameter Inputs Drive/HP Test Function Valve Variable Pitch Fan Differential Locks Module Diagnostics

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

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

Press the back button (or F1) to return to the main menu page.

2.43

Tigercat 635D Skidder PREFERENCES MENU

Controls and operation

From the main menu page press the F3 button (Preferences) to access the preferences menu.

The following menu items can be selected for adjustment.

•

Display - Press F1 to select

•

Date/Time - Press F2 to select

•

Language - Press F3 to select Press the back button to return to the main menu page.

2.44

Tigercat 635D Skidder

Controls and operation

DISPLAY ADJUSTMENT From the preferences menu press the F1 button to access display adjustment.

Screen Saver Adjustment Press F3 to access the screen saver adjustment.

•

Main Menu Page - Press F1 to select

Use the Arrow Up and Arrow Down buttons to scroll through the choices. Three choices are available:

•

Backlight - Press F2 to select Screen Saver - Press F3 to select

•

SCREEN SAVER OFF

•

•

DIMMED - Timeout - Dimmed light

•

BLACK - Timeout

The following menu items can be selected:

Press the back button to return to the preferences menu.

After making a selection press the OK button to confirm selection.

Backlight Adjustment Press F2 to access the backlight adjustment.

Use the Arrow Up or Arrow Down buttons to adjust the display backlight. The range is 10 to 100. The default setting is 100.

When the desired setting is selected press the OK button to confirm the setting. A good rule to follow is the lower the number the longer the life of the display unit.

2.45

Tigercat 635D Skidder

Controls and operation

DATE/TIME ADJUSTMENT

Date Adjustment

From the preferences menu press the F2 button to access date/time adjustment.

Press F1 to access the date adjustment.

The following menu items can be selected:

Use the Arrow Up or Arrow Down to scroll through the YEAR list to select the year.

•

Date - Press F1 to select

Press the OK button to confirm year selected.

•

Time - Press F2 to select Press the back button to return to the preferences menu.

When the year has been confirmed the display will highlight the MONTH. Use the Arrow Up or Arrow Down to select the month.

Press the OK button to confirm month selected.

2.46

Tigercat 635D Skidder

Controls and operation Time Adjustment Press F1 to access the time adjustment.

When the month has been confirmed the display will highlight the DAY. Use the Arrow Up or Arrow Down to select the day.

Use the Arrow Up or Arrow Down to select the HOUR.

Press the OK button to confirm day selected.

Press the OK button to confirm selection.

The display will return to the Date/Time menu.

When the hour has been confirmed the display will show the MINUTES highlighted.

Press the back button to return to the preferences menu.

Use the Arrow Up or Arrow Down to select the minute.

Press OK button to confirm the selection.

The display will return to the DATE/TIME menu screen.

Press the back button to return to the preferences menu.

2.47

Tigercat 635D Skidder

Controls and operation

LANGUAGE ADJUSTMENT

INFO MENU

From the preferences menu press the F2 button to access language adjustment screen.

From the main menu page press the F4 button

The languages available for selection will be shown.

Use the Arrow Up or Arrow Down to move to the preferred language.

Press OK to confirm the selection.

The display will return to the LANGUAGE menu screen.

Press the back button to return to the preferences menu.

(Info) and the access the info menu.

The machine ID information will be displayed on the screen.

The following menu items can be selected: •

Modules - Press F1 to select

•

Logs - Press F3 to select Press the back button to return to the main menu page.

2.48

Tigercat 635D Skidder

Controls and operation

MODULES

LOGS

From the Info menu press F1 to select the modules menu.

Press F3 from the info menu page to select logs.

This menu lists the logs available in the machine program and the number of records within each log.

This menu provides information on the following machine modules: • • • •

Display (MD3 Computer Module) Cab Module (XS2 Module) Front Chassis Module (XA2 Module) Cummins Engine ECM

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

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

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

Press the back button (or F1) to return to the main menu page.

Shown above the MD3 module has been selected. Specific information for the MD3 is displayed on the screen.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

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

Press the back button (or F1) to return to the main menu page.

2.49

Tigercat 635D Skidder MESSAGES AND WARNINGS ALARM MD3 COMPUTER LIGHT

Controls and operation

MASTER ALARM

INSTRUMENT PANEL The MD3 computer displays messages and warnings, activates the master alarm and alarm light whenever a system fault occurs. Note that the computer control system will automatically perform a bulb test at engine start up to ensure that master alarm and alarm light are functioning.

Refer to STARTING ENGINE in THIS SECTION. There are different types of Messages and Alarms, they appear on the screen as a block message.

The types of messages are: • • • •

CRITICAL MESSAGE - Colour RED ERROR MESSAGE - Colour RED ALERT MESSAGE - Colour YELLOW INFORMATION MESSAGE - Colour BLUE

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

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

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

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

2.50

Tigercat 635D Skidder CRITICAL MESSAGES AND WARNINGS (RED)

Controls and operation

Critical messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

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

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

A list of CRITICAL MESSAGES is as follows: Hydraulic Oil Level Low. Drive Motor Clutch Pressure Low

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

Drive Motor Overspeed

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

Hydraulic Oil Temperature High

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to move the machine to a safe location then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

Hardware Fault - Engine

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

Engine Intake Manifold Temperature High

Critical messages and warnings flash the critical

Engine Fault Code Messages - Critical

Interlock System Engine Stop Hardware Fault - MD3 Hardware Fault - XS2 Hardware Fault - XA2 Engine Coolant Temperature High Engine Coolant Level low Engine Oil Pressure Low

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

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

2.51

Tigercat 635D Skidder CRITICAL MESSAGES AND WARNINGS

Controls and operation

Hydraulic Oil Level Low.

HYDRAULIC OIL LEVEL LOW This warning will be displayed, alarm warning light will flash and alarm will sound when the main hydraulic tank oil level is low.

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

When this alarm is activated stop the engine and look for signs of broken hoses or other leaks.

Repair leaks and refill the main hydraulic tank to FULL mark on the sight gauge with grapple head fully open, grapple head and dozer blade on the ground. Restart engine and inspect for leaks.

Drive Motor Clutch Pressure Low.

DRIVE MOTOR CLUTCH PRESSURE LOW (EHS TRANSMISSION) This warning will be displayed, alarm warning light will flash and alarm will sound when the drive motor clutch pressure is low.

Stop the machine immediately when this alarm is activated and check the EHS transmission for proper operation.

2.52

Tigercat 635D Skidder

Controls and operation

Drive Motor Overspeed. Reduce travel speed.

DRIVE MOTOR OVERSPEED This warning will be displayed, alarm warning light will flash and alarm will sound when the drive motor is overspeeding.

Reduce speed immediately when this alarm is activated to prevent damage to the machine.

Operating drive motors at high speeds will damage the drive motors.

Note that machines equipped with an EHS transmission have separate warnings for left hand and right hand drive motors.

2.53

Tigercat 635D Skidder

Controls and operation

Hydraulic Oil Temperature High.

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

If the temperature rises above the recommended operating range for the type of hydraulic oil in use check the following: • • • • • •

Plugged oil cooler Malfunction in a hydraulic system High loads on the hydraulic system Malfunction of the cooling fan Low hydraulic oil level Correct Hydraulic Oil Grade Selection

If hydraulic oil temperature rises above the recommended operating range DO NOT continue to operate the machine.

This alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main menu, together with the operating range chart in SECTION 3 to prevent damage to the hydraulic system.

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

Operating outside the recommended operating range will shorten hydraulic component life.

Refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in THIS SECTION for hydraulic oil grade selection settings information.

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

Refer to COMPUTER ~ INFORMATION MODE MENU ~ HYDRAULIC OIL TEMPERATURE in THIS SECTION for hydraulic oil temperature information display.

2.54

Tigercat 635D Skidder

Controls and operation

Interlock System Door open or park brake on! Machine drive disabled.

INTERLOCK SYSTEM This warning will be displayed, alarm warning light will flash and alarm will sound to a alert the operator that the interlock system has disabled the machine drive.

The interlock system prevents the machine from being driven and function controls from being operated while the parking brake is ENGAGED. The parking brake is operated using the parking brake switch or lever. This message indicates that the parking brake was engaged, by the parking brake control or opening a cab door, while the machine was in motion.

Engine Stop Critical engine fault active - contact dealer.

ENGINE STOP This warning will be displayed, alarm warning light will flash and alarm will sound when the engine stops while the ignition switch is in the RUN position and/or when critical engine alarms are triggered.

Refer to engine manufacturer's manual for specific information regarding the engine.

2.55

Tigercat 635D Skidder

Controls and operation

Hardware Fault - MD3 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

HARDWARE FAULT - MD3 This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the MD3 Display module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF error is an example of the type of hardware fault which will be the original active fault which triggers this message.

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

HARDWARE FAULT - ENGINE This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the Engine has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

No contact error is an example of the type of hardware fault which may be the original active fault which triggers this message.

2.56

Tigercat 635D Skidder

Controls and operation

Hardware Fault - XS2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

HARDWARE FAULT - XS2 This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the XS2 Cab module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which triggers this message.

Hardware Fault - XA2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

HARDWARE FAULT - XA2 This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the XA2 Front Chassis module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which triggers this message.

2.57

Tigercat 635D Skidder

Controls and operation

Engine Coolant Temperature High

ENGINE COOLANT TEMPERATURE HIGH This warning will be displayed, alarm warning light will flash and alarm will sound when engine temperature exceeds recommended temperature.

When this alarm is activated check for:

• •

Plugged air intake access panel screens Plugged radiator.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in THIS SECTION.

SPN: 111 FMI: 1 1 of 1 Engine coolant level low Below normal, severe.

SPN: 111 FMI: 1 1 of 1 Engine coolant level low Below normal, severe.

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

WARNING

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.

Refer to SERVICE AND LUBRICATION POINTS CHART in SECTION 3 of THIS MANUAL.

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.

2.58

Tigercat 635D Skidder

Controls and operation

SPN: 105 FMI: 0 1 of 1 Intake manifold temperature high Above normal, most severe SPN: 105 FMI: 0 1 of 1 Intake manifold temperature high Above normal, most severe

INTAKE MANIFOLD TEMPERATURE HIGH This warning will be displayed, alarm warning light will flash and alarm will sound when engine charge air cooler temperature exceeds recommended termperatures.

When this alarm is activated check for: •

Plugged air intake access panel screens

•

Plugged charge air cooler.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in THIS SECTION.

SPN: 100 FMI: 1 1 of 1 Engine Oil Pressure Low Below normal, most severe SPN: 100 FMI: 1 1 of 1 Engine Oil Pressure Low Below normal, most severe

ENGINE OIL PRESSURE LOW This warning will be displayed, alarm warning light will flash and alarm will sound when engine oil pressure falls below 10psi (0.7Bar).

Stop the engine when this alarm is activated.

Check engine oil levels.

Refer to STARTING ENGINE in THIS SECTION for more information.

2.59

Tigercat 635D Skidder

Controls and operation

SPN: 612 FMI: 2 1 of 1 Crankshaft speed/position signal lost Erratic or intermittent SPN: 612 FMI: 2 1 of 1 Crankshaft speed/position signal lost Erratic or intermittent

ENGINE FAULT CODE MESSAGES - CRITICAL Critical engine fault message(s) will be displayed, alarm warning light will flash and alarm will sound when a critical engine fault message is received from the engine electronic control module.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Critical engine fault codes are higher priority messages than alert level engine fault code messages. Critical messages can be hidden but immediate action must be taken, STOP machine operation and service engine immediately to resolve the cause of the fault.

An example of a critical engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

2.60

Tigercat 635D Skidder ERROR MESSAGES (RED)

Controls and operation

Error messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Error messages are computer system generated and are generally triggered by computer system error and fault related conditions.

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

A list of some types of ERROR MESSAGES is as follows:

Error messages are activated whenever a fault such as an electrical connection is broken/ disconnected. Most error messages are due to computer system hardware or connection faults.

Module No Contact Error Module VREF Error Voltage Input Error (VIN)

When an error message is displayed, the master alarm and alarm light will sound and flash continuously. The message remains on the screen until the operator hides it.

Digital Input Error (DIN) Digital Output Error (DOUT) Current Output Error (COUT)

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

* Note that not all error messages are shown.

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

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to move the machine to a safe location then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

Messages are acknowledged by pressing the F2 button (OK). To recall active messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

Error messages flash the critical symbol

or the

above the F4 button when active messages are hidden depending on the type of error message. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

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

2.61

Tigercat 635D Skidder ERROR MESSAGES

Controls and operation XS2-A0

Cab Module No contact

MODULE NO CONTACT ERROR XA2-A0 The module no contact error message will be displayed to indicate a loss of communication with or power to a module. The module is identified on the display screen.

When a module goes loses contact all machine functions controlled by that module cease and all messages and warnings associated with that module are triggered. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

Note that if the MD3 display module has a loss of power or other malfunction the screen may go blank and all machine functions controlled by the computer system will be affected..

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HARDWARE FAULT in THIS SECTION.

2.62

Tigercat 635D Skidder

Controls and operation MD3

Display VREF error

MODULE VREF ERROR The module VREF message will be displayed to indicate a problem related to the 5 V reference signal coming from the module.

The module is identified on the display screen.

This message indicates a problem with a sensor, connecting wires or the 5V reference signal itself.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HARDWARE FAULT in THIS SECTION.

2.63

Tigercat 635D Skidder

Controls and operation Cab Module Pin C1:25

Travel Direction Select VIN High error

VOLTAGE INPUT ERROR (VIN) Voltage input error messages will be displayed to indicate a problem with a voltage input signal to a computer system module.

The module and pin number are identified on the display screen.

CURRENT OUTPUT ERROR (COUT)

The heading identifies the signal source and the text indicates the type of error.

Current output error messages will be displayed to indicate a problem with a current output signal from a computer system module.

An example of a voltage input error message is shown above.

The module and pin number are identified on the display screen.

DIGITAL INPUT ERROR (DIN)

The heading identifies the signal destination and the text indicates the type of error.

Digital input error messages will be displayed to indicate a problem with a digital input signal to a computer system module.

The display is similar to the voltage input error message shown above.

The module and pin number are identified on the display screen.

Once acknowledged these message will be replaced with a hardware failure message for the corresponding module when active faults recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAILURE in THIS SECTION.

The heading identifies the signal source and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

DIGITAL OUTPUT ERROR (DOUT) Digital output error messages will be displayed to indicate a problem with a digital output signal from a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal destination and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

2.64

Tigercat 635D Skidder ALERT MESSAGES (YELLOW)

Controls and operation

Alert messages advise the operator that machine operation will be compromised.

Alert messages have the third level of priority and are used to indicate to the operator that action is required to prevent future damage to the machine.

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

Action should be taken to service the machine to correct the problem at the earliest opportunity to prevent future damage to the machine.

There are two types of alert messages: Alert programmed messages generally triggered by machine function related conditions.

Alert messages flash the alert symbol above the F4 button when active messages are hidden.

When an alert message is displayed, the external alarm and light will sound and flash three times to alert the operator of the message. The message remains on the screen until the operator hides it.

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

Alert computer system generated messages are generally triggered by computer system error and fault related conditions.

Active messages that have been hidden can be reviewed by pressing the F4 button. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

When a system generated alert message is displayed he external alarm and light will sound and flash three times to alert the operator of the message.

Note that if both a critical level fault and an alert level fault are present the critical symbol will take priority until the critical fault becomes inactive.

The message remains on the screen until the operator hides it.

Note that active hardware fault alert messages are acknowledged by pressing the F2 button (OK). To recall these messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

2.65

Tigercat 635D Skidder

Controls and operation

A list of ALERT MESSAGES is as follows: Fuel Level low.

Engine Air Intake Filter Restricted Drive Charge Filter Bypassed Machine Voltage Low. Machine Voltage High Drive Motor Speed Sensor No motor speed Service Brake Pressure Low Drive Charge System Pressure Low. Fuel Water In Fuel Hardware Fault - MD3 Hardware Fault - XS2 Hardware Fault - XA2 Hardware Failure - VIN Hardware Failure - DIN Hardware Failure -DOUT Hardware Failure -COUT Engine Voltage Low Engine Voltage High Engine Fault Code Messages - Alert Some types of computer system generated alert messages are listed below: Module High Temperature - Alert Module High Supply Voltage - Alert Module Low Supply Voltage - Alert * Note that not all system generated alert messages are shown.

2.66

Tigercat 635D Skidder ALERT MESSAGES

Controls and operation

Fuel Level low.

FUEL LEVEL LOW This warning will be displayed when the fuel level falls below 5% of full.

Refer to FUEL TANK in THIS SECTION for tank capacities.

Engine Air Intake Filter Restricted. Service Machine to correct.

ENGINE AIR INTAKE FILTER RESTRICTED This warning will be displayed when a signal is received from the restriction indicator switch on the engine air cleaner.

When this happens the engine air cleaner requires immediate service.

Refer to AIR CLEANER MAINTENANCE in SECTION 3 of THIS MANUAL.

2.67

Tigercat 635D Skidder

Controls and operation

Drive Charge Filter Bypassed. Service machine to correct.

DRIVE CHARGE FILTER BYPASSED This warning will be displayed when an oil flow restriction in excess of 50 psi (3.5 Bar) 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.

When this happens the filter requires immediate service.

If alarm sounds during cold start-ups, the engine speed should be reduced and the warm-up procedure continued. Note that the bypass warning will only be displayed when hydraulic oil temperature is above 85°F (29°C) and the filter is in bypass mode.

Machine Voltage Low. Service machine to correct.

MACHINE VOLTAGE LOW This warning will be displayed when machine voltage readings of less than 20 volts are detected.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

2.68

Tigercat 635D Skidder

Controls and operation

Machine Voltage High. Service machine to correct.

MACHINE VOLTAGE HIGH This warning will be displayed when machine voltage readings of greater than 30 volts are detected.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

Drive Motor Speed Sensor No motor speed. Drive overload or speed sensor malfunction.

DRIVE MOTOR SPEED SENSOR NO MOTOR SPEED (EARLIER PROGRAM REVISIONS ONLY) This warning will be displayed when a drive motor speed sensor malfunction is detected.

If the message is displayed when the machine is not travelling it indicates a drive overload. Check drive pump POR. If this message is displayed when the machine is travelling it indicates a sensor malfunction.

2.69

Tigercat 635D Skidder

Controls and operation

Service Brake Pressure Low. Service machine to correct.

SERVICE BRAKE PRESSURE LOW This warning will be displayed when service brake pressure falls below 800 psi (55 Bar).

When this warning is activated check first for leaks in the brake circuit. If no leaks are found check for proper operation of the brake pedal valve, accumulator, check valve and brake pressure sensor.

For more information about the service brake circuit refer to SECTION 9 of THE SERVICE MANUAL.

Drive Charge System Pressure Low. Service machine to correct.

DRIVE CHARGE SYSTEM PRESSURE LOW This warning will be displayed when drive charge pressure falls below 250 psi (17 Bar). The charge pressure is monitored at the forward and reverse pressure sensors on the drive pump.

When this warning is activated check the charge filter for proper operation then, if necessary, check the charge pressure using a gauge.

Refer to DRIVE PUMP PRESSURE CHECKS in SECTION 8 of THE SERVICE MANUAL. Refer also to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ DRIVE CHARGE FILTER BYPASSED warning in THIS SECTION.

2.70

Tigercat 635D Skidder

Controls and operation

SPN: 97 FMI: 15 1 of 1 Water in Fuel Above normal.

SPN: 97 FMI: 15 1 of 1 Water in Fuel Above normal.

FUEL - WATER IN FUEL This warning will be displayed when water is detected in the fuel by the engine computer system.

Refer to engine manufacturer's manual for specific information regarding the engine.

Hardware Fault - MD3 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

HARDWARE FAULT - MD3 This warning will be displayed when an alert level active hardware fault related to the MD3 Display module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

2.71

Tigercat 635D Skidder

Controls and operation

Hardware Fault - XS2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

HARDWARE FAULT - XS2 This warning will be displayed when an alert level active hardware fault related to the XS2 Cab module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

Hardware Fault - XA2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

HARDWARE FAULT - XA2 This warning will be displayed when an alert level active hardware fault related to the XA2 Front Chassis module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

2.72

Tigercat 635D Skidder

Controls and operation

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

HARDWARE FAILURE - VIN This warning will be displayed when a voltage input error message has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

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

HARDWARE FAILURE - DIN This warning will be displayed when a digital input error message has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

2.73

Tigercat 635D Skidder

Controls and operation

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

HARDWARE FAILURE - DOUT This warning will be displayed when a digital output error message has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

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

HARDWARE FAILURE - COUT This warning will be displayed when a current output error message has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

2.74

Tigercat 635D Skidder

Controls and operation

SPN: 168 FMI: 18 1 of 1 Engine voltage low Below normal, severe SPN: 168 FMI: 18 1 of 1 Engine voltage low Below normal, severe

ENGINE VOLTAGE LOW This warning will be displayed when engine voltage readings of less than 20 volts are detected.

When this alarm is activated investigate the cause immediately.

