Tigercat AD610C CARRIER OPERATOR’S MANUAL SN 6109001 to 6109250 - PDF DOWNLOAD

AD610C CARRIER

OPERATOR’S MANUAL SERIAL NUMBER 6109001 to 6109250

ISSUE 4.0 AUGUST 2015 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat AD610C Carrier

Introduction

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Tigercat AD610C Carrier

Introduction

Tigercat AD610C CARRIER TABLE OF CONTENTS SECTION INTRODUCTION.....................................................................................................................................v S.A.E. STANDARDS..............................................................................................................................vi NON-APPROVED FIELD PRODUCT CHANGES................................................................................. vii 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.

AD610C Available Literature Operator's Manual, English (This Manual)............................................Part No. 35611A Service Manual, English........................................................................Part No. 35612A Vehicle Moving and Transporting Instructions.......................................Part No. 35761AMUL Parts Catalog, English...........................................................................Part No. 35609A

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Tigercat AD610C Carrier

Introduction

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Tigercat AD610C Carrier

Introduction

Tigercat AD610C Carrier 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 AD610C Carrier.

Serial numbers:6109001 to 6109250 The AD610C Carrier is designed as an aerial device carrier for forestry/utility applications including tree trimming and line clearing as well as general aerial work on and around energized conductors.

The operator's manual will assist the operator with the techniques of proper and safe operation of the AD610C Carrier. 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 AD610C Carrier

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 AD610C Carrier

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 AD610C Carrier

Introduction

viii

Tigercat AD610C Carrier SECTION 1 - SAFETY

ISSUE 4.0 AUGUST 2015

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.................................................................................................... 1.15 CAB SUPPORT BRACE................................................................................................ 1.15 COOLING SYSTEM....................................................................................................... 1.14 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................................................................................................................ 1.14 GREASE INJECTION INJURY....................................................................................... 1.18 HYDRAULIC PRESSURE HAZARD.............................................................................. 1.14 LIGHTNING SAFETY AWARENESS LIGHTNING SAFETY................................................................................................. 1.19 WHAT IS A LIGHTNING STRIKE................................................................................ 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 AD610C Carrier

Safety

1.2

Tigercat AD610C Carrier

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 As per TigercatOperation test ETR00131 0.1070 x-axis (back-to-chest) 0.2240 Microphone direction: Check with your local Safety Left Commission Right0.0912to detery-axis (right-to-left) 0.1190 Driving max speed 82 mine hearing protection 83 is required at these levels. 0.1480 0.2290 z-axisif(buttocks-to-head) Driving low speed 76 75  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 AD610C Carrier

Safety

SAFETY SYMBOLS

GENERAL SAFETY PRECAUTIONS 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.

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 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 AD610C Carrier

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.

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

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.

Tigercat AD610C Carrier

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 AD610C Carrier

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:

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.

•

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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

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.

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

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.

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.

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.

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

Read, understand and follow all general safety precautions specified by attachment 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.

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.

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

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.

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.

Tigercat AD610C Carrier

Safety

GENERAL SAFETY PRECAUTIONS continued

Avoid Injury from Backover Accidents 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.

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

Wash hands after handling.

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

To avoid backover accidents:

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

• •

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 AD610C Carrier

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.

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

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

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

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

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

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.

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

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

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 AD610C Carrier

Safety When parking the machine:

OPERATING SAFETY PRECAUTIONS continued

•

Park on level ground ONLY and engage parking brake

•

Do not park on a hillside or incline.

•

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

•

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

WARNING

1. Fully apply brake foot pedal 25 times or more.

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

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

Use caution when loosening hydraulic connections.

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

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

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

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.

E625C-111

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

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

WARNING

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

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

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

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

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

1.10

Tigercat AD610C Carrier

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, park the attachment, raise dozer blade off the ground and keep it high enough to clear obstacles such as stumps.