SPN: 168 FMI: 16 1 of 1 Engine voltage high Above normal, severe SPN: 168 FMI: 16 1 of 1 Engine voltage high Above normal, severe

ENGINE VOLTAGE HIGH This warning will be displayed when engine voltage readings of greater than 30 volts are detected.

When this alarm is activated investigate the cause immediately.

2.75

Tigercat 635D Skidder

Controls and operation

SPN: 110 FMI: 16 1 of 1 Engine coolant temperature high Above normal, severe SPN: 110 FMI: 16 1 of 1 Engine coolant temperature high Above normal, severe

ENGINE FAULT CODE MESSAGES - ALERT Alert engine fault message(s) will be displayed, alarm warning light will flash and alarm will sound when an alert engine fault message is received from the engine electronic control module.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Alert engine fault codes are lower priority messages than critical level engine fault code messages. Alert messages can be hidden but action (service engine) is required to resolve the cause of the fault.

An example of an alert engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

NOTE: Contact your Tigercat dealer to obtain an Engine Fault Codes chart. An up to date copy should be kept in the Manual’s Box (in the cab). The chart is updated regularly by the engine manufacturer, so it is important to check periodically with the Tigercat dealer to ensure that you have a current copy of the Engine Fault Codes chart.

2.76

Tigercat 635D Skidder

Controls and operation MD3

Display High temperature

Value: 75 °C MODULE HIGH TEMPERATURE - ALERT Module high temperature alert message will be displayed to indicate that the computer control system has detected high temperature readings in a system module.

The module is identified on the display screen.

The temperature reading value is also displayed.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAULT in THIS SECTION.

2.77

Tigercat 635D Skidder

Controls and operation MD3

Display High supply voltage

Value: 34 V MODULE HIGH SUPPLY VOLTAGE - ALERT Module high supply voltage alert message will be displayed to indicate that the computer control system has detected high supply voltage readings in a system module.

The module is identified on the display screen.

The voltage reading value is also displayed.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAULT in THIS SECTION.

2.78

Tigercat 635D Skidder

Controls and operation

MODULE LOW SUPPLY VOLTAGE - ALERT MD3

Display Low supply voltage

Module low supply voltage alert message will be displayed to indicate that the computer control system has detected low supply voltage readings in a system module.

The module is identified on the display screen.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAULT in THIS SECTION.

2.79

Tigercat 635D Skidder INFORMATION MESSAGES (BLUE)

Controls and operation

Information messages give the operator information regarding an event or problem condition while the event or problem exists.

Information messages have lowest priority and are used to give the operator information that is useful to the operator, but requires no action to prevent immediate or future damage to the machine When an information message is displayed on the screen the message will either automatically disappear when the condition no longer exists or stay on the screen until the operator acknowledges the message.

A list of the INFORMATION MESSAGES is as follows:

Information messages can be acknowledged by pressing the F2 button (OK). Acknowledged information messages are removed from the screen.

Setup Mode - Drive Pump POR Setup

Setup Mode - Engine HP Test Setup Mode - Drive Motor Setup Setup Mode - Drive Pump Regulation Setup Setup Mode - Function Setup Setup Mode - Max Current Setup (if equipped*) Machine Steering Invert Disabled * NOTE: Used for machines equipped with EHS transmission only.

Information messages do not have an indicator after they have been acknowledged.

Most information messages that have been acknowledged cannot be reviewed.

Recurrence of an event or problem condition related to an information message may cause the message to be shown again.

Restarting the machine may also cause the message to be shown again.

2.80

Tigercat 635D Skidder INFORMATION MESSAGES

Controls and operation IMPORTANT !

Machine must be in the Normal Program Mode to operate normally.

SETUP MODE One of these warnings will be displayed until the message is acknowledged when the machine is placed in a service program mode:

Other program modes are used for service/setup procedures only.

When setup program modes are chosen an information message is shown on the electronic display until the message is acknowledged.

• Engine HP Test Mode • Drive Motor Setup Mode • Drive Pump POR Setup Mode • Drive Pump Regulation Setup • Function Valve Setup Mode • Max Current Setup Mode (if equipped) Setup Program Modes are intended for setup and testing and should only be used by qualified Tigercat service technicians or on specific instructions from a service technician.

In each program mode some controls are deactivated for safety during setup procedures.

Attempting to use these controls will reactivate the information message.

NOTE ALSO: •

In Engine HP Test, Drive Motor Setup, Drive Pump POR Setup, Drive Pump Regulation and Max Current Setup Modes the arch and boom are deactivated. Attempting to use these controls will reactivate the information message.

•

In Function Setup Mode the drive pedals and steering are deactivated. Attempting to use these controls will reactivate the information message.

For more information on the setup mode settings refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ PROGRAM MODE in THIS SECTION.

Setup Mode Engine HP Test Mode for service use only.

Return to Normal Mode to operate machine.

2.81

Tigercat 635D Skidder

Controls and operation

Setup Mode Drive Motor Setup Mode for service use only.

Return to Normal Mode to operate machine.

Setup Mode Drive Pump POR Setup Mode for service use only. Return to Normal Mode to operate machine.

Setup Mode Drive Pump Regulation Setup for service use only. Return to Normal Mode to operate machine.

2.82

Tigercat 635D Skidder

Controls and operation

Setup Mode Function Setup for service use only. Return to Normal Mode to operate machine.

Setup Mode Max Current Setup for service use only.

Return to Normal Mode to operate machine.

2.83

Tigercat 635D Skidder

Controls and operation

Machine Steering Steering invert disabled. Steer joystick direction does not change when operator is facing rearward.

MACHINE STEERING INVERT DISABLED This message will be displayed each time the machine is started when the joystick steering invert function is disabled.

When the joystick steering invert function is disabled. Steer joystick direction does not change when operator is facing rearward. Therefore LEFT articulation and RIGHT articulation are considered to be left and right as viewed by the operator from the forward facing seat position regardless of the position of the operator's seat.

For more information regarding the steer invert function setting refer to COMPUTER ~ ADJUSTMENT MENU - SERVICE SETTINGS ~ STEER INVERT (JOYSTICK STEERING ONLY) in THIS SECTION. Refer also to LEFT HAND JOYSTICK ~ STEERING, ROTATING SEAT KICK LEVER and COMPUTER ~ MESSAGES AND WARNINGS INFORMATION ~ MACHINE STEERING INVERT DISABLED in THIS SECTION.

2.84

Tigercat 635D Skidder CAB VENTILATION

Controls and operation

1. AIR VENTS

1

The Air Conditioner/Heater package has 8 air outlets in the cab.

• 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.

193-8

R.H. DOOR POST VENTS - 2

2. FILTER, RECIRCULATING AIR - A/C UNIT 1

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 on a regular basis.

This is done by removing two thumb screws in the filter box cover.

3. FILTER - FRESH AIR

151-11

When the air source switch is in the ON 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. The filter should be inspected on a regular basis and cleaned/replaced when severely plugged or wet. 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.

REAR DASH VENTS - 2 2

1

151-9

VENTS BEHIND SEAT - 2 3

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

E620C-09

2.85

FRESH AIR FILTER

Tigercat 635D Skidder

Controls and operation

E625C-105

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

610-15

RADIO - CB (IF EQUIPPED) Consult the manufacturer's instruction manual for additional information.

2.86

Tigercat 635D Skidder

Controls and operation

LOCATED IN OPERATOR'S CAB

CHARGE GAUGE

E625C-107

FIRE EXTINGUISHER, PORTABLE

FIRE EXTINGUISHER, PORTABLE A portable fire extinguisher is located in the 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.

2.87

Tigercat 635D Skidder CAB FUSE AND RELAY PANEL

Controls and operation

The fuse panel is located in the left rear of the cab behind the seat. The fuses and relays are protected beneath a panel which can be opened by removing two screws.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

E625C-120

2

4

6

8

1

3

5

7

10A

16

9

15

10

14

11

13

12

14

20A

28

13

20A

27

12

20A

26

11

20A

25

3A

24

5A

10 9

15A

23

3A

8

20A

22

5A

7

10A

21

5A

6

5A

20

3A

19

10A

5 4

5A

18

20A

3

30A

17

20A

2

10A

16

1

FUSE AND RELAY PANEL

15

3A

FUSES

1 - SPARE 2 - CIGARETTE LIGHTER 3 - HVAC SYSTEM 4 - KEY POWER 5 - SPARE 6 - HORN 7 - AIR SEAT 8 - ACCESSORY POWER 9 - 12V CONVERTER 10 - SPARE 11 - WORK LIGHTS FRONT 12 - WORK LIGHTS REAR 13 - WORK LIGHTS AUXILIARY 1 14 - WORK LIGHTS AUXILIARY 2 15 - HVAC SWITCHES 16 - SPARE 17 - XS2 MODULE 18 - XA2 MODULE 19 - AC COMPRESSOR/FRESH AIR BLOWER 20 - MD3 MODULE 21 - REAR CHASSIS SENSORS 22 - ECM POWER 23 - SENSORS 24 - SWITCHES 25 - INTERIOR LIGHT 26 - SPARE 27 - START/PARK BRAKE 28 - SPARE

RELAYS

1 - PARK BRAKE OFF 2 - PARK BRAKE ON 3 - START SOLENOID 4 - UNLOADING VALVE OFF 5 - WORK LIGHTS AUXILIARY 2 6 - WORK LIGHTS AUXILIARY 1 7 - WORK LIGHTS FRONT 8 - WORK LIGHTS REAR 9 - A/C COMPRESSOR/FRESH AIR BLOWER 10 - HVAC FAN 11 - REAR DIFFERENTIAL LOCK SELECTOR 12 - SPARE DIODE HOLDER 13 - SPARE 14 - PARK BRAKE SIGNAL 15 - MD3 DISCONNECT 16 - ACCESSORY POWER

48200BENG R0

CAB FUSE AND RELAY PANEL 2.88

Tigercat 635D Skidder FUSES AND RELAYS (ELECTRICAL BOX)

Controls and operation

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

625C-95

ELECTRICAL BOX (LEFT SIDE FRONT CHASSIS)

ELECTRICAL BOX FUSES AND RELAYS 2.89

Tigercat 635D Skidder

Controls and operation

CHASSIS

BOLT ON ACCESS PANELS

MAINTENANCE ACCESS DOORS

BOLTS

E620C-15

ACCESS PANELS LEFT SIDE

DOOR PROP

620D-208

FRONT DOOR E620C-14

DOORS AND ACCESS PANELS FRONT DOOR TO OPEN: Park machine on level ground and lower the grapple and dozer to the ground.

Remove the two bolts from the left side of the door and swing open.

When the maintenance is complete, close the door and reinstall bolts.

Do not operate DOZER with door open.

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

CAUTION Park on level ground to prevent unexpected door closing.

2.90

MAINTENANCE ACCESS DOOR (LEFT SIDE SHOWN)

Tigercat 635D Skidder ACCESS PANELS

Controls and operation

This machine is equipped with bolt on access panels to provide service access.

DOOR PROP

620D-207

MAINTENANCE ACCESS DOOR (RIGHT SIDE SHOWN)

Some panels are equipped with a maintenance access door to provide quick access for routine daily maintenance. Maintenance access doors are equipped with a door prop to hold them open while in use as shown above.

Always ensure that all access panels are secured in place and all access doors are closed and secured before operating the machine.

CAUTION Always use the door props provided to safely hold access doors open while in use.

The engine compartment access panels are bolted in place. Whenever bolts are removed panels can fall during the process of removing them from the machine.

2.91

Tigercat 635D Skidder

620D-211

Controls and operation

STANDARD FUEL TANK

FUEL TANK

620D-212

Located in the rear chassis, the fuel reservoir consists of two tanks interconnected. There is one filling location (right tank). The filler tube also contains a fuel tank filler screen.

HIGH CAPACITY FUEL TANK

REFUELING Park machine on level ground, shut off engine and allow machine to cool.

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

DO NOT refuel while smoking or near an open flame or sparks.

A sending unit is installed and connected to the computer display on the instrument panel.

Clear obstructions from steps and handles needed to access fuel tank.

The standard fuel tank has a capacity of 81 US gal (305 L).

Open cover on top of fuel tank (if equipped)and clear any debris from around the fill cap.

There is also a high capacity fuel tank available for machines without winches. It is a single 145 US gal (550 L) replacement tank.

Remove filler cap slowly to allow pressure to escape from tank.

Inspect fill cap gasket.

Inspect fuel strainer located under the fill cap for debris or damage.

Attach grounding strap if the fueling tank or nozzle is so equipped.

Fill tank until fuel level reaches the strainer or the full mark on the sight gauge if equipped. Do not leave nozzle unattended or spillage may occur.

Remove nozzle and ground strap (if applicable), then install fill cap hand tight before closing fill cap cover.

Before restarting the machine, check that no other personnel have moved into the hazardous area and sound the horn.

2.92

Tigercat 635D Skidder

Controls and operation PRESSURIZED WATER SYSTEM WATER TANK

WATER CONTROL VALVE

DOZER BLADE

BATTERY DISCONNECT SWITCH

E625C-117

BATTERY DISCONNECT SWITCH LEFT SIDE ENGINE COMPARTMENT

HOSE STORAGE COMPARTMENT

BATTERY DISCONNECT SWITCH

SHUT-OFF VALVE IN CLOSED POSITION

Located in the engine compartment on the left side of the machine, this switch is wired to the positive side of the battery.

620C-41

A water tank is incorporated into the dozer blade and is pressurized to 60 psi (4 bar). A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade.

When in the OFF position it completely disconnects all the machine's electrical circuits from the battery and isolates the engine control module (ECM) power fuses.

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 shut-off valve should be in the CLOSED position when the system is not in use.

BELOW RIGHT HAND CAB DOOR

TRANSMISSION DIPSTICK

630D-15

PRESSURIZED WATER SYSTEM

The pressure gauge on the valve should read 60 psi (4 bar) check system pressure daily.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3.

TRANSMISSION OIL FILL LOCATION

TRANSMISSION DIPSTICK AND FILL LOCATION

All handles should be hand tight only at all times.

This is particularly important for easy access to the pressurized water system in the event of a fire or other emergency.

TRANSMISSION DIPSTICK

The transmission dipstick is located below the right hand cab door.

TRANSMISSION OIL FILL LOCATION The transmission oil fill is located below the right hand cab door.

Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL. 2.93

Tigercat 635D Skidder

Controls and operation

ENGINE AIR CLEANER

IMPORTANT !

For peak engine performance and maximum fuel economy, please ensure that the air precleaner is regularly checked and cleaned as required. All intake air tubes and clamps should be thoroughly inspected on a regular basis and any damaged or missing components should be replaced immediately.

ENGINE AIR PRECLEANER

3

3 4

AIR CLEANER

2 1

AIR CLEANER UNLOADER VALVE

635D-128

5

ENGINE AIR CLEANER

630C-19

AIR PRECLEANER

CENTRI® PRECLEANER OPERATION

OPERATION: 1. Air enters the precleaner.

2. Specially designed vanes move dirty air toward the impeller.

3. The spinning impeller spins the air creating centrifugal force to separate contaminants from the clean air.

4. Contaminants are blown out the discharge louver.

5. Clean air enters the intake to the air cleaner.

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. The air precleaner should be checked every 8 hours to make sure that foreign materials have not plugged the intake area or the discharge louver area. Clean as required.

IMPORTANT !

The air precleaner must be check every 8 hours and cleaned as required.

If the inlet/precleaner is plugged causing a restriction to airflow, reduced engine performance and increased fuel consumption may result.

If a plugged inlet/precleaner is left too long excessive air intake restriction may damage the rubber air intake tube. A damaged air intake tube will lead to ingestion of dirt into the engine which may result in engine failure.

Note that the air filter restriction indicator may not function properly if the air intake tube is damaged.

Engine failures due to improper maintenance are not covered by Tigercat or Engine Manufacturer’s Warranty and any such claim will be denied.

2.94

Tigercat 635D Skidder

Controls and operation

AIR CLEANER

FILTER RESTRICTION INDICATOR

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

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

FILTER RESTRICTION SWITCH (IF EQUIPPED)

AIR CLEANER

A filter restriction indicator is mounted to the output side of the filter, this should show green when the engine is running under load. Service is required if the indicator shows red. Later machines may be equipped with a switch used to send a signal to the computer control system in the event of a filter restriction.

635D-129

ENGINE AIR CLEANER

FILTER RESTRICTION INDICATOR A filter restriction indicator is connected to the outlet side of the air filter. Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

Engine Air Intake Filter Restricted. Service Machine to correct.

NOTE: Replace the safety element every third primary filter change.

In addition refer to the LUBRICATION AND MAINTENANCE SCHEDULE and AIR CLEANER MAINTENANCE in SECTION 3 of THIS MANUAL

When a signal is received from the restriction indicator switch on the engine air cleaner a warning message will be displayed. Refer to COMPUTER~MESSAGES AND WARNINGS - ALERT~ENGINE AIR INTAKE FILTER RESTRICTED in THIS SECTION. 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.

2.95

Tigercat 635D Skidder MAIN HYDRAULIC OIL TANK

Controls and operation Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HYDRAULIC OIL LEVEL LOW in THIS SECTION.

Located at the rear of the engine compartment, the hydraulic tank has a capacity of 26.4 US gal (100 L).

HYDRAULIC FILTERS The hydraulic cooling circuit contains a two element, full flow, 7 micron filter with a built in 25 psi (1.7 bar) bypass valve. It is recommended that all machines use two different filter elements:

A sight gauge, indicates the HIGH and LOW level of the main hydraulic oil tank. For earlier machines (6351001 to 6351030) the sight gauge is accessible through the left rear access panel.

For later machines (6351031 and up) the sight gauge is accessible through the right rear access panel.

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.

HYDRAULIC TANK

Check hydraulic oil level and fill tank with grapple head fully open, grapple head and dozer blade on the ground. Fill tank until hydraulic oil level reaches the sight gauge full mark. Note that the oil level will drop 2 to 3 in (2 to 7.5 cm) when all cylinders are extended.

BLUE ELEMENT

HYDRAULIC HAND FILL PUMP

DOUBLE ELEMENT FILTER

630D-05

CHARGE PRESSURE FILTER

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351031 TO 6351180)

BREATHER HYDRAULIC TANK

BLUE ELEMENT

HYDRAULIC HAND FILL PUMP

BREATHER

SIGHT GAUGE

A hydraulic oil level switch is connected to the computer control system. On earlier machines the hydraulic oil level switch is mounted on the hydraulic tank. On later machines the hydraulic oil level switch is incorporated into the base of the sight gauge. This switch triggers the hydraulic oil level low warning.

HYDRAULIC TANK

DOUBLE ELEMENT FILTER

SIGHT GAUGE

DOUBLE ELEMENT FILTER

BREATHER

SIGHT GAUGE

BLUE ELEMENT

LEVEL SWITCH

HYDRAULIC HAND FILL PUMP

CHARGE PRESSURE FILTER

E620C-02

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351001 TO 6351030)

620D-202

2.96

CHARGE PRESSURE FILTER

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351181 TO 6351500)

Tigercat 635D Skidder

Controls and operation

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

The charge circuit contains a single element, full flow, Tigercat hydraulic filter with a restriction indicator sending unit and a third port bypass valve.

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION

For additional information on these filters refer to FILTERS and SERVICE AND LUBRICATION POINTS in SECTION 3.

TO TANK VIA FILTERS

SHUT-OFF VALVE IN OFF POSITION

HAND FILL PUMP

620C-27

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 SECTION 3 of THIS MANUAL.

QUICK CONNECT TO SUCTION HOSE (STORED IN STEP COMPARTMENT BELOW LEFT HAND CAB DOOR)

630D-05X

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION BELOW LEFT HAND CAB DOOR

Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

HYDRAULIC HAND FILL PUMP

HYDRAULIC HAND FILL PUMP

IMPORTANT !

Close shut-off valve after filling. Replace cap on suction tube, wipe dry, disconnect and store.

Swing pump handle up and lock. Replace all access covers.

The hydraulic hand fill pump, located on the front of the hydraulic tank (right side access), is used to add oil to the hydraulic oil tank. Refer to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL. TO ADD OIL TO THE MAIN HYDRAULIC TANK: Park machine on level ground, lower dozer blade and grapple onto the ground. Open right rear engine compartment access panels. Get the hydraulic oil fill suction hose from its storage location in the step compartment below the left cab door. Clean the suction hose, connect to hydraulic hand pump 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 the double element filter. The pump should always be operated at a medium speed with a steady motion.

2.97

Tigercat 635D 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. 3. When computer checks are complete place ignition switch in the OFF position.

For the Diesel Engine supplied with this machine, refer to the engine manufacturer's operating manual.

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

Read and understand the entire manual before operating the machine.

PRE-START CHECKS:

620D-211

FUEL TANK

4. Check fuel sight gauge. Refer to FUEL TANK in THIS SECTION for standard tank capacity information.

1. Place the ignition switch in the RUN position (engine NOT running). Check for any alarms noted on the computer display and investigate the cause. Refer to COMPUTER in THIS SECTION. ICON ILLUMINATED (RED) WHEN PARKING BRAKE IS ENGAGED

E625C-118

2. Check parking brake for proper operation and engage parking brake.

2.98

Tigercat 635D Skidder

Controls and operation BELOW RIGHT HAND CAB DOOR

SIGHT GAUGE

TRANSMISSION DIPSTICK

TRANSMISSION OIL FILL LOCATION

TRANSMISSION DIPSTICK AND FILL LOCATION 7. Check transmission oil level. The level of the oil must be between the ADD and the FULL marks on the dipstick.

630D-15

E625C-54

MAIN HYDRAULIC OIL SIGHT GAUGE (6351001 TO 6351030)

FUEL FILTER

SIGHT GAUGE

FUEL FILTER/ WATER SEPARATOR

DRAIN TAP

630D-05

MAIN HYDRAULIC OIL SIGHT GAUGE (6351031 AND UP)

620C-82

5. Check hydraulic tank oil level with grapple head fully open, grapple head and dozer blade on the ground. In this position the oil level should reach the full mark. Note that the oil level will drop 2 to 3 in (2 to 7.5 cm) when all cylinders are extended.

8. Drain water from fuel line water separator.

DIPSTICK

LEFT SIDE OF ENGINE 620C-81

FUEL WATER SEPARATOR

ENGINE OIL LEVEL

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

2.99

Tigercat 635D Skidder

Controls and operation ENGINE AIR PRECLEANER

AIR CLEANER

33952AUNI R0

FILLER CAP

AIR CLEANER UNLOADER VALVE

620C-36

ENGINE COOLANT LEVEL

9. Check the engine coolant level.

635D-128

ENGINE AIR CLEANER

11. Check air intake precleaner for foreign material build-up in air intake area or discharge louver area.

12. Check air cleaner unloader valve

A/C COMPRESSOR BELT

FILTER RESTRICTION INDICATOR

FILTER RESTRICTION SWITCH (IF EQUIPPED)

SERPENTINE BELT AIR CLEANER

635D-129

620C-83

CHECK CONDITION OF ENGINE BELTS

ENGINE AIR CLEANER

13. Check engine air cleaner restriction indicator.

10. Check tension and condition of all engine belts.

2.100

Tigercat 635D Skidder

Controls and operation 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.

620C-10

IMPORTANT! Unlock both doors before operating machine to allow opening from the outside in case of an emergency. Make sure that the doors are operational, open the doors twice, once using the exterior handle and once using the interior latch handle.

CLEAN RADIATOR, OIL COOLER, CAC AND A/C CONDENSER

14. Clean radiator, oil cooler, CAC (charge air cooler) and A/C condenser. Remove debris from front door and screened access panels on both sides of the machine.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in THIS SECTION. WATER TANK

WATER CONTROL VALVE

DOZER BLADE

HOSE STORAGE COMPARTMENT

620C-41

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.

2.101

Tigercat 635D Skidder STARTING ENGINE

Controls and operation IMPORTANT !

After engine has started, keep engine speed low until engine oil pressure registers on computer display. If engine oil pressure does not register within 10 seconds, stop engine and investigate cause.

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

2. Parking brake ENGAGED. NOTE: The engine will not turn over unless the parking brake is ENGAGED.

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.

3. Turn ignition key to RUN position and observe computer display.

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

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

8. Before applying any load to the engine proceed with SYSTEM TEST AND WARM-UP. IMPORTANT !

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.

4. Wait for WAIT TO START warning on computer display to turn off.

NOTE: For cold weather conditions refer to COLD IDLE OPERATION on the following pages.

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

6. Turn ignition key switch to the START position to crank the engine. When engine is started place key switch in RUN position and observe computer display.

Note that the computer control system will automatically perform a bulb test when the keyswitch is released to the RUN position.

The alarm light will flash and the master alarm will sound briefly to test for proper operation.

7. Engine idle speed setting will automatically default to LOW IDLE. Keep engine speed low until engine oil pressure registers on computer display ( ENGINE MENU - ENGINE FUNCTIONS). Low engine oil pressure will trigger an alarm.

Refer to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ENGINE OIL PRESSURE LOW.

2.102

Tigercat 635D Skidder STARTING IN COLD WEATHER

Controls and operation

Cold temperatures may require the use of the engine block heater and the engine oil pan heater.

The engine is equipped with an intake air heater with a grid element.

WARNING: Using starting fluid (or ether start aids) on an engine equipped with a grid heater element can cause an explosion. NEVER USE STARTING FLUIDS on an engine equipped with a grid heater element.

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

The grid element preheats engine intake air during cold starts. The wait to start warning is shown on the computer display for the duration of the preheating phase of engine startup. To minimize cranking time during cold weather startups, ALWAYS wait for the wait to start warning on the computer display to turn off before cranking the engine. Before applying any load to the engine proceed with SYSTEM TEST AND WARM-UP. IMPORTANT !

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

Wait 2 minutes between each attempt to start the engine.

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

IMPORTANT !

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

NOTE: For cold weather conditions refer to COLD IDLE OPERATION on the following pages.

2.103

Tigercat 635D Skidder

Controls and operation

COLD IDLE OPERATION Cold Idle operation is provided to increase engine idle speed to assist in warming the engine and cab temperature in cold weather conditions.

NOTE: To set COLD IDLE function ON the engine must be running and the parking brake must be ENGAGED. Disengaging the parking brake will turn the COLD IDLE function OFF.

TO TURN COLD IDLE OFF: When engine and cab have warmed to the desired temperature, cold idle can be turned off by pressing the F2 ( ) button again (at the engine display screen) or by disengaging the parking brake.

TO TURN COLD IDLE ON: From the main menu press the F1 button to select the engine display.

Press the F2 button to toggle the cold idle function ON. The cold idle icon at the top of the screen is illuminate when the cold idle function is ON. Refer to COLD IDLE SPEED ADJUSTMENT in THIS SECTION to adjust the cold idle speed setting if required.

2.104

Tigercat 635D Skidder

Controls and operation

COLD IDLE SPEED ADJUSTMENT

From the main menu press F2 button to select the ADJUSTMENT MENU.

Press the arrow up or arrow down buttons to scroll to the setting to be adjusted.

Press the F2 button to reset to default setting.

Press F2 (Yes) or F3 (No) to confirm.

The engine settings menu will appear by default.

Continued on next page

Press F1 (Adjust) to adjust engine settings

2.105

Tigercat 635D Skidder OR

Controls and operation OR

Press the OK button to go to the adjustment display.

To reset to default setting press the F2 button.

Press F2 (Yes) or F3 (No) to confirm.

Press the arrow up or arrow down buttons to make the adjustment.

Press the back button to return to the adjustment menu.

Press the OK button to confirm the setting.

Press the back button again to return to the main menu.adjustment menu.

Press the back main menu.

2.106

button again to return to the

Tigercat 635D Skidder SYSTEM TEST AND WARM-UP

Controls and operation (l) Engage the parking brake. (m) Decrease engine idle speed to LOW IDLE.

Before commencing skidding operations, follow steps (a) through (n) to accomplish the following: • Warm up the hydraulic system.

CAUTION

• Test all systems for proper operation.

• Inspect for hydraulic oil leaks.

Ensure that the machine was parked on level ground at last shutdown:

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.

(a) Start engine. (b) Ensure that computer displays are indicating normal operating conditions. (c) Check that all personnel are clear of the machine. Disengage the parking brake. (d) Slowly raise and lower the arch, check for proper operation.

With the grapple and dozer raised slightly off the ground:

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

(e) Operate the grapple arms and check for proper operation. (f) Rotate grapple in each direction for several revolutions and check that it is operating correctly. (g) Raise and lower dozer blade (h) Steer the machine to the left and right. (i) When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps (e) through (h) several times. As the hydraulic system warms up, engine speed can be increased gradually to the HIGH IDLE. (j) 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, lower the dozer blade and grapple to the ground. (k) Check service brake for proper operation.

Refer to SERVICE BRAKE ~ CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3 of THIS MANUAL.

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Tigercat 635D Skidder

Controls and operation RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL

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 lower grapple and dozer blade to the ground.

2. Reduce engine speed to LOW IDLE and let run for approximately three to five minutes to allow gradual dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

If the engine runs out of fuel, the fuel line is self priming.

1. Refill fuel tank completely.

2. Turn ignition key to RUN position and observe computer display.

3. Wait for WAIT TO START warning on computer display to turn off.

4. Turn ignition switch to the START position to crank engine.

If it fails to start after 20 seconds, stop and wait for 2 minutes before trying again.

5. When engine starts, release ignition key to RUN position and observe the computer display.

3. Do not race engine before shut-off.

IMPORTANT !

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

Wait 2 minutes between each attempt to start the engine.

4. Parking brake ENGAGED. 5. Stop engine by turning ignition switch to the OFF position.

WARNING

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

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

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 battery disconnect switch to OFF

.

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Tigercat 635D Skidder 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) Check the position of the maximum speed control to ensure that it is set to the desired position.

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

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

Caution: Setting the maximum speed control to the minimum setting lowers maximum travel speed only, it will NOT prevent the machine from travelling when the forward or reverse travel controls are used.

Controls and operation Refer to STEERING in THIS SECTION for more detailed steering control information.

(5) 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: This machine is equipped with a 10 minute AUTO-OFF feature which automatically deactivates the differential locks after 10 minutes have passed.

NOTE: The high idle adjust function is available.

This function is intended to allow the automatic reduction of the engine high idle speed limit when travelling without a load. Refer also to COMPUTER ~ ADJUSTMENT MENU - ENGINE SETTINGS ~ ENGINE HIGH IDLE ADJUST in THIS SECTION.

(3) ROTATING SEAT & JOYSTICK STEERING

Use the direction selection switch on the left hand joystick to choose forward or reverse and press the travel foot pedal to move the machine in that direction.

STATIONARY SEAT & STEERING WHEEL

Operate the drive travel pedals to move the machine forward or reverse.

(4) Be aware of the type of steering control (and steer valve option - if applicable) the machine is equipped with. Steering control operation varies with the type of controls in use.

Generally, this machine is equipped with Load Sensing Steering. The speed that the vehicle responds to steering control input will vary, depending on the speed that the steering control is moved.

When operating on the road, a slow movement of the steering control 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 control, which will quickly change the vehicles direction.

2.109

Tigercat 635D Skidder

Controls and operation

OPERATING GRAPPLE: DAILY INSPECTION/SERVICE 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.

E620C-10

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.

The Constant Pressure button on the joystick 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.

Refer to RIGHT HAND JOYSTICK in THIS SECTION for specific information on grapple operating controls.

2.110

Tigercat 635D Skidder OPERATING WINCH: Place the skidder in a safe, stable location, in line with the load.

Lower the grapple and dozer blade to the ground to anchor the machine.

Place the winch select switch in the (freespool) position. The winch freespool icon on the main menu of the computer display will be illuminated.

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

Controls and operation CENTER JOINT: 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.

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: Close cab door and disengage parking brake.

Place the winch select switch (to the left of the lever) in the I (ON) position. Pull and hold the lever BACK to wind in the winch cable. For safety reasons this lever returns to the neutral (center) position when released and actuates the brake, which locks the drum.

Avoid pulling the hook over the drum and through the throat of the winch.

Refer also to WINCH SELECT SWITCH and WINCH CONTROL LEVER in THIS SECTION.

2.111

Tigercat 635D 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.

•

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

SAFETY:

•

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

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

•

Never travel across a STEEP slope or side hill.

•

Never make an uphill turn on a slope

•

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

Never approach an unstable log from the downhill side.

•

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

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

•

Wear heavy gloves when handing the cables.

•

Use the PARKING BRAKE where appropriate.

•

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

•

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

•

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

WARNING

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

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

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

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.

•

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.

•

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

10. Be aware of what is happening around you.

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

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.

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Tigercat 635D Skidder

Controls and operation

CORRECT KEEP LOAD LOW AND CLOSE TO SKIDDER FOR BEST STABILITY. BETTER WEIGHT DISTRIBUTION BETWEEN FRONT AND REAR OF MACHINE.

INCORRECT DECREASED STABILITY DUE TO LOAD POSITION. POORER WEIGHT DISTRIBUTION BETWEEN FRONT AND REAR OF MACHINE

EFFECT OF LOAD POSITION ON STABILITY AND WEIGHT DISTRIBUTION

2.113

Tigercat 635D 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.

WARNING Backup carefully. If a log strikes an object, it could be pushed forward through the grapple and into the operator's cab.

When running empty, always keep grapple tongs closed to prevent striking the tires or the machine.

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.

2.114

Tigercat 635D 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.

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. Note that cab doors must be closed and parking brake disengaged to operate the winch in function.

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 and winch the load back into the butt pan.

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

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Tigercat 635D Skidder

Controls and operation

CARE OF THE MACHINE

CARE OF POLYCARBONATE WINDOWS IN CAB

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

Most windows used in the cab are made from a polycarbonate resin thermoplastic. This material is a replacement for glass when improved strength, durability and safety is required.

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

Polycarbonate material is expected to resist heavy impact from large branches and falling tree tops and to absorb high levels of energy when contacted by high velocity thrown objects such as wood chips, disc saw blade teeth or broken harvester head saw chain.

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 AND COOLING ASSEMBLY in THIS SECTION. 7. Be sure that the grapple and dozer blade are resting on the ground before servicing or parking the machine.

The extreme operating environment seen in logging applications heightens the need to regularly inspect and properly maintain polycarbonate cab windows.

Polycarbonate windows are an essential piece of operator protective equipment and should be maintained as such. It is important to note that cracks, chips, notches or scarring anywhere on the viewing surface or edges of the window will decrease ability to resist heavy impacts and therefore compromise effectiveness as operator safety protective equipment. Windows with these defects must be replaced immediately.

Refer to the next section for detailed information regarding inspection and maintenance of polycarbonate windows.

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Tigercat 635D Skidder

Controls and operation

INSPECTION AND MAINTENANCE

RESISTANCE TO CHEMICALS

Daily inspection and maintenance is essential to confirm that the window’s ability to protect the operator has not been compromised.

The resistance of polycarbonate material to chemical exposure varies widely. Fortunately, polycarbonate materials have good resistance to diesel fuel, grease, hydraulic oil, kerosene and engine oil.

•

Inspect all windows daily and immediately after any impacts.

•

Check for any damage to the window material or steel structure in the area of the window mounting.

Other chemicals however can seriously weaken the polycarbonate.

•

The edges of the polycarbonate window must be evenly and fully supported on a flat surface around the entire window opening at all times.

Bent or dented skylight structures must be replaced immediately. Bent or dented cab structures must be evaluated immediately for possible repair or replacement.

•

The edges of the polycarbonate window must be free from cracks, chips, notches or scarring and must not be pinched or stressed.

These defects will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

•

Cracks, chips, notches or scarring anywhere on the viewing surface of the window will decrease ability to resist heavy impacts.

Windows with these defects must be replaced immediately.

DO NOT permit any of the following chemicals to come into contact with polycarbonate windows: • • • • • • • • • • • • •

acetone air conditioning refrigerant ammonia anti-freeze benzene brake fluid carbon tetrachloride cutting oils gasoline lacquer thinner toluene turpentine xylene

RESISTANCE TO WATER

•

Bent, dented or missing window retaining parts must be replaced immediately.

•

Rubber materials used in mounting the window must be maintained in good condition.

•

Identification of the polycarbonate originally used by Tigercat is hot stamped in a corner of the window to identify its composition. Do not use any replacement window without proof of its material composition. Do not substitute with any other materials.

•

Skylights, cab structures, windows and window retaining parts must not be modified or replaced with components that are not approved by Tigercat.

Polycarbonate material has good resistance to water up to approximately 65°C (150°F). Above this temperature the effect of water is timetemperature related. This means that the higher the water temperature, the shorter the time before the polycarbonate is adversely affected.

Exposing polycarbonate to repeated steam cleanings or high temperature pressure washing may result in crazing, a phenomenon that causes clouding of the surface. Crazing can ultimately result in a loss of physical strength and may precede a fracture.

2.117

Tigercat 635D Skidder

Controls and operation

CLEANING INSTRUCTIONS

CAUTIONS

The viewing surfaces of polycarbonate cab windows are specially treated with a hard coating to provide enhanced resistance to abrasion and ultra-violet (UV) radiation.

•

DO NOT use abusive cleaning procedures either by hand or pressure washing on polycarbonate windows.

•

DO NOT use brushes, razor blades, scrapers, squeegees or other sharp tools on polycarbonate windows.

•

DO NOT clean polycarbonate windows when the daytime temperature is high or in direct sunlight.

•

DO NOT use abrasive or highly alkaline cleaners on polycarbonate windows.

•

DO NOT use glass cleaners in either aerosol or non-aerosol containers to clean polycarbonate windows.

•

Failure to follow these cleaning instructions will shorten the service life of polycarbonate and may cause visual hazing, loss of light transmission and delamination of the polycarbonate hard surface coating.

The following instructions are provided to prolong the life of this protective hard coating.

1. Rinse the window thoroughly with lukewarm water 2. Using a soft cloth, cellulose sponge or chamois, gently wash the window with a mild solution of soap or detergent in lukewarm water. Do not scrub or use brushes or squeegees.

Brand name soaps and detergents recommended for cleaning polycarbonate are: • Fantastik • Formula 409 • Hexcel F.O. 554 • Joy • Lysol • Mr. Clean • Neleco-Placer • Pine-Sol • Top Job 3. Rinse the window thoroughly with lukewarm water.

4. Dry the window with a moist soft cloth, cellulose sponge or chamois to prevent water spotting.

5. To remove grease or oil, first rub lightly with a good grade of VM&P Naphtha or isopropyl alcohol followed by the same rinse, wash, rinse and dry procedure described in steps 1 to 4.

CONCEALING HAIRLINE SCRATCHES The appearance of scratches and minor abrasions on the surfaces of polycarbonate windows can be minimized by using a mild automotive polish such as: • • •

Johnson’s Paste Wax Novus Plastic Polish #1 and #2 Mirror Glaze Plastic Polish

Be certain to clean the polycarbonate window as outlined prior to application of an automotive polish. Refer to CLEANING INSTRUCTIONS.

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

2.118

Tigercat 635D Skidder

Controls and operation

GRAFFITI REMOVAL •

•

For removal of paints, marking pen inks, etc., the use of Butyl Cellosolve is generally effective. The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

WINDOW SCREEN HANDKNOB

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.

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

173-25

SIDE WINDOW SCREEN

SIDE WINDOW SCREENS 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.

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.

FIRE PRECAUTIONS Polycarbonate window material will ignite when exposed to an ignition source in excess of 427°C (800°F). When working around polycarbonate windows, observe similar fire precautions to those in place for wood.

All handles should be hand tight only at all times.

2.119

Tigercat 635D Skidder

Controls and operation

CLEANING A/C CONDENSER AND COOLING ASSEMBLY

CHARGE AIR COOLER (CAC)

A/C CONDENSER HYDRAULIC OIL COOLER

The side by side A/C condenser, radiator, charge air cooler (CAC) and hydraulic oil cooler is mounted at the front of the machine. The engine fan draws air from the engine compartment, through the A/C condenser and cooling assembly and blows it out through the front door screen.

The screened access panels on each side of the engine compartment act as debris screens to prevent debris from being drawn into the engine compartment.

RADIATOR

FRONT DOOR SCREEN

The A/C condenser and cooling assembly should be checked every 8 hours (every shift) for accumulation of twigs, leaves, pine needles and dust.

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.

620C-10

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.

E620C-15

CLEAN A/C CONDENSER AND COOLING ASSEMBLY

CLEAN SCREENED ACCESS PANELS BOTH SIDES

CAUTION 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 30psi or less.

Always use personal protective equipment to guard against flying debris.

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.

2.120

Tigercat 635D Skidder

Controls and operation

USING THE FAN CLEAN FUNCTION TO REMOVE DEBRIS DURING OPERATION (IF EQUIPPED-VARIABLE PITCH FAN OPTION) The Flexxaire® cooling fan has a CLEAN function for use in cleaning debris from the machines engine enclosure. The pitch of the fan blades is changed and the direction of airflow through the engine enclosure is reversed. This change in airflow blows debris from the machine's engine enclosure to eliminate potential overheating and poor machine performance caused by overheating. Ensure that there are no personnel standing directly to the sides of the machine when performing this operation, as dust and debris will fly out.

When the fan control switch is in the AUTOMATIC position, the system will automatically cycle through an auto clean cycle. The frequency and duration of the auto clean cycle is adjustable through the computer control system menu.

Refer to FAN CONTROL SWITCH in THIS SECTION for more information.

USING THE FAN CONTROL SWITCH IN THE EVENT OF AN ENGINE COOLANT TEMPERATURE AND/OR HYDRAULIC OIL TEMPERATURE ALARM. In the event of an engine 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 CLEAN function to reverse fan flow and clean debris from the machine's engine enclosure 4. In severe operating conditions manual cleaning of debris may be required.

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 the AUTOMATIC position 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.

2.121

Tigercat 635D Skidder ARTICULATION LOCK ~ STRAIGHT LOCKED POSITION 1. Position machine on level ground and steer machine into a straight ahead position.

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

ARTICULATION LOCK

REAR CHASSIS 630D-02

ARTICULATION LOCK ~ ARTICULATED LOCKED POSITION 1. Position machine on level ground and steer machine into a fully articulated position to the right.

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

ARTICULATION LOCK

RETAINING PINS

ARTICULATION LOCK STORED POSITION

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.

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

630D-03

Controls and operation

REAR CHASSIS 630D-02

RETAINING PINS

ARTICULATION LOCK STORED POSITION

3. Remove both retaining pins from the articulation lock. Relocate articulation lock between front and rear chassis. Line up holes on the articulation lock with holes in chassis’ as shown and secure in place with both retaining pins.

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

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

630D-01

2.122

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

Tigercat 635D Skidder RETRIEVAL POINTS

Controls and operation 3. REAR RETRIEVAL POINTS If the machine becomes immobile with its rear oriented towards the aiding machine, there are retrieval points located at the rear chassis on each end of the rear axle. These points are labeled 'I' and 'J' on the machine lifting/tiedown label.

Retrieval of the machine may be required, in the event that a machine becomes immobile due to terrain conditions that do not permit it to escape under its own power.

Refer also to TOWING INSTRUCTIONS in THIS SECTION, in the event that the engine or drive system are not functioning well enough to allow the machine to move in tandem with the aiding machine.

These points must be used together in a retrieval situation.

These points are designed to accept a lifting chain/hook in either a basket or choker hitch configuration. Warning: Use chains that are appropriately sized for the load to be retrieved. These points must be used together in a retrieval situation.

1. There are retrieval points located on both the front and rear of the machine to aid in its retrieval.

2. FRONT RETRIEVAL POINTS If the machine becomes immobile with its front oriented towards the aiding machine, there are two retrieval points located at the front of the front chassis in front of the heat exchanger. These points are labeled 'G' and 'H' on the machine lifting/tie-down label.

4. Once the immobile machine has been connected to the aiding machine, both machines can move in tandem to free the immobile machine.

These points must be used together in a retrieval situation.

These points are designed to accept a lifting chain shackle. Warning: Use shackles and chains that are appropriately sized for the load to be retrieved.

E

B1

B2

AF

J

H G

I

E

C1

C2

DF

I,J

G,H

A B C D E F G H I J

E B1,C1

A,D F

B2,C2

43510BUNI R0

2.123

Tigercat 635D Skidder TRANSPORTING INSTRUCTIONS

Controls and operation CAUTION

The skidder may be transported with the wheels on or off.

As a fire prevention measure, AFTER transporting (trucking) a machine from one job sight to the next, open all doors and access panels and blow off any debris that could have re-positioned itself onto the engine and exhaust parts due to wind turbulance caused by the journey. Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL.

With wheels on:•

DO NOT remove air from tires, this will result in damage to the tires!

With wheels 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.

With the wheels on or off:•

The dozer blade must be down on the truck bed.

•

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

630D-03

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

•

The articulation lock bar must be installed so that the machine is oriented in the straight locked position.

•

The machine must be cross chained (side to side) at both the front and rear axle area.

E

B1

•

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 bottom cab access steps.

IMPORTANT !

When transporting the machine, chains must be used to prevent forward, reverse and side to side movement of the machine.

Do not secure the machine to the truck ANYWHERE near the center joint area as this can seriously damage the center joint.

Use only transport regulation chains for this purpose, example; 5/16" grade 7 with a tensile strength of 43500 kg (96,000lb)/chain. Using inferior or damaged chains could cause the load to shift.

B2

AF

J

H G

I

E

C1

C2

DF

I,J

G,H

A B C D E F G H I J

E B1,C1

A,D F

B2,C2

43510BUNI R0

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Tigercat 635D Skidder

TIE DOWN POINTS 1. When a skidder is to be transported on a flat bed the articulation lock bar must be installed so that the machine is oriented in the straight locked position.

2. Chains must be used to prevent forward, reverse and side to side movement of the machine. Tie-down locations are provided on the machine for this purpose. All tie-down points must be used to ensure no movement of the machine, or it’s associated parts, occur during transport.

Controls and operation

6. The dozer blade is to be stored in a position with its blade tip supported by the flat bed platform. The dozer blade tie-down points are labelled 'F' on the machine lifting/tie-down label.

A strap or chain is to be tightened across the top of the dozer blade arms to prevent movement.

LIFTING POINTS Lifting of the machine should be done for transportation purposes only.

WARNING

3. The front axle of the machine must be cross chained from side to side. The front axle tie-down points are labeled 'A' and 'D' on the machine lifting/tie-down label.

The chain should be wrapped around each end of the axle housing, without overlapping, and chained at a 45° angle in the forward, reverse and side to side directions.

4. In the case of a 4 wheeled machine, the rear axle of the machine must be cross chained from side to side of the flat bed. The rear axle tie-down points are labeled 'B' and 'C' on the machine lifting/tie-down label.

The chain should be wrapped around each end of the axle housing, without overlapping, and chained at 45° angle in the forward, reverse and side to side directions.

5. The grapple is to be stored in a position with grapple tongs closed and supported by the flat bed platform. The grapple tie-down points are labelled 'E' on the machine lifting/tie-down label.

A strap or chain is to be tightened across the top of the grapple box to prevent grapple movement.

Use shackles and chains that are appropriately sized for the load to be lifted.

1. The articulation lock bar must be installed so that the machine is oriented in the straight locked position.

2. There are two lifting points located at the front of the front chassis in front of the heat exchanger. These points are labeled 'G' and 'H' on the machine lifting/tie-down label.

These points are designed to accept a lifting chain shackle.

3. Additionally there are lifting points located at the rear chassis on each end of the rear axle.

These points are labeled 'I' and 'J' on the machine lifting/tie-down label.

These points are designed to accept a lifting chain/hook in either a basket or choker hitch configuration.

4. All lifting points must be used during a lifting operation.

5. Position the hoist above the centre of gravity to ensure machine stability & levelling.

2.125

Tigercat 635D Skidder TOWING INSTRUCTIONS

Controls and operation PARKING BRAKE SUPPLY HOSE

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.

PARKING BRAKE PRESSURE SWITCH

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, below the cab. A short bar is placed through the hole in the lever and pulled upwards to put the transmission into neutral.

Note if equipped with an EHS transmission please refer to TOWING INSTRUCTIONS EHS TRANSMISSION in THIS SECTION.

620D-241

REMOVE PARKING BRAKE SUPPLY HOSE AND CONNECT TO REMOTE POWER SOURCE TO DISENGAGE PARKING BRAKE WHILE TOWING

On machines equipped a caliper parking brake [spring applied hydraulic release] (6351191 to 6351500) manually release the parking brake. Refer to PARKING BRAKE (6351191 to 6351500) ~ MANUAL RELEASE OF PARKING BRAKE in SECTION 3 of THIS MANUAL. Alternately this parking brake can be released with a remote power source as describe above for a drive line parking brake.

2. On machines equipped with a driveline parking brake (6351001 to 6351054) remove parking brake supply hose from the manifold and connect to a remote power source.

Pressurize circuit to 250 psi to disengage parking brake.

On machines equipped with a parking brake lever (6351055 to 6351190) ensure that the parking brake is disengaged.

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

TRANSMISSION DISCONNECT LEVER SHOWN IN NEUTRAL

2.126

Tigercat 635D Skidder

Controls and operation

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

STEERING CYLINDERS

STEERING CYLINDERS

4. 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.

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

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.

6. When towing is completed, reconnect parking brake supply hose and steering cylinder hoses in their proper locations.

2.127

NORMAL HOSE CONNECTIONS

HOSES ON ONE CYLINDER CROSS CONNECTED FOR TOWING

Tigercat 635D Skidder

Controls and operation

2.128

Tigercat 635D Skidder SECTION 3 - LUBRICATION & MAINTENANCE

NOVEMBER 2013

CONTENTS - SECTION 3 AIR CLEANER MAINTENANCE....................................................................................3.33 AIR CONDITIONING SYSTEM, CHECKING.................................................................3.42 APPROVED HYDRAULIC OILS....................................................................................3.13 ARTICULATION LOCK...................................................................................................3.37 CAB SAFETY CABLE....................................................................................................3.45 CAB SUPPORT BRACE................................................................................................3.45 CENTER JOINT LUBRICATION............................................................................................................ 3.36 MAINTENANCE.......................................................................................................... 3.36 DEPRESSURIZING SUSPENDED MACHINE ELEMENTS..........................................3.29 DRAINING ENGINE COOLANT.....................................................................................3.27 DRAINING HYDRAULIC TANK......................................................................................3.26 DRAINING PARKING BRAKE OIL (6351001 TO 6351054)...........................................3.28 DRAINING THE FUEL TANK.........................................................................................3.22 DRAINING TRANSMISSION OIL...................................................................................3.28 EMERGENCY EXITS, CHECK MONTHLY......................................................................3.7 FILLING HYDRAULIC TANK..........................................................................................3.26 FILTERS CHARGE PRESSURE FILTER................................................................................... 3.25 FUEL FILTER/WATER SEPARATOR.......................................................................... 3.20 FUEL TANK STRAINER............................................................................................. 3.20 HYDRAULIC OIL DOUBLE FILTERS......................................................................... 3.23 SERVICING GUIDELINES FOR OIL FILTERS........................................................... 3.23 FIRE PREVENTION.........................................................................................................3.8 FRONT AXLE FRONT AXLE PINION SEAL GREASE FITTING....................................................... 3.53 LEVEL CHECK, FILL AND DRAIN LOCATIONS....................................................... 3.52 GENERAL MAINTENANCE.............................................................................................3.7 GRAPPLE SNUBBER MAINTENANCE.........................................................................3.38 HOUR METER ~ MAINTENANCE...................................................................................3.3 LUBRICATION AND SERVICE POINTS 6351001 TO 6351054................................................................................................. 3.14 6351055 TO 6351500................................................................................................. 3.16 6351055 TO 6351500 (WITH REAR BOGIE TIGERCAT DIFFERENTIAL)................ 3.18 NEW MACHINE MAINTENANCE....................................................................................3.3 FIRST 125 HOUR INSPECTION AND SERVICE REPORT......................................... 3.3 INITIAL PRE-DELIVERY INSPECTION........................................................................ 3.3 OIL ANALYSIS PROGRAM.............................................................................................3.4 OIL LOST FROM LEAKAGE............................................................................................3.7 OIL SAMPLE COLLECTION PROCEDURES..................................................................3.5 PARKING BRAKE 6351191 TO 6351500 MANUAL RELEASE OF PARKING BRAKE............................................................... 3.30 PARKING BRAKE ADJUSTMENT.............................................................................. 3.30 PRESSURIZED WATER SYSTEM MAINTENANCE.....................................................3.40

Tigercat 635D Skidder

Lubrication and Maintenance

REAR (BOGIE) AXLE DRAINING AND REFILLING BOGIE AXLE................................................................ 3.50 SLEW BEARING LUBRICATION................................................................................ 3.51 SCHEDULED MAINTENANCE FREQUENTLY.............................................................................................................. 3.9 8 HOURS...................................................................................................................... 3.9 48 HOURS.................................................................................................................... 3.9 125 HOURS................................................................................................................ 3.10 250 HOURS................................................................................................................ 3.10 500 HOURS................................................................................................................ 3.10 1000 HOURS.............................................................................................................. 3.11 2000 HOURS.............................................................................................................. 3.12 SEASONAL................................................................................................................. 3.12 SERVICE AND LUBRICATION POINTS 6351001 TO 6351054................................................................................................. 3.14 6351055 TO 6351500................................................................................................. 3.16 6351055 TO 6351500 (WITH REAR BOGIE TIGERCAT DIFFERENTIAL)................ 3.18 SERVICE BRAKE CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION................ 3.32 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE..........................................3.54 TILTING THE CAB.........................................................................................................3.44 TIRE PRESSURES........................................................................................................3.62 TORQUE, FLUID CONNECTIONS................................................................................3.58 TORQUE SPECIFICATIONS - GENERAL.....................................................................3.57 WEIGHTS OF COMMERCIAL WOOD...........................................................................3.61 WHEELS, INSTALLING....................................................................................................3.3 WINCH MAINTENANCE - ALLIED WINCH....................................................................3.46 WINCH MAINTENANCE - CARCO................................................................................3.48

3.2

Tigercat 635D Skidder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 635D SKIDDER NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBER 5339; "PDI AND 125 HOUR INSPECTION REPORT"

*FIRST 125 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBER 5339; "PDI AND 125 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 125 HOUR TIME FRAME. *IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY, THIS REPORT MUST BE COMPLETED AND RETURNED TO Tigercat Industries Inc. WARRANTY DEPARTMENT.

IMPORTANT!

TIGHTENING POINTS FOR:THE FIRST 125 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 Transmission securing bolts Engine mounting bolts Axle mounting bolts Wheel retaining bolts Cab securing bolts Pin retainers Any other loose nut, bolt or fitting

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

HOUR METER ~ MAINTENANCE: Check the hour meter on a regular basis to determine your scheduled maintenance times.

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

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

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

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

3.3

Tigercat 635D Skidder

Lubrication and Maintenance

TIGERCAT OIL ANALYSIS PROGRAM Effective for all 2007 model year 600'D' series skidders sold in North America, oil sampling and analysis must be performed during the warranty period as per the schedule below.

Warranty coverage of powertrain components, specifically hydrostatic pumps and motors, auxilliary pumps, axles, transfer case and driveshafts is contingent on performance of regular oil sampling at the owner’s expense during the warranty period.

Location Hydraulic Oil Transmission Bogie Axle Front Axle

Model 635D

First Sample 125 Hours 125 Hours 125 Hours 125 Hours

Follow-up Samples Every 1000 Hours or 6 Months Every Oil Change (500 Hours or 3 Months) Every Oil Change (1000 Hours or 6 Months) Every Oil Change (1000 Hours or 6 Months)

FIRST SAMPLE There will be no charge for the first oil samples required to be taken during the 125-Hour Inspection Service that will be scheduled and performed by your Tigercat dealer. Refer to NEW MACHINE MAINTENANCE in THIS SECTION. FOLLOW-UP SAMPLES All follow-up samples must be taken as indicated in the chart above and will be the responsibility of the machine owner.

Copies of all oil analysis results must be forwarded to the Tigercat Warranty Department for continued warranty coverage. If samples are taken using the Tigercat Oil Analysis Program, a copy of all results will automatically be sent to Tigercat.

Tigercat Oil Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required followup oil samples.

Refer also to OIL SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain plug locations.

TIGERCAT OIL ANALYSIS KITS Each kit includes a Pre-paid Sample Bottle and Sample Information Form. Pre-printed mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

The same type of sample bottle can be used for all types of oil testing including: Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.

To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on how properly collect, prepare and ship the oil samples.

Contact your Tigercat Dealer Parts Department to order Kits.

3.4

Tigercat 635D Skidder

Lubrication and Maintenance

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

HYDRAULIC SAMPLE VALVE

MAIN HYDRAULIC OIL

The accuracy of the lab analysis results is very dependent on the quality of the oil sample taken. Collection of clean oil samples that are representative of the main body of oil are essential if meaningful lab results are to be obtained.

Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all follow-up samples should be consistently taken from the same location using the same techniques as all previous samples.

•

Ensure that all sample valves and drain plugs are clean and free of debris.

•

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

•

Do not allow any airborne dirt, etc. to enter the sample bottle.

•

Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full.

OS MAIN 604 610 620C

Hydraulic Oil Samples: •

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

•

To obtain a representative oil sample, sample valves must be purged before the actual oil sample is taken. Drain a minimum of 3 or 4 ounces of oil into a separate container and discard this oil using approved recycling methods.

•

Replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

All samples taken should be immediately forwarded to the lab for processing.

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

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

SAMPLE LOCATION / TRANSMISSION DRAIN 630C-100

3.5

TRANSMISSION OIL

Tigercat 635D Skidder

Lubrication and Maintenance

TIGERCAT OIL ANALYSIS PROGRAM Transmission and Axle Oil Samples: •

These samples can be taken during the oil change process.

•

To obtain a representative oil sample, ensure the oil is warm and has not settled very long (within 30 minutes of shutdown).

•

Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

•

Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

DIFFERENTIAL SAMPLE LOCATION/ DRAIN PLUG (1 PLACE) BOTTOM OF DIFFERENTIAL NOT VISIBLE IN THIS ILLUSTRATION

BOGIE HOUSING SAMPLE LOCATION / DRAIN PLUG (2 PLACES - LOWER) ONE SAMPLE FROM EACH HOUSING

BOGIE AXLE - 3 SAMPLE LOCATIONS

625C-94

AXLE LEVEL CHECK AND FILL (FAR SIDE)

BRAKE INSPECTION PORT (FAR SIDE)

BRAKE INSPECTION PORT

AXLE LEVEL CHECK AND FILL

AXLE DRAIN

625C-99

FRONT AXLE DRAIN AND FILL LOCATIONS 3.6

Tigercat 635D Skidder

Lubrication and Maintenance

GENERAL Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler.

Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

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

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

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

Always have a fire extinguisher at hand

Top up diesel fuel AT END OF Each shift to reduce contamination by condensation

For safety; when leaving the cab or leaving machine unattended or during service, always lower grapple and dozer blade to the ground

Clean up oil spills on walking surfaces and top of engine enclosure immediately

For safety, always block or support grapple and dozer blade when working under them.

Before welding on machine be sure master switch is disconnected

CHECK EMERGENCY EXITS MONTHLY~

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

Alternate exit routes are provided: the sliding windows in the cab doors. These are only to be used if the cab doors cannot be opened.

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires

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

*OIL LOST FROM LEAKAGE

PER LEAKAGE RATE DAY ONE DROP IN 10 SECONDS 0.424 ONE DROP IN 5 SECONDS 0.852 ONE DROP PER SECOND 4.26 THREE DROP PER SECOND 14.2 DROPS BREAK INTO STREAM 90.83

LOST 0IL (LITERS) LOST 0IL (GALLONS) PER PER PER PER PER MONTH YEAR DAY MONTH YEAR 12.72 152.0 0.112 3.36 40.0 25.6 306.6 0.225 6.75 81.0 127.76 1533.1 1.125 33.75 405.0 425.86 5110.31 3.75 112.5 1350.0 2725.5 32706.0 24.00 720.0 8640.0

3.7

Tigercat 635D Skidder

Lubrication and Maintenance

GENERAL 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.

3.8

Tigercat 635D Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE Clean:~ • Potentially damaging limbs or sticks from machine

FREQUENTLY:~ • Check engine cooling air intake screens for possible restriction.

• A/C condenser, oil cooler, radiator refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR'S MANUAL.

EVERY 8 HOURS (EVERY SHIFT):~ • Perform "frequently" maintenance check, and in addition:~ • Check engine coolant level

Check:~ • Service brake for proper operation. Refer to SERVICE BRAKE ~ CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in THIS SECTION. • All engine air intake system components (including charge air cooler) rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair immediately.

• Check engine oil level • Drain secondary fuel filter/water separator • Check air intake precleaner, clean as required • Check air cleaner unloader valve • Check air intake filter restriction indicator.

Replace primary filter if indicator is in red zone.

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

• Check hydraulic oil level with grapple head fully open, grapple head and dozer blade on the ground.

• Charge Air Cooler for damage, wear, cracks, or leaks and repair immediately.

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

• Check winch sump oil level

• For loose nuts, bolts and fittings

• Check transmission oil level with dipstick

• Condition and tension of fan belts.

• Lubricate front axle pivot, 2-fittings, purge

• Exhaust system for leaks.

• Lubricate mid drive shaft 1-fitting, purge

• Water pressure (60 psi [4 Bar]) for pressurized water system.

Note: Lubrication of mid drive shaft slip joint should be done with machine fully articulated and locked. Refer also to ARTICULATION LOCK ~ ARTICULATED LOCKED POSITION in THIS SECTION.

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

• Conduct an overall visual inspection.

• On earlier machines with driveline parking (6351001 to 6351054) lubricate rear drive shaft bearing, 1-fitting, purge

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

• On later machines (6351055 to 6351500) lubricate rear drive shaft bearings, 2-fittings, purge

EVERY 48 HOURS

• Lubricate center joint bearings, 2-fittings, purge

• 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.

• Lubricate steering cylinder ends, 4-fittings, purge • Lubricate arch cylinders and pivots, 6 or 12-fittings, purge • Lubricate dozer blade cylinders and pivots, 6-fittings, purge • Lubricate grapple snubbers, 2-fittings, purge • Lubricate grapple, 8-fittings, purge • Lubricate grapple yoke, 8-fittings, purge

3.9

Tigercat 635D Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 125 HOURS:~

EVERY 250 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

And in addition:~ • Lubricate grapple rotator shaft, 2-fittings, 5-shots

• Perform 125 hour maintenance And in addition:~ • Replace primary fuel filter and secondary fuel filter/water separator

• Carry out A/C system inspection; Refer to AIR CONDITIONING SYSTEM, CHECKING in THIS SECTION

• Lubricate grapple pinion gear spline, 1-fitting, 5-shots, (Note: remove pipeplug to access)

Check:~ • Check oil level in front axle. Refer to FRONT AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION.

• On machines with a driveline parking brake (6351001 to 6351054) check parking brake oil level.

• Clean and thoroughly inspect all surfaces of the arch and boom for cracks. All cracks must be properly repaired in their early stages.

Note that in most cases cracks will continue to grow in size and often lead to major structural damage. Failure to regularly inspect for cracks and immediately repair the boom system will void the structural warranty.

Contact your Tigercat dealer for specific procedures required to correctly repair any cracks found.

• Oil level in bogie axle, 1-place • Fluid level in batteries unless maintenance free • Engine rpm.

• All hydraulic pressures • Hydraulic pump and motor securing bolts • Check fuel tank filler screen • Torque tightening points as per new machine maintenance • Proper operation of pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. Visually check for damage to:• Arch and pivot linkage • Front and rear frame

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

EVERY 500 HOURS:~ • Perform "frequently" maintenance

• Center joint area

• Perform 8 hour maintenance

• Attachment

• Perform 125 hour maintenance

Make repairs immediately Visually inspect for:• Frayed electrical wiring and hydraulic hose • Wear in any other components Clean/replace:• Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

• Perform 250 hour maintenance And in addition : ~ • Replace hydraulic oil double element filters (2 elements) † 1 white, high performance element.

1 blue, water absorbing element.

• Replace charge pressure filter † • Replace oil in transmission. Sample transmission oil for testing. NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period. Refer to OIL SAMPLING PROGRAM in THIS SECTION for details.

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

3.10

Tigercat 635D Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE • Lubricate front drive shaft 1-fitting, purge • On earlier machines with driveline parking brake (6351001 to 6351054) lubricate mid rear drive shaft 1-fitting, purge • Check for proper adjustment of the parking brake. Refer to PARKING BRAKE ADJUSTMENT in SECTION 9 of the SERVICE MANUAL. For later machines refer to PARKING BRAKE (6351191 to 6351500) ~ PARKING BRAKE ADJUSTMENT in SECTION 3 of THIS MANUAL. • Lubricate door hinges, 8-fittings, purge • 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

• Drain and refill front axle. Refer to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils. Refer also to FRONT AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION. Sample front axle oil for testing. NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period. Refer to OIL SAMPLING PROGRAM in THIS SECTION for details.

• Drain and refill bogie axle differential, housings and planetary drives. Refer to REAR (BOGIE) AXLES in THIS SECTION. Refer also to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils.

Sample bogie axle oil for testing. NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period. Refer to OIL SAMPLING PROGRAM in THIS SECTION for details.

• Sample hydraulic oil from the main hydraulic tank for testing. NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period.

Refer to OIL SAMPLING PROGRAM in THIS SECTION for details.

• Perform 250 hour maintenance • Perform 500 hour maintenance And in addition replace oil in:~ • 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.

• Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. • Lubricate bogie axle slewing rings, 2-fittings; 2-places . Refer to REAR (BOGIE) AXLE~SLEW BEARING LUBRICATION in THIS SECTION.

• Replace oil in winch sump.

• Lubricate front axle pinion grease seal.

• On machines with a driveline parking brake (6351001 to 6351054) replace oil in parking brake.

• Lubricate rear axle pinion grease seal (if equipped with a rear (bogie) Tigercat differential).

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

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

3.11

Tigercat 635D Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE 2000 HOURS:~ • Replace all air intake rubber components such as elbows and connectors - High temperatures in this area can cause the rubber to harden.

See AIR INTAKE MAINTENANCE in THIS SECTION • Check all air intake tubing, rubber couplings and band clamps for signs of wear and leakage

SEASONAL:~ • Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Fill tank with grapple head fully open, grapple head and dozer blade on the ground until hydraulic oil level reaches the sight gauge full mark. Note that the oil level will drop 2 to 3 in (2 to 7.5 cm) when all cylinders are extended.

Check to ensure that the hydraulic oil type selected in the computer program matches the oil type being used. Adjust oil type if needed.

This will allow the program to optimize the cooling and warnings functions to best suite the oil being used.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge. Operating outside the recommended operating range will shorten hydraulic component life. Refer to COMPUTER ~ ADJUSTMENT MENU - SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in SECTION 2 of the OPERATOR'S MANUAL or SECTION 6 of the SERVICE MANUAL, for hydraulic oil grade selection settings information.

• Drain and refill front axle. Refer to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils. Refer also to FRONT AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION. • Drain and refill bogie axle differential, housings and planetary drives. Refer to REAR (BOGIE) AXLES in THIS SECTION. Refer also to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils.

3.12

• Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. • Perform service brake wear plate inspection.

Refer to SECTION 8 in the SERVICE MANUAL.

Tigercat 635D Skidder

Lubrication and Maintenance

APPROVED HYDRAULIC OILS Use only one of the following oils to fill or replenish the MAIN HYDRAULIC SYSTEM.

3.13

Tigercat 635D Skidder

Lubrication and Maintenance

MACHINES 6351001 TO 6351054

3.14

Tigercat 635D Skidder

Lubrication and Maintenance

MACHINES 6351001 TO 6351054 Tigercat® Model 635D SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

CHK

2

ENGINE OIL/FILTER CUMMINS QSB SERIES

CHK

3

PRIMARY FUEL FILTER

3A

•

34.4

9.1

•

•

REP

SECONDARY FUEL FILTER / WATER SEPARATOR

DRN

QTY

2000

1000

500

CHANGE COOLANT EVERY 2 YEARS

DESCRIPTION USG

COOLING SYSTEM

CAPACITY LITERS

1

250

8

ITEM

125

SERVICE POINT NO.

SERVICE EVERY

60/40 ANTIFREEZE *

• SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS 1

REP

1

4

FUEL TANK FILLER SCREEN

5

AIR INTAKE PRECLEANER/INLET HOOD

CHK

1

CLEAN AS REQUIRED

AIR INTAKE PRIMARY ELEMENT

CHK

1

6

CHK

AIR INTAKE SAFETY ELEMENT

CHK

7

AIR CLEANER UNLOADER VALVE

CHK

8

AIR INTAKE CONNECTIONS

CHK

9

MAIN HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10

HYDRAULIC FILTER, FULL FLOW, INCLUDES: 1 BLUE WATER ABSORBING ELEMENT * 1 WHITE HIGH PERFORMANCE FILTER

11

CHARGE PRESSURE FILTER

12

WINCH: ALLIED

CHK

13

PRESSURIZED WATER SYSTEM

CHK

14

TRANSMISSION

CHK

15

AXLES: FRONT

16

PINION GREASE SEAL - FRONT AXLE

CAST

17

BOGIE AXLE - DIFFERENTIAL

18

BOGIE AXLE - HOUSINGS

1

REP REP

100 26.4

REP

†

REP

†

TEST

CHK

19

BOGIE AXLE - SLEWING RINGS

20

AXLE - PIVOT (FRONT ONLY)

21

MID DRIVE SHAFT

22

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

1

DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE (SEE HYDRAULIC OIL CHART)

2

*NOTE: MUST USE 1 BLUE FILTER ELEMENT AND 1 WHITE FILTER ELEMENT

1

CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL

1

D/R

52

13.7

6

1.6

1

D/R ***

36

9.5

1

LUB

PURGE

1

LITHIUM BASE EP2 GREASE

3

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140 REFER TO MANUAL SECTION 3 FOR REAR (BOGIE) AXLE FILLING PROCEDURE

LUB LUB

246

65

SEASONAL DRAIN AND REFILL FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

PURGE

4

LITHIUM BASE EP2 GREASE

PURGE

2

LITHIUM BASE EP2 GREASE

PURGE

1

LITHIUM BASE EP2 GREASE

PURGE

2

LITHIUM BASE EP2 GREASE

LUB LUB **

MID REAR DRIVE SHAFT REAR DRIVE SHAFT: BEARING

REFER TO SECTION 3 IN MANUAL

3.8

D/R

FRONT DRIVE SHAFT

1

D/R

D/R

CHK

1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENANCE FOR DETAILS.

LUB LUB

CENTER JOINT

LUB

CENTER JOINT BEARING PRELOAD

CHK 48

REFER TO SECTION 3 OF THE MANUAL FOR DETAILS

CHK

23

STEERING CYLINDERS

LUB

PURGE

4

24

DOUBLE ARCH CYLINDER & PIVOTS

LUB

PURGE

12

LITHIUM BASE EP2 GREASE

25

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE

26

PARKING BRAKE

27

GRAPPLE, Tigercat

635D LUBECHART 42703BENGR2.XLS 04/10

CHK

D/R

0.5

0.13

LITHIUM BASE EP2 GREASE

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

SEE LUBRICATION POINTS DIAGRAM

3.15

Tigercat 635D Skidder

Lubrication and Maintenance

MACHINES 6351055 TO 6351500 MID DRIVE SHAFT

REAR DRIVE SHAFTS 21 2 FTG/8

18

1 FTG/8

21

11 3A

3

10

BOGIE AXLE SLEWING RINGS

4 FTG/1000

19

GRAPPLE YOKE

8 FTG/8

26

GRAPPLE SNUBBERS 26 2 FTG /8 GRAPPLE ROTATOR

2 FTG/125 5 SHOTS

23

2 FTG/8

4 FTG/8

GRAPPLE PINION GEAR 26 1 FTG/250 26

AXLE-PIVOT, FRONT

STEER CYLINDERS

ARCH

5 SHOTS

12

1

13

DOOR HINGES

24

12 FTG/8

NOTE: REMOVE PIPEPLUG TO ACCESS

20 2

8 FTG/500

4

9 10

5

11

6 7

1

8

14

GRAPPLE 26

8 FTG/8

CENTER JOINT 17

22

FRONT DRIVE SHAFT 21 1 FTG/500

2 FTG/8

AXLE PINION 16

DOZER

6 FTG/8

15

25

1 FTG/1000

LEGEND * ANTIFREEZE SOLUTION MUST MEET GM 6038M SPECIFICATIONS - SEE MANUFACTURERS MAINTENANCE MANUAL ** STEER MACHINE FULLY BEFORE GREASING MID DRIVE SHAFT SLIP YOKE. *** MAY USE UP TO BUT NOT MORE THAN 1 LITER OF LUBRIZOL 6178, DSL-178, OR EQUA-TORQUE 2411 OR 2414 (FRONT AXLE ONLY, BRAKE NOISE REDUCTION).

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2FTG) AND HOURS BETWEEN 2 FTG/125 SERVICING (125 ). JOINT TO BE PURGED. ♦ USE LITHIUM BASED GREASE CONTAINING MOLYBDENUM DISULFIDE. † USE OF FILTERS OTHER THAN GENUINE TIGERCAT REPLACEMENT FILTERS IS NOT RECOMMENDED.

3.16

CHK REP DRN D/R LUB

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

Tigercat 635D Skidder

Lubrication and Maintenance

MACHINES 6351055 TO 6351500 Tigercat Model 635D SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

2

ENGINE OIL/FILTER CUMMINS QSB SERIES

CHK

3

PRIMARY FUEL FILTER

3A

•

SECONDARY FUEL FILTER / WATER SEPARATOR

DRN

34.4

9.1

•

•

QTY

2000 

1000 

500 

CHANGE COOLANT EVERY 2 YEARS

DESCRIPTION USG

CHK

CAPACITY LITERS

COOLING SYSTEM

250 

8

1

125 

SERVICE POINT NO.

SERVICE EVERY ITEM

60/40 ANTIFREEZE *

• SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS

REP

1

REP

1

4

FUEL TANK FILLER SCREEN

5

AIR INTAKE PRECLEANER/INLET HOOD

CHK

1

CLEAN AS REQUIRED

AIR INTAKE PRIMARY ELEMENT

CHK

1

6

CHK

AIR INTAKE SAFETY ELEMENT

CHK

7

AIR CLEANER UNLOADER VALVE

CHK

8

AIR INTAKE CONNECTIONS

CHK

9

MAIN HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10

HYDRAULIC FILTER, FULL FLOW, INCLUDES: 1 BLUE WATER ABSORBING ELEMENT * 1 WHITE HIGH PERFORMANCE FILTER

11

CHARGE PRESSURE FILTER

12

WINCH: ALLIED

CHK

13

PRESSURIZED WATER SYSTEM

CHK

14

TRANSMISSION

CAST

15

AXLES: FRONT

16

PINION GREASE SEAL- FRONT AXLE

17

BOGIE AXLE - DIFFERENTIAL

18

BOGIE AXLE - HOUSINGS

1

REP REP

100 26.4 REP

†

REP

†

TEST

CHK

19

BOGIE AXLE - SLEWING RINGS

20

AXLE - PIVOT (FRONT ONLY)

21

22

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

1

DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE (SEE HYDRAULIC OIL CHART)

2

*NOTE: MUST USE 1 BLUE FILTER ELEMENT AND 1 WHITE FILTER ELEMENT

1

CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL

1

D/R

52

13.7

SEASONAL DRAIN AND REFILL

1.6

1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE 75W-90

D/R ***

36

9.5

1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

LUB

PURGE

1

LITHIUM BASE EP2 GREASE 

65

3

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140 REFER TO MANUAL SECTION 3 FOR REAR (BOGIE) AXLE FILLING PROCEDURE

PURGE

4

LITHIUM BASE EP2 GREASE 

PURGE

2

LITHIUM BASE EP2 GREASE 

PURGE

1

D/R

LUB LUB

FRONT DRIVE SHAFT

REFER TO SECTION 3 IN MANUAL

3.8

6

CHK

1

D/R

D/R

CHK

1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENANCE FOR DETAILS.

LUB

246

MID DRIVE SHAFT

LUB **

PURGE

1

REAR DRIVE SHAFT: BEARINGS

LUB

PURGE

2

PURGE

2

CENTER JOINT

LUB

CENTER JOINT BEARING PRELOAD

CHK 48

LITHIUM BASE EP2 GREASE 

LITHIUM BASE EP2 GREASE  REFER TO SECTION 3 OF THE MANUAL FOR DETAILS

CHK

23

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

24

DOUBLE ARCH CYLINDER & PIVOTS

LUB

PURGE

12

LITHIUM BASE EP2 GREASE 

25

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE 

26

GRAPPLE, Tigercat

SEE LUBRICATION POINTS DIAGRAM

LUBECHART 48199BENG R3 08/13

3.17

Tigercat 635D Skidder

Lubrication and Maintenance

MACHINES 6351055 TO 6351500 (WITH REAR BOGIE TIGERCAT DIFFERENTIAL) 18 16

MID DRIVE SHAFT

REAR DRIVE SHAFTS 21 2 FTG/8

AXLE PINION

1 FTG/1000

1 FTG/8

21

11 3A

3

10

BOGIE AXLE SLEWING RINGS

4 FTG/1000

19

GRAPPLE YOKE

8 FTG/8

26

GRAPPLE SNUBBERS 26 2 FTG /8 GRAPPLE ROTATOR

2 FTG/125 5 SHOTS

23

4 FTG/8

GRAPPLE PINION GEAR 26 1 FTG/250 26

AXLE-PIVOT, FRONT 20 2 2 FTG/8

STEER CYLINDERS

ARCH

5 SHOTS

12

13

DOOR HINGES

24

12 FTG/8

NOTE: REMOVE PIPEPLUG TO ACCESS

1

8 FTG/500

4

9 10

5

11

6 7

1

8

14

GRAPPLE 26

8 FTG/8

CENTER JOINT 17

22

FRONT DRIVE SHAFT 21 1 FTG/500

2 FTG/8

AXLE PINION 16

DOZER

6 FTG/8

15

25

1 FTG/1000

LEGEND * ANTIFREEZE SOLUTION MUST MEET GM 6038M SPECIFICATIONS - SEE MANUFACTURERS MAINTENANCE MANUAL ** STEER MACHINE FULLY BEFORE GREASING MID DRIVE SHAFT SLIP YOKE. *** MAY USE UP TO BUT NOT MORE THAN 1 LITER OF LUBRIZOL 6178, DSL-178, OR EQUA-TORQUE 2411 OR 2414 (FRONT AXLE ONLY, BRAKE NOISE REDUCTION).

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2FTG) AND HOURS BETWEEN 2 FTG/125 SERVICING (125 ). JOINT TO BE PURGED. ♦ USE LITHIUM BASED GREASE CONTAINING MOLYBDENUM DISULFIDE. † USE OF FILTERS OTHER THAN GENUINE TIGERCAT REPLACEMENT FILTERS IS NOT RECOMMENDED.

3.18

CHK REP DRN D/R LUB

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

Tigercat 635D Skidder

Lubrication and Maintenance

MACHINES 6351055 TO 6351500 (WITH REAR BOGIE TIGERCAT DIFFERENTIAL) Tigercat Model 635D SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

CHK

2

ENGINE OIL/FILTER CUMMINS QSB SERIES

CHK

3

PRIMARY FUEL FILTER

3A

•

34.4

9.1

•

•

REP

SECONDARY FUEL FILTER / WATER SEPARATOR

DRN

QTY

2000 

1000 

500 

CHANGE COOLANT EVERY 2 YEARS

DESCRIPTION USG

COOLING SYSTEM

CAPACITY LITERS

1

250 

8

ITEM

125 

SERVICE POINT NO.

SERVICE EVERY

60/40 ANTIFREEZE * • SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS 1

REP

1

4

FUEL TANK FILLER SCREEN

5

AIR INTAKE PRECLEANER/INLET HOOD

CHK

1

CLEAN AS REQUIRED

AIR INTAKE PRIMARY ELEMENT

CHK

1

AIR INTAKE SAFETY ELEMENT

CHK

1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENANCE FOR DETAILS.

7

AIR CLEANER UNLOADER VALVE

CHK

1

REFER TO SECTION 3 IN MANUAL

8

AIR INTAKE CONNECTIONS

CHK

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

9

MAIN HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

1

DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE (SEE HYDRAULIC OIL CHART)

10

HYDRAULIC FILTER, FULL FLOW, INCLUDES: 1 BLUE WATER ABSORBING ELEMENT * 1 WHITE HIGH PERFORMANCE FILTER

2

*NOTE: MUST USE 1 BLUE FILTER ELEMENT AND 1 WHITE FILTER ELEMENT

11

CHARGE PRESSURE FILTER

1

CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW

12

WINCH: ALLIED

13

PRESSURIZED WATER SYSTEM

CHK

14

TRANSMISSION

CHK

15

AXLES: FRONT

16

PINION GREASE SEAL

17

BOGIE AXLE - DIFFERENTIAL

18

BOGIE AXLE - HOUSINGS

6

CHK

1

REP REP

100 26.4 REP

†

REP

†

CHK

CAST

TEST

3.8

1

D/R

52

13.7

6

1.6

1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE 75W-90

D/R ***

36

9.5

1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

3

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

D/R

CHK

CHK

REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL

D/R

D/R

LUB

246

65

SEASONAL DRAIN AND REFILL

PURGE

4

LITHIUM BASE EP2 GREASE 

PURGE

2

LITHIUM BASE EP2 GREASE 

19

BOGIE AXLE - SLEWING RINGS

20

AXLE - PIVOT (FRONT ONLY)

PURGE

1

21

MID DRIVE SHAFT

LUB **

PURGE

1

REAR DRIVE SHAFT: BEARINGS

LUB

PURGE

2

PURGE

2

LUB

FRONT DRIVE SHAFT

22

LUB

CENTER JOINT

LUB

CENTER JOINT BEARING PRELOAD

CHK 48

LITHIUM BASE EP2 GREASE 

LITHIUM BASE EP2 GREASE  REFER TO SECTION 3 OF THE MANUAL FOR DETAILS

CHK

23

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

24

DOUBLE ARCH CYLINDER & PIVOTS

LUB

PURGE

12

LITHIUM BASE EP2 GREASE 

25

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE 

26

GRAPPLE, Tigercat

SEE LUBRICATION POINTS DIAGRAM

LUBECHART 57174BENG R3 08/13

3.19

Tigercat 635D Skidder

Lubrication and Maintenance

FILTERS

WARNING

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.

The fuel pump high-pressure fuel lines and fuel rail contain very high pressure fuel.

Never loosen any fittings while the engine is running. Personal injury and property damage can result.

Changing the primary fuel filter:

PRIMARY FUEL FILTER AND SECONDARY FUEL FILTER/WATER SEPARATOR (CUMMINS QSB ENGINE) This machine is equipped with two fuel filters.

The secondary fuel filter is a combination unit, with a replaceable fuel filter with drain valve and a reusable water in fuel sensor. For service and replacement intervals see SERVICE AND LUBRICATION POINTS in THIS SECTION. Refer also to engine manufacturer's manual for more detailed information.

PRIMARY FUEL FILTER

PLUG

SECONDARY FUEL FILTER/ WATER SEPARATOR

HAND PRIMER

DRAIN VALVE WATER IN FUEL SENSOR

620C-86

1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to the ground, stop engine, engage parking brake and block wheels.

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. Dispose of any fuel and the fuel filter properly.

5. Check the seating area for the o-ring on the filter head and wipe clean.

6. Lubricate the o-ring on top of the new filter with clean engine oil. DO NOT PRE-FILL the new filter.

7. Screw the new filter on to the filter head as specified by the filter manufacturer. Note: Mechanical overtightening can damage the filter element.

8. Prime the fuel system using the hand primer on the secondary fuel filter/water separator before starting the engine.

Loosen the plug on the top of the secondary fuel filter. Pump the hand primer until fuel begins to seep out around the loosened plug, continue to pump until no air bubbles are visible (approximately 30 pumps). Tighten the plug. Pump the hand primer 30 more times.

FUEL WATER SEPARATOR

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

9. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL.

3.20

Tigercat 635D Skidder

Lubrication and Maintenance

Changing the secondary fuel filter/water separator:

8. Install the water in fuel sensor in the new filter.

(Inspect water in fuel sensor for damage and replace as required.)

1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to the ground, stop engine, engage parking brake and block wheels.

9. Check the seating area for the o-ring on the filter head and wipe clean.

2. Wipe clean the area around the filter and head.

3. Use filter drain to drain fuel out of the filter for approximately 5 seconds. This will prevent fuel from running over the top of the filter when it is removed.

4. Disconnect the water in fuel sensor from the wiring harness.

5. Place rags below to catch the spillage of fuel.

6. Wearing face protection (in case of a fuel spray) unscrew the old filter. Dispose of any fuel properly .

10. Lubricate the o-ring on top of the new filter with clean engine oil. DO NOT PRE-FILL the new filter.

11. Screw the new filter on to the filter head as specified by the filter manufacturer. Note: Mechanical overtightening can damage the filter element.

12. Connect water in fuel sensor to the wiring harness.

13. Prime the fuel system using the hand primer on the secondary fuel filter/water separator before starting the engine.

Loosen the plug on the top of the secondary fuel filter. Pump the hand primer until fuel begins to seep out around the loosened plug, continue to pump until no air bubbles are visible (approximately 30 pumps). Tighten the plug. Pump the hand primer 30 more times.

7. Remove the water in fuel sensor from the fuel filter. Dispose of the fuel filter properly.

PRIMARY FUEL FILTER

PLUG

SECONDARY FUEL FILTER/ WATER SEPARATOR

HAND PRIMER

DRAIN VALVE WATER IN FUEL SENSOR

620C-86

14. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL. 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.

FUEL WATER SEPARATOR

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

3.21

Tigercat 635D 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, engage parking brake and block wheels.

LEFT HAND TANK

630D-07

2. Drain the fuel tank. (plug in bottom)

REAR COVER

RIGHT HAND TANK

STANDARD FUEL TANKS FUEL TANK FILLER CAP

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.

REAR COVER

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.

630D-08

HIGH CAPACITY FUEL TANK

DRAINING THE FUEL TANK 1. The fuel system is equipped with either two standard saddle tanks or a single high capacity tank. A siphon should be used to drain the fuel tank(s).

2. Use the fuel gauge on the computer display or the dipstick to estimate the container capacity required to properly drain the fuel.

Refer to FUEL TANK in SECTION 2 of the OPERATOR'S MANUAL for tank capacities.

3. Remove the fuel tank filler cap.

4. Remove the drain plugs* and drain the fuel into a suitable container.

Note that both the left and right sides of the high capacity tank need to be drained to fully empty this tank. *Some early fuel tanks (6351001 to 6351030) may not be equipped with drain plugs. Siphon fuel from both left and right sides of the fuel tank to drain fuel from these tanks.

5. Once the fluid has been drained replace the drain plugs and filler cap.

3.22

Tigercat 635D Skidder

Lubrication and Maintenance

HYDRAULIC OIL DOUBLE ELEMENT FILTERS

HYDRAULIC TANK

DOUBLE ELEMENT FILTER

BREATHER

DOUBLE ELEMENT FILTER HYDRAULIC TANK

SIGHT GAUGE

BREATHER

BLUE ELEMENT

BLUE ELEMENT

HYDRAULIC HAND FILL PUMP

SIGHT GAUGE HYDRAULIC HAND FILL PUMP

630D-05

CHARGE PRESSURE FILTER

E620C-02

The hydraulic oil cooling circuit contains a double filter head with a built in 25 psi (1.7 Bar) 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. It is recommended that all machines use two different filter elements:

DOUBLE ELEMENT FILTER

BREATHER

SIGHT GAUGE

BLUE ELEMENT

LEVEL SWITCH

CHARGE PRESSURE FILTER

HYDRAULIC HAND FILL PUMP

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

620D-202

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 SECTION 3 of THIS MANUAL.

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351181 TO 6351500)

HYDRAULIC FILTER SERVICING GUIDELINES

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION AND SERVICE POINTS in THIS SECTION.

Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351031 TO 6351180)

HYDRAULIC TANK

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351001 TO 6351030)

CHARGE PRESSURE FILTER

NEVER PRE-FILL HYDRAULIC FILTERS

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil. Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit.

Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors. The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

3.23

Tigercat 635D Skidder

Lubrication and Maintenance

Changing the filters: 1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to ground, stop engine, engage parking brake and block wheels.

DOUBLE ELEMENT FILTER HYDRAULIC TANK

2. Wipe clean the area around the filter and head.

BREATHER

3. Place rags below to catch the spillage of oil.

BLUE ELEMENT

4. Wearing face protection (in case of an oil squirt), unscrew the old filter. Dispose of old filter and any oil properly.

HYDRAULIC HAND FILL PUMP

5. The new Tigercat filter is 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.

SIGHT GAUGE

FILTER HEAD CHARGE PRESSURE FILTER

GASKET

FILTER ELEMENT FILTR_SEALS 2

E620C-02

SQUARE SECTION GASKET 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)

 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.

Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351001 TO 6351030)

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.

FILTER HEAD

GASKET FILTER ELEMENT FILTR_SEALS 2

'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.

3.24

Tigercat 635D Skidder

Lubrication and Maintenance

CHARGE PRESSURE FILTER The charge circuit contains a single element, full flow Tigercat hydraulic filter with a 50 psi (3.5 Bar) third port bypass valve. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the charge circuit.

HYDRAULIC TANK

DOUBLE ELEMENT FILTER

BREATHER

SIGHT GAUGE

Changing a pressure filter: 1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to ground, stop engine, engage parking brake and block wheels.

BLUE ELEMENT

2. Wipe clean the area around the filter and head.

3. Place rags below to catch the spillage of oil.

HYDRAULIC HAND FILL PUMP

4. Wearing face protection (in case of an oil squirt), unscrew the old 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.

630D-05

7. This filter has an o-ring gasket. Replace o-ring as required and apply hydraulic oil to the gasket surface.

CHARGE PRESSURE FILTER

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351031 TO 6351180)

HYDRAULIC TANK

DOUBLE ELEMENT FILTER

BREATHER

8. Screw on the new filter until the gasket makes contact with the seat in the filter head.

SIGHT GAUGE

9. Hand tighten filter an additional 1/2 turn only.

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

BLUE ELEMENT

LEVEL SWITCH

10. Start the engine and check for leaks.

WARNING HYDRAULIC HAND FILL PUMP

620D-202

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

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

•

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

•

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

3.25

CHARGE PRESSURE FILTER

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (6351181 TO 6351500)

Tigercat 635D Skidder

Lubrication and Maintenance

DRAINING HYDRAULIC TANK

CAUTION

TO TANK VIA FILTERS

Perform the hydraulic tank drain when the hydraulic oil temperature is below 100°F (38°C), but warm enough to be viscous.

HAND FILL PUMP

1. The hydraulic tank is equipped with a hose that routes from the bottom of the tank to the bottom of the front chassis belly pan.

2. The hose is plugged at the end and can be accessed by removing the belly pan door.

SHUT-OFF VALVE IN OFF POSITION

QUICK CONNECT TO SUCTION HOSE (STORED IN STEP COMPARTMENT BELOW LEFT HAND CAB DOOR)

3. The drain hose for the hydraulic tank can be lowered from the belly of the chassis and positioned in a drip pan.

4. Remove the plug in the hose end to drain tank.

5. Once fluid has been drained, replace the drain plug in the drain hose.

630D-05X

FILLING HYDRAULIC TANK

HYDRAULIC HAND FILL PUMP

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 SECTION 3 of THIS MANUAL.

Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Refer to SERVICE AND LUBRICATION POINTS chart in THIS SECTION for hydraulic tank capacity.

1. Park machine on level ground, lower dozer blade and grapple onto the ground.

Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

2. Open right rear engine compartment access panels.

3. Get the hydraulic oil fill suction hose from its storage location in the step compartment below the left cab door. Clean the suction hose, connect to hydraulic hand pump and remove cap.

4. 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 the double element filter.

The pump should always be operated at a medium speed with a steady motion. Refer also to HYDRAULIC HAND FILL PUMP in SECTION 2 of the OPERATOR'S MANUAL. Fill tank with grapple head fully open, grapple head and dozer blade on the ground until hydraulic oil level reaches the sight gauge full mark. Note that the oil level will drop 2 to 3 in (2 to 7.5 cm) when all cylinders are extended.

5. Close shut-off valve after filling. Replace cap on suction tube, wipe dry, disconnect and store. Swing pump handle up and lock.

Replace all access covers.

3.26

Tigercat 635D Skidder

Lubrication and Maintenance

DRAINING ENGINE COOLANT

CAUTION DO NOT remove the coolant filler cap from a hot engine. Wait until coolant temp is below 122°F (50°C) before removing cap.

FILLER CAP

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

33952AUNI R0

620C-36

1. The radiator is equipped with a hose to drain the contents of the radiator system fluid into a storage container.

ENGINE COOLANT FILLER CAP

CHARGE AIR COOLER (CAC)

A/C CONDENSER HYDRAULIC OIL COOLER

2. Remove the front nose belly pan in the front chassis.

RADIATOR

3. Remove the radiator pressure cap.

4. The radiator is located on the right hand side of the heat exchanger.

DRAIN HOSE

FRONT DOOR SCREEN

SHUT-OFF VALVE

620C-10

630D-06

LOWER RADIATOR TUBE SPUD AND SHUT-OFF VALVE

The lower radiator tube is equipped with a spud and shut-off valve. The drain hose is attached to the shut off valve.

5. Place the free end of the drain hose in a storage container and remove the gear clamp and bolt from the end of the hose.

6. Slowly open the shut-off valve to drain the radiator fluid.

7. Once fluid has been drained, close the shut-off valve and replace the gear clamp and bolt on the drain hose.

3.27

COOLING ASSEMBLY

Tigercat 635D Skidder

Lubrication and Maintenance DRAINING TRANSMISSION OIL

DRAINING PARKING BRAKE OIL (6351001 TO 6351054)

1. The transmission is equipped with a plug to drain the contents of the transmission into a storage container.

1. The parking brake is equipped with a hose to drain the oil contents of the parking brake into a storage container.

2. Remove the belly pan in the front chassis closest to the articulation joint.

2. Remove the belly pan in the rear chassis closest to the articulation joint.

3. The hose is plugged at the end. Place the free end of the drain hose in a storage container and remove the plug.

4. Once fluid has been drained, replace the drain plug in the drain hose.

3. Remove the drain plug on the hydraulic motor side of the transmission (pic).

4. Once fluid has been drained, replace the drain plug in the transmission housing once draining has completed.

DRAIN HOSE

TRANSMISSION DRAIN

630D-001

630C-100

PARKING BRAKE

3.28

TRANSMISSION OIL

Tigercat 635D Skidder

Lubrication and Maintenance

DEPRESSURIZING SUSPENDED MACHINE ELEMENTS When operator controls cannot be used to lower suspended machine elements due to an engine stall or other machine malfunction, suspended elements can be lowered manually using this procedure.

1. When suspended the dozer blade, grapple, and arch/boom will tend to extend the hydraulic cylinders supporting them due to gravity.

2. Remove the function valve cover in the rear chassis.

WARNING Use caution when working on top of the rear chassis, as there are many pinch areas between the arch, arch cylinders and winch.

DO NOT move arch when workers are in this area.

Use caution and follow all safety warnings when working in this area. Never stand under an object supported with hydraulics. Always use safety stands or a locking device.

Do not work under the arch without properly supporting the arch/grapple assembly.

NEVER move the arch/grapple assembly when workers are in this area.

3. Refer to the label in the valve compartment or this manual to locate valve section for the element you wish to lower. Locate the spool limiting set screw at the end of the spool section of interest.

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

4. Use a wrench to loosen the jam nut that secures the spool limiting set screw. Use an allen wrench to slowly turn the set screw clockwise (IN). Continue until the set screw starts to contact the spool inside the valve.

Movement of booms and cylinders could result in death or serious injury.

DO NOT perform work on valves or piping until boom and attachment are lowered to the ground and engine is shut off.

5. At this point the spool will allow pressurized oil on the rod side of the cylinder to travel to the valve tank port and thus lower the implement.

6. Repeat steps 3 to 5 for all raised implements.

7. Restore spool limiting set screws to their factory setting and secure jam nuts prior to operating the machine.

B

A

Factory settings are dozer section 6mm from the end of the screw to the tightened jam nut, all other sections 10mm.

SPOOL LIMITING SET SCREW

620D-09

MAIN VALVE FUNCTIONS

MAIN VALVE SPOOL LIMITING SET SCREWS

32849AUNI R0

3.29

Tigercat 635D Skidder PARKING BRAKE 6351191 TO 6351500 (SPRING APPLIED HYDRAULIC RELEASE)

Lubrication and Maintenance PARKING BRAKE ADJUSTMENT 6351191 TO 6351500 For proper adjustment the parking brake must be released during this procedure.

1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to the ground and block wheels.

Engine must be ON to operate parking brake switch for this procedure.

620D-223

PARKING BRAKE CALIPER (SPRING APPLIED HYDRAULIC RELEASE) 6351191 TO 6351500

MANUAL RELEASE OF PARKING BRAKE For towing purposes or in the event of a failure of the pressure release the parking brake can be released manually using the following procedure: 1. If possible, park machine on level ground, install articulation lock bar, lower dozer and grapple to the ground, stop engine and block wheels.

2. Remove the cover (turn counterclockwise).

3. Loosen the lock nut (M20) and turn the adjusting screw counterclockwise until the brake disc is free.

2. Change the program mode from NORMAL to FUNCTION SETUP MODE and press OK. Using the IQAN MD3 from the main menu navigate to ADJUSTMENT MENU (F2) ~SERVICE SETTINGS~Program Mode~Normal. Refer to COMPUTER ~ ADJUSTMENT MENU in SECTION 2 of the OPERATOR'S MANUAL or SECTION 6 of the SERVICE MANUAL

Note that a torque of 52 lbf-ft (70 Nm) will be required to loosen the adjusting screw and manually release the parking brake when the parking brake is engaged.

CAUTION

Once the disc is free the parking brake is inoperable.

IMPORTANT !

When setup program modes are chosen an information message is shown on the electronic display until the message is acknowledged.

4. Tighten the lock nut and reinstall the cover to protect to protect the brake from dirt.

5. When towing and/or repairs have been completed readjust the parking brake before resuming normal operations.

In each program mode some controls are deactivated for safety during setup procedures.

Attempting to use these controls will reactivate the information message.

3. With the aid of an assistant in the cab disengage the parking brake by placing the parking brake switch in the OFF position.

NOTE: As part of the interlock system this machine automatically engages the parking brake whenever a cab door is open. This prevents accidental or improper operation of the controls from anywhere but the operator's seat.

3.30

Tigercat 635D Skidder

Lubrication and Maintenance

LOCK NUT

COVER

620D-224

ADJUSTING SCREW

4. Remove the cover (turn counter clockwise).

5. Loosen the lock nut (M20) and turn the adjusting screw clockwise until the two brake pads make contact with the brake disc.

6. Turn the adjusting screw counterclockwise 1/4 turn to set correct clearance.

14. Change the program mode from FUNCTION SETUP MODE back to NORMAL and press OK. Using the IQAN MD3 from the main menu navigate to ADJUSTMENT MENU (F2) ~SERVICE SETTINGS~Program Mode~Normal. Refer to COMPUTER ~ ADJUSTMENT MENU in SECTION 2 of the OPERATOR'S MANUAL or SECTION 6 of the SERVICE MANUAL

7. Engage the parking brake by placing the parking brake switch in the ON position. Hold the adjusting screw in position and tighten the lock nut.

8. Cycle the parking brake OFF and ON, then OFF again.

IMPORTANT !

Machine must be in the Normal Program Mode to operate normally.

9. With the parking brake OFF, verify correct clearance between the two brake pads and the brake disc with a feeler gauge. Correct clearance is .020-.060 in (0.5-1.5 mm).

Other program modes are used for service/ setup procedures only.

10. Reinstall the cover.

When setup program modes are chosen an information message is shown on the electronic display until the message is acknowledged.

11. Remove articulation lock bar.

12. Engage the parking brake several times and check the braking efficiency on a slope.

In each program mode some controls are deactivated for safety during setup procedures.

Attempting to use these controls will reactivate the information message.

13. If further adjustment is required repeat steps 1 to 12.

15. Stop engine.

3.31

Tigercat 635D Skidder

Lubrication and Maintenance

SERVICE BRAKE CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION

Service Brake

The main pump supplies oil directly to the brake accumulator, via a check valve inside the main pump block to charge the accumulator to specified pressure. The accumulator is installed to ensure that the brake control remains responsive at all times by maintaining an optimum pilot pressure of 3000psi to the brake pilot valve. This oil from the accumulator side of the check valve is sent to the brake foot control valve.

Pressure Low. Service machine to correct.

8. If the Service Brake Pressure Low warning appears on the screen before the brake has been pumped 5 times from a full charge investigate the cause.

The accumulator when functioning properly will hold sufficient pressure for up to 5 brake applications after the engine stalls or is shut down, beyond this the pressure drops substantially.

Check first for leaks in the brake circuit. If no leaks are found check for proper operation of the brake pedal valve, accumulator, check valve and brake pressure sensor.

For more information about the service brake circuit refer to SECTION 9 of THE SERVICE MANUAL. PROCEDURE: 1. Park machine on level ground, lower dozer and grapple to the ground, stop engine and engage parking brake and block wheels.

2. Press the brake pedal 25 times or more to release the pressure stored in the brake accumulator.

3. Start engine.

NOTE: The engine will not turn over unless the parking brake is ENGAGED. 4. Disengage parking brake to fully charge the accumulator. Run engine for 10 seconds, then shut engine off.

NOTE: When the parking brake is DISENGAGED full pressure is available from the main pump to the brake accumulator.

5. Engage the parking brake.

6. Fully apply the brake pedal 5 times. The accumulator pressure should remain above 800 psi (no warning on the computer display).

As the pressure drops in the accumulator the brake pedal will become spongy.

Once the pressure falls below 800 psi the Service Brake Pressure Low warning will appear on the screen.

3.32

For more information about the service brake circuit refer to SECTION 9 of THE SERVICE MANUAL.

Tigercat 635D Skidder

Lubrication and Maintenance

AIR CLEANER MAINTENANCE

IMPORTANT !

For peak engine performance and maximum fuel economy, please ensure that the air precleaner is regularly checked and cleaned as required. All intake air tubes and clamps should be thoroughly inspected on a regular basis and any damaged or missing components should be replaced immediately.

ENGINE AIR PRECLEANER

3

3 4

AIR CLEANER

2 1

AIR CLEANER UNLOADER VALVE

635D-128

5

ENGINE AIR CLEANER

630C-19

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. The air precleaner should be checked every 8 hours to make sure that foreign materials have not plugged the intake area or the discharge louver area. Clean as required.

IMPORTANT !

The air precleaner must be check every 8 hours and cleaned as required.

CENTRI® PRECLEANER OPERATION

OPERATION: 1. Air enters the precleaner.

2. Specially designed vanes move dirty air toward the impeller.

3. The spinning impeller spins the air creating centrifugal force to separate contaminants from the clean air.

4. Contaminants are blown out the discharge louver.

5. Clean air enters the intake to the air cleaner.

Continued on next page

If the inlet/precleaner is plugged causing a restriction to airflow, reduced engine performance and increased fuel consumption may result.

If a plugged inlet/precleaner is left too long excessive air intake restriction may damage the rubber air intake tube. A damaged air intake tube will lead to ingestion of dirt into the engine which may result in engine failure.

Note that the air filter restriction indicator may not function properly if the air intake tube is damaged.

Engine failures due to improper maintenance are not covered by Tigercat or Engine Manufacturer’s Warranty and any such claim will be denied.

3.33

Tigercat 635D Skidder FILTER RESTRICTION INDICATOR

Lubrication and Maintenance AIR CLEANER UNLOADER VALVE

FILTER RESTRICTION SWITCH (IF EQUIPPED)

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.

AIR CLEANER

635D-129

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.

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.

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

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

A filter restriction indicator is connected to the outlet side of the air filter. Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

FILTER RESTRICTION INDICATOR

A filter restriction indicator is mounted to the output side of the filter, this should show green when the engine is running under load. Service is required if the indicator shows red. Later machines may be equipped with a switch used to send a signal to the computer control system in the event of a filter restriction.

NOTE: Replace the safety element every third primary filter change.

Engine Air Intake Filter Restricted. Service Machine to correct.

When a signal is received from the restriction indicator switch on the engine air cleaner a warning message will be displayed. Refer to COMPUTER~MESSAGES AND WARNINGS - ALERT~ENGINE AIR INTAKE FILTER RESTRICTED in SECTION 2 of the OPERATOR'S MANUAL.

3.34

Tigercat 635D Skidder

Lubrication and Maintenance

INTAKE TUBING AND JOINTS

OVER SERVICING

Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware at the beginning of every shift. (8 hours). Repair or replace defective parts immediately.

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.

Replace all air intake rubber components such as elbows and connectors every 2000 hours - High temperatures in this area can cause the rubber to harden.

In addition to the LUBRICATION AND MAINTENANCE SCHEDULE, the following instructions should also be noted.

The most common and damaging servicing problems are:

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.

Continued on next page

3.35

Tigercat 635D Skidder

Lubrication and Maintenance CENTER JOINT

OUTLET TUBE

MAINTENANCE OF CENTER JOINT Maintenance in this area is usually limited to:

PRIMARY ELEMENT

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.

SAFETY ELEMENT

AIRCLEANER

AIR FILTER ELEMENTS

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.

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS 1. Release the cover latch gently to reduce the amount of dust dislodged.

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.

2. Avoid dislodging dust from filter element(s) by gently pulling the element off the outlet tube.

3. Always clean the sealing surface of the outlet tube before inserting a new filter element.

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.

4. Always clean the inside of the outlet tube and filter housing.

5. Check your old filter, It can help you detect foreign material on the sealing surface that is causing leakage.

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.

REAR CHASSIS

6. Inspect the new filter for damage.

CHECK FOR MOVEMENT IN THIS JOINT AREA

7. Insert the new filter properly. Apply pressure to the outer rim of the filter not the flexible centre.

8. Inspect connections and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points and replace as needed. Leaks in these locations send dust directly to the engine.

DIG-003

3.36

FRONT CHASSIS

CENTER JOINT PRE-LOAD CHECK

Tigercat 635D Skidder

Lubrication and Maintenance

ARTICULATION LOCK ~ STRAIGHT LOCKED POSITION

ARTICULATION LOCK ~ ARTICULATED LOCKED POSITION

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

1. Position machine on level ground and steer machine into a fully articulated position to the right.

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

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

ARTICULATION LOCK

REAR CHASSIS 630D-02

ARTICULATION LOCK

RETAINING PINS

ARTICULATION LOCK STORED POSITION

REAR CHASSIS 630D-02

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.

ARTICULATION LOCK STORED POSITION

3. Remove both retaining pins from the articulation lock. Relocate articulation lock between front and rear chassis. Line up holes on the articulation lock with holes in chassis’ as shown and secure in place with both retaining pins.

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

630D-03

RETAINING PINS

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

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

630D-01

3.37

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

Tigercat 635D Skidder

Lubrication and Maintenance

GRAPPLE SNUBBER MAINTENANCE SNUBBER ASSEMBLY USED ON TIGERCAT GRAPPLES In this model the snubbers are part of the link.

Two separate snubbers provide snubbing action in two directions. There is a grease fitting on each snubber assembly for daily lubrication. Be sure to lubricate all the grapple snubbers on your machine.

Proper lubrication prevents excessive clutch wear.

IMPORTANT !

All service points on snubbers must be greased every shift (8 hours) to ensure a long service life.

ADJUSTING SNUBBER TENSION Each snubber should be adjusted such that: •

It is capable of stopping the grapple within one full swing.

Snubbers that are too loose can allow the grapple to swing violently and cause damage to the grapple and/or other machine components.

•

It is capable of holding the grapple at approximately a 5° angle.

Snubbers that are overtightened can reduce the effect of lubricating grease and cause premature clutch wear.

615C-022

SNUBBER ASSEMBLY

PROCEDURE Tension is adjusted by removing shims from the snubber. Remove only the minimum number of shims required to achieve correct adjustment.

1. Park machine on level ground, install articulation lock bar, lower dozer and grapple to ground, stop engine, engage parking brake and block wheels.

2. Remove one shim at a time to increase snubber friction. One split shim at a time can be removed from each snubber without completely removing the end caps.

Remove 3 bolts on the left side then loosen 3 bolts on the right side of the snubber enough to separate the end cap from the housing to remove the first half of the shim.

Loosely reinstall the 3 bolts on the left side of the snubber then remove the 3 bolts on the right side keeping the end cap separated from the housing enough to remove the other half of the shim.

Reinstall bolts and tighten in a crisscross pattern.

3. Fill snubber with grease until grease comes out the exhaust port.

3.38

Tigercat 635D Skidder

Lubrication and Maintenance

SNUBBER HOUSING

GREASE FILL PORT

SPLINED SHAFT

GREASE EXHAUST PORT

ALIGN TAB ON SHIMS WITH TAB ON END CAP

FRICTION PLATE REACTION PLATE

BELLEVILLE WASHERS

SHIMS O-RING END CAP

630D-011

SNUBBER ASSEMBLY 3.39

Tigercat 635D Skidder

Lubrication and Maintenance

PRESSURIZED WATER SYSTEM MAINTENANCE WATER TANK

WATER CONTROL VALVE

SYSTEM TEST 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 [4 Bar]) the system needs to be PURGED. Refer to PURGING PRESSURIZED WATER SYSTEM in THIS SECTION.

DOZER BLADE

After testing, the tank must be refilled and pressurized to 60 psi (4 Bar). Refer to the following FILL AND CHARGE procedure. This FILL AND CHARGE procedure should be carried out yearly.

HOSE STORAGE COMPARTMENT SHUT-OFF VALVE IN CLOSED POSITION

620C-41

FILL & CHARGE PRESSURIZED WATER SYSTEM

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.

A water tank is incorporated into the dozer blade and is pressurized to 60 psi (4 Bar). A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade.

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 shut-off valve should be in the CLOSED position when the system is not in use.

The pressure gauge on the valve should read 60 psi (4 Bar) check system pressure daily. The pressurized water system should be drained and refilled every 1000 hours as per the maintenance schedule.

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.

DOZER BLADE

FILL PLUG

WATER TANK

PRESSURE GAUGE

OUTLET CONNECTION

E625C-104

AIR CHARGE VALVE

3. Close water shut off valve.

WATER SHUT-OFF VALVE (SHOWN CLOSED)

620C-42

PRESSURIZED WATER SYSTEM

4. Fill tank with clean water.

When temperatures below 32°F (0°C) are anticipated, use a 60/40 solution of Nontoxic R. V. Antifreeze or other suitable antifreeze.

Antifreeze solution must meet GM 6038M specifications.

WATER CONTROL VALVE

Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL. 3.40

Tigercat 635D 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 (4 Bar).

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 (4 Bar) as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

7. Open the water shut off valve.

8. Discharge about 1/2 US gal (2 L) 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 US gal (8 L) of CLEAN water to the tank.

4. Install the fill plug NOTE: This is a special plug designed to withstand pressurization of the water tank.

Do not substitute.

10. Close the water shut-off valve.

11. Release pressure and fluid from the hose.

12. Pressurize the system to 60 psi (4 Bar) 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 (4 Bar) 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. 3.41

Tigercat 635D Skidder

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

CAUTION

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' rings and fittings during assembly.

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 30psi or less.

Always use personal protective equipment to guard against flying debris.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

1.76 kg (3 lbs 14 oz)

0.25 kg (9.0 oz)

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.

The compressor and charge valves are accessed from the left side engine compartment. The receiver dryer is mounted in the compartment behind the right cab door, on the outside of the cab.

IMPORTANT !

It is recommended that during cold weather when the A/C system is not in use, that it be run for a period of 5 minutes every 2 weeks. This will circulate oil to all components of the A/C system.

Perform following inspection along with 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION. a. Check re-circulating and fresh air filters in operator's cab. Refer to SECTION 2 of the OPERATOR'S MANUAL.

c. Check for dirt and debris; on the evaporator coil located inside the A/C-heater unit and also the inside of the A/C-heater unit. Clean as required. d. Check and adjust compressor drive belt tension. e. Check all A/C hoses for kinks.* f.

g. Check air temperature exiting vents in cab. h. Listen to compressor and blower motor for abnormal noises.* i.

CHECK A/C CONDENSER CORE

620C-10

Run air conditioning system for 3 - 5 minutes.

CHECK A/C CONDENSER CORE

b. Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR'S MANUAL. 3.42

Check to see that compressor clutch will engage.*

Tigercat 635D Skidder

Lubrication and Maintenance

SIGHT GLASS INDICATES CONDITION OF CHARGE

BINARY SWITCH, SYSTEM PROTECTION

MOISTURE INDICATOR BLUE - OK. PINK - REPLACE DRYER, RECHARGE SYSTEM

BACK WALL OF CAB A/C RECEIVER/DRYER

870-D43

j.

A/C RECEIVER/DRYER

Inspect sight glass on receiver dryer with A/C ON. A constant stream of bubbles indicates system requires charging.* Check colour in moisture indicator; BLUE is OK. PINK indicates desiccant material in dryer is saturated with moisture. In this situation replace receiver/dryer, evacuate system and recharge system with both refrigerant and PAG oil.* * Indicates that these repairs must only be carried out by a certified A/C technician.

For additional SERVICE information refer to the Tigercat A/C SERVICE MANUAL part number 18795A, available from Tigercat parts department.

3.43

Tigercat 635D Skidder 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.

NOTE: The cab tilt circuit is closed and does not normally require scheduled maintenance other than lubrication of cylinders and pivot points.

Tigercat recommends the use of DEXTRON III TYPE transmission fluid in this circuit (total circuit capacity 1 L [0.25 US gal]). The fill port is located on the pump.

Lubrication and Maintenance RAISING THE CAB 1. Position the Skidder on level ground.

2. Lower the Grapple and Dozer to the ground.

3. Engage parking brake and turn ignition off.

4. Remove the sweep mounting bolts at the cab.

(2 bolts) 5. Remove the right side Cab Locking Pins (2 pins). This is done by first removing the locking bolts. (2 bolts) 6. Open the maintenance door on the right front access panel to access the cab tilt hand pump.

PUMP HANDLE

LOCATED ON THE RIGHT SIDE AT THE FRONT OF THE ENGINE COMPARTMENT

CAB SWEEP BOLTS PUMP PUMP LEVER SHOWN IN "RAISE" POSITION 620C-19

620D-218

PUMP CONTROL LEVER IN RAISE CAB POSITION

7. Turn the lever on the pump manifold to RAISE (pointing to the front of the machine).

8. Insert handle into pump and pump in a steady manner to raise the cab to the tilt position. The pump handle is stored in brackets inside the cab.

CAUTION

620D-217

PUMP HANDLE STORAGE PUMP HANDLE STORAGE

604C-222 311-2

CAB LOCKING PINS

630D-13

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.

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.

3.44

Tigercat 635D Skidder

Lubrication and Maintenance LOWERING THE CAB

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.

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.

PUMP HANDLE

LOCATED ON THE RIGHT SIDE AT THE FRONT OF THE ENGINE COMPARTMENT

PUMP

PUMP LEVER SHOWN IN "LOWER" POSITION

CAB SUPPORT BRACE STORED IN BATTERY BOX RIGHT SIDE UNDER CAB

620C-19

CAB SUPPORT BRACE

PUMP CONTROL LEVER IN LOWER CAB POSITION

3. Turn the lever on the pump manifold to LOWER (pointing to the rear of the machine)

CAUTION Keep hands away from the locking pin area as the cab is being lowered.

E625C-24

SAFETY CABLE

CAB LOCKING PIN

CAB SUPPORT BRACE (3291B).

MUST USE CAB & CHASSIS LUGS SHOWN CAB LOCKING PIN

E620C-17

PARTIAL TILT WITH CAB SUPPORT BRACE

4. Pump the handle in a steady motion to lower the cab.

5. Watch closely for pinching of hydraulic lines 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 to point toward the front of the machine and store the pump handle inside the cab.

8. Reinstall the access panel.

9. Replace the Cab Sweep Bolts. (2 bolts)

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.

CAB SAFETY CABLE (3361B)

WARNING

E620C-16

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.

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE 3.45

Tigercat 635D Skidder

Lubrication and Maintenance

WINCH MAINTENANCE - ALLIED

LUBRICATION

WINCH OPERATION

Refer to the manufacturer's maintenance and service manual for information on your winch.

The winch is driven by a hydraulic motor through the sprag clutch and winch drive components. The pinion sprag holds the load in conjunction with the free spool clutch to prevent reverse rotation of the drum. The free spool clutch separates the drum from other drive components and permits the cable to unwind freely.

The winch is controlled through the winch select switch and the winch control lever. The winch select switch is used to activate/deactivate the winch control lever and to activate the winch freespool function. The winch control lever when activate is used to wind in the winch. Refer to CAB CONTROLS~WINCH CONTROL LEVER , CAB CONTROLS~WINCH SELECT SWITCH in SECTION 2 of the OPERATOR'S MANUAL.

The sump holds 1.0 US gal (3.8 L).

The oil supplied is Esso Hydraul 56 (Summer) or Esso Hydraul 50 (Winter). Use these oils or the equivalent.

Oil should be changed every 1000 hrs, depending on use.

The oil level should be checked every day (if the winch is being used) before starting the machine.

AIR BREATHER/FILLER CAP

Refer also to OPERATING MACHINE ~ OPERATING WINCH and SKIDDING~CABLE SKIDDING in SECTION 2 of the OPERATOR'S MANUAL. Refer to SECTION 13 of the SERVICE MANUAL and the winch manufacturer's service manual for additional service information.

WINCH SPECIFICATIONS ALLIED WINCH MODEL W400

610C-41

WINCH LUBRICATION

Maximum rated line pull bare drum ............................40000 lbs (18180 kg) full drum................................28100 lbs (12745 kg)

OIL LEVEL PLUG

Maximum cable size.............1 in (25.4 mm) Drum Size and Capacities Barrel Diameter....................12.0 in (305 mm) Barrel Width..........................7.79 in (200 mm) Cable Capacity 3/4 in (19.1 mm) ..................215 ft (65.5 m) 7/8 in (22.2 mm) ..................160 ft (48.8 m) 1 in (25.4 mm) .....................92 ft (28 m)

610C-42

The oil level should be up to the oil level check plug (remove with allen wrench) on the left side of the winch. Keep the winch sump filled to the correct level by adding oil through the air breather check valve assembly on the left side of the winch.

Winch Ratio Model W410.....21.65:1 Dry Weight ...........................1150 lbs (520 kg) Oil supply maximum pressure...............................3045 psi (210 bar) Oil supply maximum flow......47 USgpm(178 L/min)

3.46

Tigercat 635D Skidder

Lubrication and Maintenance

MAINTENANCE

CABLE RETAINER PLATE

Maintenance of the winch is limited to the hydraulic system maintenance of the skidder itself.

CABLE GROOVE

Periodically check the winch, control valve, and connecting hoses for damage or hydraulic oil leakage. If any problems are found, they should be corrected before operating the winch.

LOCKSCREW

INSTALLING THE WINCH MAINLINE 610C-40

ADJUST THE WINCH FREESPOOL TENSION

INSTALLING THE WINCH MAINLINE

WARNING

ADJUST THE WINCH FREE-SPOOL TENSION

Use extreme care when removing cable and ferrule from the drum. When the ferrule is released the cable may spring out with force.

If the winch cable requires too little effort to pull it from the cable drum, the tension can be adjusted as follows: •

Loosen the lockscrew.

•

Tighten the adjusting nut to increase the tension and/or loosen it to decrease it.

•

Tighten the locknut.

Installing the winch mainline as follows will provide a safety break-away feature. If the load should fall down a hillside, the operator should IMMEDIATELY put the winch control in FREESPOOL position. This will allow the cable to unwind freely from the cable drum and break away from the winch, preventing the machine from being pulled over.

•

Start the engine and rotate the winch cable drum so that the cable and ferrule groove in the inside, left hand wall of the drum is at the top and shut down engine.

•

Remove the cable retainer plate capscrews and retainer plate from the cable drum.

•

Insert the cable ferrule into the groove in the drum and hold the cable against the drum.

•

Install the retaining plate and capscrews to hold the cable in place.

•

Start the engine and winch in the cable onto the drum.

3.47

Tigercat 635D Skidder WINCH MAINTENANCE - CARCO WINCH OPERATION The winch is controlled through the winch select switch and the winch control lever. The winch select switch is used to activate/deactivate the winch control lever and to activate the winch freespool function. The winch control lever when activate is used to wind in the winch. Refer to CAB CONTROLS~WINCH CONTROL LEVER , CAB CONTROLS~WINCH SELECT SWITCH in SECTION 2 of the OPERATOR'S MANUAL. Refer also to OPERATING MACHINE ~ OPERATING WINCH and SKIDDING~CABLE SKIDDING in SECTION 2 of the OPERATOR'S MANUAL. Refer to SECTION 13 of the SERVICE MANUAL and the winch manufacturer's service manual for additional service information.

Lubrication and Maintenance WINCH SPECIFICATIONS CARCO STANDARD (GEAR MOTOR) Maximum rated line pull bare drum ............................40000 lbs (18180 kg) full drum................................21700 lbs (9840 kg) Maximum cable size.............7/8 in (22.2 mm) Drum Size and Capacities Barrel Diameter.................... 9.0 in (228 mm) Barrel Width.......................... 8.31 in (211 mm) Cable Capacity 3/4 in (19.1 mm) ..................275 ft (83.8 m) 7/8 in (22.2 mm) ..................202 ft (61.6 m) 1 in (25mm)..........................169 ft (51 m) Winch Ratio..........................118.65:1 Dry Weight ...........................1430 lbs (649 kg) Oil supply maximum pressure...............................3300 psi (228 bar) Oil supply maximum flow......46 USgpm(174 L/min) WINCH SPECIFICATIONS CARCO HIGH SPEED (PISTON MOTOR) Maximum rated line pull bare drum ............................40000 lbs (18180 kg) full drum................................24000 lbs (10890 kg) Maximum cable size.............7/8 in (22.2 mm) Drum Size and Capacities Barrel Diameter.................... 9.0 in (228 mm) Barrel Width.......................... 8.31 in (211 mm) Cable Capacity 3/4 in (19.1 mm) ..................275 ft (83.8 m) 7/8 in (22.2 mm) ..................202 ft (61.6 m) 1 in (25mm)..........................169 ft (51 m) Winch Ratio..........................66.98:1 Dry Weight ...........................1475 lbs (669 kg) Oil supply maximum pressure...............................4500 psi (310 bar)

3.48

Tigercat 635D Skidder

Lubrication and Maintenance

LUBRICATION

OIL FILL PLUG

Refer to the manufacturer's maintenance and service manual for information on your winch.

The sump holds: The sump holds 3 US gal (12 L).

OIL LEVEL SIGHT GAUGE

The oil supplied is Esso Hydraul 56 (Summer) or Esso Hydraul 50 (Winter). Use these oils or the equivalent.

WINCH FREESPOOL

DYNAMIC BRAKE CLUTCH

Oil should be changed every 1000 hrs, depending on use.

The oil level should be checked every day (if the winch is being used) before starting the machine.

DRAIN PLUG

The oil level should be up to the center of oil level sight gauge on the left side of the winch. Check oil when the oil is cool and has been allowed to settle after use. The oil fill plug is on the top of the winch.

WINCH LUBRICATION

620E-079

WINCH MAINTENANCE

SPRING HOUSING

Maintenance of the winch is limited to the hydraulic system maintenance of the skidder itself.

JAM NUT

Periodically check the winch, control valve, and connecting hoses for damage or hydraulic oil leakage. If any problems are found, they should be corrected before operating the winch.

ADJUST THE WINCH FREE-SPOOL TENSION If the winch cable requires too little effort to pull it from the cable drum, the tension can be adjusted as follows: •

Loosen the jam nut.

•

Tighten the spring housing to increase the tension and/or loosen it to decrease it.

•

Tighten the jam nut.

620E-078

Refer to the manufacturer's maintenance and service manual for information on your winch.

3.49

ADJUST THE WINCH FREESPOOL TENSION

Tigercat 635D Skidder

Lubrication and Maintenance

REAR (BOGIE) AXLE

BOGIE AXLE FILL (3 FILLING POINTS)

The bogie axle oil reservoirs (differential, bogie housings and planetaries are all connected and can be are at 3 locations to get the proper level of lubrication in the bogie axle.

1. Note that the bogie housings must be level to drain and refill them properly.

Refer to SERVICE AND LUBRICATION POINTS CHART in SECTION 3 for differential oil capacity and recommended gear oils.

DRAINING AND REFILLING BOGIE AXLE •

Park the machine on level ground.

•

Stop the engine and engage parking brake.

•

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. 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.

3. Remove the DIFFERENTIAL FILL/LEVEL PLUG and the BOGIE HOUSINGS FILL/ LEVEL PLUGS (1 per housing).

4. Remove the BOGIE HOUSING DRAIN PLUGS (2 per housing) and drain the oil into a suitable container for disposal.

5. Remove the DIFFERENTIAL DRAIN PLUG and drain the oil into a suitable container for disposal.

6. Clean any filings from the five drain plugs.

7. Replace the DIFFERENTIAL DRAIN PLUG and the BOGIE HOUSING DRAIN PLUGS (2 per housing – lower plugs) 8. Refill the differential and bogie housings with new oil until the level reaches the bottom of the FILL/LEVEL PLUGS. Refer to SERVICE AND LUBRICATION POINTS CHART in SECTION 3 for differential oil capacity and recommended gear oils.

DIFFERENTIAL FILL/LEVEL PLUG (1 PLACE)

BOGIE HOUSINGS FILL/LEVEL PLUG (2 PLACES)

BOGIE HOUSING DRAIN PLUG (4 PLACES )

625C-94

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS 3.50

Tigercat 635D Skidder

Lubrication and Maintenance

9. Replace the DIFFERENTIAL FILL/LEVEL PLUG and the BOGIE HOUSINGS FILL/ LEVEL PLUGS. 10. Check all drain, fill and level plugs for leaks.

11. Run axle for at least 10 minutesto remove trapped air in confined spaces.

12. Recheck oil level and top up as necessary.

SLEW BEARING LUBRICATION BOGIE AXLES The slew bearing has a lifetime lubrication in the raceway grease chamber and needs no service.

The only service work is the replacement of soiled grease in pre-chamber (buffer chamber).

buffer grease chamber

BOGIE 2

Then open the opposite outlet plug (also pos. 92 covered with white plastic cap).

Grease with a hand grease gun, at both grease nipples per side, until grease squeezes out thumb wide from the outlet opening (pos. 92). Then close this outlet hole with plug and cap.

Grease with a hand grease gun, at both grease nipples per side. When grease squeezes out from the gap, the gap has sealed itself with grease all the way around the circumference. Leave the excess grease built up to protect against dirt.

Cover the grease nipples with plastic caps.

BOGIE 1

Clean the area around the grease nipples and outlet plugs (pos. 90/92).

BOGIE 3

Open outlet plug, first the one on side A (pos. 92; covered with white plastic cap).

Fill at both grease nipples per side (pos. 90; covered with white plastic caps) standard grease.

Lubricate with hand grease gun until grease squeezes out with thumb wide from the outlet opening (pos. 92). Then close this outlet hole with plug and cap.

3.51

Tigercat 635D Skidder

Lubrication and Maintenance

FRONT AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS

FRONT AXLE - LIMITED SLIP ADDITIVES

Refer to LUBRICATION AND SERVICE CHART and SCHEDULED MAINTENANCE in THIS SECTION for service intervals and recommended gear oils.

AXLE LEVEL CHECK AND FILL (FAR SIDE)

BRAKE INSPECTION PORT (FAR SIDE)

Front axles are equipped with brakes. It is permissible to use a limited slip additive in the front axle to reduce brake chatter noise. Do not exceed the maximum recommended amount of additive as this may cause a loss of differential lock slipping torque and brake holding torque. Refer to LUBRICATION AND SERVICE CHART for additive recommendation details.

BRAKE INSPECTION PORT

AXLE LEVEL CHECK AND FILL

AXLE DRAIN 4634D02

SEVERE DUTY AXLE DRAIN AND FILL LOCATIONS (FRONT AXLE SHOWN)

3.52

Tigercat 635D Skidder

Lubrication and Maintenance CAUTION

Fluid spray hazard. Contact with fluid under pressure may cause injury.

PINION SEAL GREASE FITTING

E620C-41

Pressure may build up inside axle due to temperature changes. Use caution when removing drain and fill plugs, slowly loosen plug to relieve pressure before removing completely.

FRONT AXLE

3.53

Tigercat 635D Skidder

Lubrication and Maintenance

STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE

•

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.

•

Loosen the plug on the top of the left hand drive motor.

•

Operate the hand fill pump at medium speed, using a steady motion.

•

Watch for oil leaking from the plug previously loosened and tighten 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.

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.

PRE-STARTUP AND FILLING 1. Ensure all filters are in place. Refer to FILTERS in THIS SECTION. 2. Check oil levels in the engine, transmission, main hydraulic tank, winch (if equipped), axles and cab tilt system.

MACHINE STARTUP Before beginning this procedure, perform the PRE-STARTUP AND FILLING steps.

3. Check coolant level in the radiator.

4. Do a final inspection of all fittings and clamps to make sure they are tight and will not leak.

CAUTION Machine operator must ONLY take directions from the person doing the set-up.

5. Install the articulation lock bar and engage the parking brake.

6. Turn differential lock switch to OFF.

1. Ensure the articulation lock bar is installed.

7. Do not start engine. Purge air from hydraulic system by adding oil as follows: •

Pre-fill the cases of the hydrostatic drive pump, main pump and any other components that have been drained of oil with clean, filtered hydraulic oil.

CASE DRAIN MAKE-UP LINE

4 PIN ENGINE POWER CONNECTOR

TEE CONNECTOR

620C-81

ENGINE 4 PIN POWER CONNECTOR

2. Disconnect 4 pin engine power connector on engine (prevents engine starting).

OIL FILL LINE

620C-46

RIGHT HAND DRIVE MOTOR DISCONNECT CASE DRAIN LINE

•

Disconnect the case drain make-up line from the tee connection on the right hand drive motor and pre-fill the right hand drive motor with clean, filtered hydraulic oil.

•

Watch for oil leaking from tee connection and reconnect case drain line when oil leaks out.

3. Crank engine for 10 seconds, wait for 10 seconds. Repeat 6 times to pump oil into pumps.

4. Check hydraulic oil levels in the main hydraulic tank and add hydraulic oil as required.

3.54

Tigercat 635D Skidder

Lubrication and Maintenance

5. Reconnect 4 pin engine power connector on engine.

6. Start engine.

7. Check for leaks.

11. Top up the radiator with clean coolant.

12. With cylinders fully retracted, top up the main 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 disengaged and at LOW IDLE, slowly operate the drive function forward and reverse a few times.

CONNECTORS DRIVE PUMP

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.

E620C-01

DISCONNECT TWO CONNECTORS ON DRIVE PUMP PRIOR TO PERFORMING PROCEDURE (6351001 TO 6351035)

DRIVE PUMP

CONNECTORS

635D-161

DISCONNECT TWO CONNECTORS ON DRIVE PUMP PRIOR TO PERFORMING PROCEDURE (6351036 AND UP) 8. Bleed brakes (front axle) if required.

Prior to bleeding brakes disconnect the two connectors on the drive pump. This is a safety precaution to prevent the machine from travelling while brake bleeding is being performed.

With engine at IDLE, parking brake engaged, hold foot brake down, bleed brakes in front axle (both sides). Refer also to FRONT AXLES ~ SERVICE BRAKES ~ BRAKE BLEEDING in SECTION 8 of the SERVICE MANUAL. Reconnect two connectors on drive pump.

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.

3.55

Tigercat 635D Skidder

Lubrication and Maintenance

TORQUE CHART TORQUE (LUBRICATED) lbf-ft Nm

LOCATION

DIAMETER

Cylinders Piston nut, steer cylinder (38087B) Piston nut, arc/boom cylinder Piston nut, dozer cylinder Gland, steer cylinder (36597B) Keeper plate bolts Keeper plate bolts

1 3/8" UNF 1 1/2" UNF 1 3/8" UNF 3/4" UNC 5/8" UNC

1260 1640 1260 550 282 159

1708 2224 1708 745 382 215

Cab pin keeper plate bolts

3/4" UNC

282

393

Center joint bearing Bearing retaining bolts Pin retaining bolts

1/2" UNC 3/4" UNC

80 282

108 382

Engine mounting To Chassis To Engine

7/8" UNC M12

364 73

493 99

Pump Mounting Drive pump to flywheel adapter plate Flywheel adapter plate to flywheel housing Torsional drive coupler to flywheel Main pump to drive pump Coolant pump to main pump

3/4" UNC M10 3/8" UNC 5/8" UNC M12

282 40 37 159 73

382 54 50 215 99

5/8" UNF 5/8" UNC

170 159

230 215

1 1/4" x 18 UNEF 3/4" UNC

500 282

677 382

1/2" UNF

90

122

M12

70

95

1/2" UNF

90

122

1/2" UNF

90

122

M12

70

95

3/4" UNC M18 M20 5/8" UNC

226 310 413 225

306 420 560 306

Wheel bolts

7/8" UNF

501

679

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

5/8"UNC 7/8" UNC

159 364

215 493

Drive shafts Machines (6351001-6351054) Yoke retaining bolt, park brake Parking brake retaining bolts Machines (6351055-6351500) Yoke retaining nut, rear shaft Bearing bracket retaining bolts All machines Rear drive shaft universal joint bolts Rear axle input universal joint bolts Mid. drive shaft universal joint bolts Front drive shaft universal joint bolts Front axle input universal joint bolts Axle mounting bolts Front Rear (Bogie) Axle

Torque values pertaining to the engine and attachment are provided in the appropriate manuals.

635D TORQUECHARTR3.XLS 08/13

3.56

Tigercat 635D 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 8 BOLTS

GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS LUBRICATED DRY LUBRICATED COARSE lbf-ft Nm lbf-ft Nm lbf-ft Nm THREAD 8 - 10 11 - 13 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 20 - 28 27 - 38 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 33 - 36 45 - 49 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 52 - 57 71 - 77 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 80 - 88 109 - 119 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 115 - 127 156 - 172 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 159 - 175 216 - 237 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 282 - 310 393 - 420 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 455 - 501 617 - 679 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 682 - 750 925 - 1016 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 966 - 1062 1310 - 1441 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1360 - 1496 1844 - 2027 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED LUBRICATED lbf-ft Nm lbf-ft Nm lbf-ft Nm THREAD 10 - 13 14 - 17 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 18 - 25 25 - 33 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 37 - 41 50 - 55 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 58 - 64 79 - 86 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 90 - 99 122 - 134 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 128 - 141 174 - 191 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 180 - 198 244 - 268 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 315 - 347 427 - 470 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 501 - 550 679 - 745 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 746 - 821 1012 - 1113 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1083 - 1191 1469 - 1613 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1509 - 1660 2046 - 2250 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387 4.8

METRIC

8.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

5 5

CLASS 4.8 SIZE LUBRICATED DRY Nm lbf-ft Nm lbf-ft

10

10

5

10

12.9

12.9

12

10

12

METRIC BOLT TORQUE SPECIFICATIONS

CLASS 8.8 OR 9.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

12.9

12

DRY lbf-ft Nm 11 - 12 15 - 16 26 - 30 35 - 40 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

10

COARSE THREAD 1/4" - 20 5/16" - 18 3/8" - 16 7/16" - 14 1/2" - 13 9/16" - 12 5/8" - 11 3/4" - 10 7/8" - 9 1" - 8 1 1/8" - 7 1 1/4" - 7 FINE THREAD 1/4" - 28 5/16" - 24 3/8" - 24 7/16" - 20 1/2" - 20 9/16" - 18 5/8" - 18 3/4" - 16 7/8" - 14 1" - 14 1 1/8" - 12 1 1/4" - 12

CLASS 10.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0 700.0 1,200.0 875.0 1,350.0 1,000.0 1,700.0 1,250.0 1,600.0 1,150.0 2,000.0 1,500.0 950.0 1,650.0 1,200.0 1,850.0 1,350.0 2,300.0 1,700.0 2,150.0 1,600.0 2,700.0 2,000.0

675.0 1,150.0 850.0 1,750.0 1,300.0 2,200.0 1,650.0 2,500.0 1,850.0 3,150.0 2,350.0 2,900.0 2,150.0 3,700.0 2,750.0 850.0 1,450.0 1,075.0 2,250.0 1,650.0 2,850.0 2,100.0 3,200.0 2,350.0 4,050.0 3,000.0 3,750.0 2,750.0 4,750.0 3,500.0

TORQUECHARTGENERAL.XLS

3.57

Tigercat 635D Skidder

Lubrication and Maintenance

Parker

Assembly Torque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts. The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head on to the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

The 4-Bolt Split Flange consists of four main components: • A body (flange head) • An O-ring • One “captive” or two “split” flange clamps

• Four bolts and washer

WASHERS BOLTS FLANGE CLAMP

Flange Port Assembly

FLANGE HEAD

The steps to properly assemble the flange port clamping bolts are: 1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

2. Lubricate the O-ring.

3. Position flange and clamp halves.

4. Place lock washers on bolts and insert through clamp halves.

5. Hand tighten bolts.

6. Torque bolts in diagonal sequence (see Fig. T9) in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

O-RING TAPPED HOLES

FLANGE.JPG

Fig. T8 - 4 Bolt Split Flange Components

FLANGE2.JPG

Fig. T9 - Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

17 +/- 2 25 +/- 3.5 31 +/- 4.5 41 +/- 5 52 +/- 6 60 +/- 6 85 +/- 9 144 +/- 15 125 +/- 8 125 +/- 8 125 +/- 8

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

8 12 16 20 24 32

1/2 3/4 1 1 1/4 1 1/2 2

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

17 +/- 2 30 +/- 4.5 46 +/- 4.5 69 +/- 6 125 +/- 8 208 +/- 20

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

* Does not meet ISO 6162 specification.

Table T7 - Code 62 Flange Recommended Bolt Torque

* Does not meet ISO 6162 specification.

Table T6 - Code 61 Flange Recommended Bolt Torque

3.58

Tigercat 635D Skidder

Lubrication and Maintenance

Parker

Assembly Torque

JIC 37 Degree Flare SAE Dash Size

Thread Size

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 3-12

NA NA 2 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 1 1 1

SAE Dash Size

NA NA 2 2 1 1/4 1 1 1 1 1 1 1 1 1

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

Thread Size

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok SAE Dash Size

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

SAE Dash Size

NA NA 1/2 TO 3/4 NA 1/2 TO 3/4 1/2 TO 3/4 1/2 TO 3/4 1/3 TO 1/2 NA 1/3 TO 1/2 1/3 TO 1/2 1/3 TO 1/2 NA NA

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

Thread Size

Tube Connection Swivel or Hose Connection TFFT TFFT

1/8-28 NA 1/4-19 NA 3/8-19 1/2-14 NA 3/4-14 NA 1-11 1 1/4-11 1 1/2-11 2-11 NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE = 10 % -0 SAE DASH SIZE

2 3 4 5 6 8 10 12 14 16 20 24 32

THREAD SIZE

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

SEAL-LOK lbf•ft (lbf•in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

N •m 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf•ft N •m (lbf•in) (85) 10 (155) 18 (260) 29 (280) 32 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

PLUGS

ADJUSTABLE

NON-ADJUSTABLE

SEAL-LOK lbf•ft (lbf•in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.59

N •m 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf•ft N •m (lbf•in) (60) 7 (100) 11 (180) 20 (250) 28 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

HOLLOW HEX

HEX HEAD

HP5ON-S

P5ON-S

lbf•ft (lbf•in) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

N •m 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

lbf•ft (lbf•in) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

N •m 10 18 29 32 40 70 115 183 237 271 339 414 509

Tigercat 635D Skidder

Lubrication and Maintenance

EATON Aeroquip

Assembly Torque

Recommended Parallel Connection Assembly torque

Eaton recommends that a Torque wrench be used to assure proper fitting assembly of these connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514)

Straight Thread O-Ring Boss High Pressure with ORS (J1453)

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32

The values listed are for steel connections. Contact Teaton for torque values for other materials.

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-9 12-13 13-15 18-20 14-15 19-21 23-24 32-33 40-43 55-57 43-48 59-64 68-75 93-101 83-90 113-122 112-123 152-166 146-161 198-218 154-170 209-230 218-240 296-325

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24

ORS

Dash Size -04 -06 -08 -10 -12 -16 -20 -24

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-10 11-16 14-16 20-22 18-20 24-27 24-26 33-35 50-60 68-78 72-80 98-110 125-135 170-183 160-180 215-245 200-220 270-300 210-280 285-380 270-360 370-490

SAE 37º (JIC) Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

10-12 18-20 32-35 46-50 65-70 92-100 125-140 150-165

Swivel Nut Torque Newton Meters 14-16 24-27 43-47 62-68 88-95 125-136 170-190 204-224

Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -32

Metric Thread Size mm M10x1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2

Thread Size (inches) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Swivel Nut Torque lb.-ft.

11-12 15-16 18-20 38-42 57-62 79-87 108-113 127-133 158-167 245-258

Swivel Nut Torque Newton Meters 15-16 20-22 24-28 52-58 77-85 108-119 148-154 173-182 216-227 334-352

BSPP Straight Adapter or Locknut Torque lb.-ft.

Newton Meters 13-15 18-20 15-19 20-25 19-23 25-30 33-40 45-55 37-44 50-60 52-66 70-90 55-70 75-95 81-96 110-130 96-111 130-150 162-184 220-250 170-192 230-260 258-347 350-470

Nominal Thread Size Straight Adapter or Locknut Torque inches** lb.-ft.

Newton Meters G1/8-28 13-15 18-20 G1/4-19 19-23 25-30 G3/8-19 33-40 45-55 G1/2-14 55-70 75-95 G3/4-14 103-118 140-160 G1-11 162-184 220-250 G1 1/4-11 170-192 230-260 G1 1/2-11 258-347 350-470 ** "G" denotes parallel threads, other than ISO 6149 (Port connection only)

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.60

Tigercat 635D Skidder

Lubrication and Maintenance

Weights of Commercial Wood

Species

kg/m3

lb/ft3

Species

kg/m3

lb/ft3

Alder, Red Ash, White Aspen, Quaking Bald Cypress Basswood, American Beech, American Birch, Paper Birch, Yellow Cedar, Alaska Cedar, Incense Cedar, Northern White Cedar, Port-Orford Cedar, Western Red Cherry, Black Cottonwood, Eastern Douglas Fir, Coast Douglas Fir, Inland North Elm, American Fir, Alpine Fir, Balsam Fir, Nobel Fir, Red Fir, Silver Fir, White Gum, Black Gum, Blue Gum, Red Gum, Tupelo Hemlock, Eastern Hemlock, Western Hickory, Pecan Hickory, True Larch, Western Locust, Black Magnolia, Cucumber

737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

Maple, Big Leaf Maple, Black Maple, Red Maple, Silver Maple, Sugar Oak, Black Oak, Chestnut Oak, Red Oak, Red, Swamp Oak, Swamp Chestnut Oak, White Oak, White, Swamp Pine, Jack Pine, Loblolly Pine, Lodgepole Pine, Long Leaf Pine, Norway, Red Pine, Short Leaf Pine, Slash Pine, Sugar Pine, Western Yellow Pine, White-Western Pine, White-Eastern Poplar, Yellow Redwood Spruce, Black Spruce, Engleman Spruce, Red Spruce, Sitka Spruce, White Sweetgum Sycamore, American Tamarack Walnut, Black Willow, Black

753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Note: The values shown here are green weights.

3.61

Tigercat 635D Skidder

Lubrication and Maintenance

TIRE PRESSURES Tigercat Part # BP056 BP111 BP112 BP022 BP113 BP114 BP139 BP137 BP145 BP100 BP066 BP039 BP167 BP143

Manufacturer Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Goodyear Goodyear Goodyear GPX Tire (Primex) Nokian Nokian Nokian Nokian

Inflation Pressure

Size 28L-26 16PR LS2 DW (FS) 30.5L-32 20PR LS2 (FS) 30.5L-32 26PR SS LS2 DH (FS) 73x44-32 16PR HF3 DH (FS) 35.5L-32 20PR LS2 DH (FS) 35.5L-32 24PR LS2 DH (FS) 30.5L-32 20 PR LOGLUGIII LS2 TL 30.5L-32 26 PLY CRC SS TUBELESS 35.5L-32 26PR LOGLUGIII TLL S2 66/4300-26 20PR HF4 DW (GPX) 750/55-26.5 20PR F (N) 750/55-26.5 20PR TRS (N) 780-50-28.5 24PR FOREST KING F2 SF 780/55-26.5 20PR F

psi 35 35 45 30 35 40 35 45 40 50 87 87 87 87

kPa 240 240 310 210 240 275 240 310 275 345 600 600 600 600

SKIDDER TIRE PRESSURES R4 05/13

COMMON CONVERSIONS To Convert Bar cc °C Kg KW Liters mm Nm N

Into PSI Cu. in. °F lbs.

HP Gallons Inches lb.-ft. lbs.

To Convert

Multiply By

Cu. in. °F Gallons HP Inches lbs. lb.-ft.

PSI In. of HG In. of H2O lbs.

14.5 0.06102 (°C x 9/5) + 32 2.205 1.341 0.2642 0.03937 0.7375 0.22481

3.62

Into

cc °C Liters KW mm Kg Nm Bar PSI PSI N

Multiply By

16.39 (°F - 32) /1.8 3.785 0.7457 25.4 0.4535 1.356 0.06896 . 4912 . 03613 4.4482