Check for correct tire air pressure. If the pressure is too low it will result in swaying. If the pressure is too high it will result in bouncing. Refer to also to TIRE PRESSURES in SECTION 3 of THIS MANUAL.

Never operate the attachment 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 machine 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: •

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.

Read, understand and follow all general safety precautions specified by the attachment manufacturer.

WARNING Always park the machine on level stable ground and lower the dozer blade to the ground before activating the crane. The lowered dozer blade will increase stability of the carrier when operating the crane.

In addition, always read, understand and follow all operating and safety instructions in attachment manufacturer's instructions before operating the crane attachment.

1.11

Tigercat AD610C Carrier

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:-

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

IMPORTANT

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.

610C-03

ENGINE CPU DISCONNECT -LEFT SIDE OF ENGINE

Disconnect the engine ECU (electronic control unit) by unplugging the four pin engine power connector and the two multipin connectors from the left side of the 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.

E625C-120

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

FUSE AND RELAY PANEL

Remove the MD3 module fuse from the fuse and relay panel 1.12

Tigercat AD610C Carrier

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING

LOCATED IN CAB BEHIND LEFT KICK PANEL

630D-14

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

XS2-A0 MODULE - CAB

•

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)!

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

XA2-A0 FRONT CHASSIS

XA2-A1 FRONT CHASSIS 2 (*IF EQUIPPED)

XA2 MODULES Disconnect the other IQAN control module harness connectors. One module is located in the cab. Two modules are located under the cab.

615C-007

When welding is completed reconnect all connectors, ground and fuse then attach the battery cables reconnecting the positive (+) cables first and turn the battery disconnect switch ON. When searching for leaks, wear work gloves and use a wrench or piece of wood to move hydraulic hoses. Do not grab hold of hydraulic hoses.

Wear safety goggles for eye protection.

1.13

Tigercat AD610C Carrier

Safety

SERVICING SAFETY PRECAUTIONS continued 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.

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.

Never use bare hand to check for fluid leaks.

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.

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.

WARNING

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.

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

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

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.

1.14

Tigercat AD610C Carrier

Safety

SERVICING SAFETY PRECAUTIONS continued

630D-03

SAFETY CABLE

AD610C-05

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE 630D-01

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

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

SUPPORT BRACE

WARNING E620C-17

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

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.

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

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

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

CAUTION 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.

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.

1.15

Tigercat AD610C Carrier

Safety

SERVICING SAFETY PRECAUTIONS continued BOLT ON ACCESS PANELS

MAINTENANCE ACCESS DOORS

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.

E620C-15A

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.

ACCESS PANELS LEFT SIDE

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

DOOR PROP

E620C-14

MAINTENANCE ACCESS DOOR (LEFT SIDE SHOWN)

Dispose of fluids properly.

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

CAUTION

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

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.

1.16

Tigercat AD610C Carrier

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 AD610C Carrier

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 AD610C Carrier

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.

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.

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.

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 AD610C Carrier

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 AD610C Carrier

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 AD610C Carrier

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.

FIRE PREVENTION

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.

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.

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

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.

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.

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 AND COOLING ASSEMBLY 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.

1.22

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 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.

Tigercat AD610C Carrier

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 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 AD610C Carrier

Safety WHAT TO DO WHEN A MACHINE FIRE OCCURS

FIRE PREVENTION •

•

•

•

1. Lower all working attachments to the ground.

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.

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.

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.

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.

•

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:

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

•

1. Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

1. The fire is small and not rapidly spreading.

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

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.

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.

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

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 applicable) and the fire suppression system** on your machine.

There is not enough time available to read instructions during a fire emergency.

•

Before deciding to fight the fire, be certain that:

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

•

If operating the machine when a fire occurs:

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

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 re-ignition.

Tigercat AD610C Carrier

Safety WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED

FIRE PREVENTION •

•

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

•

•

Before returning the machine to work.

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

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.

2. Ensure that the fire detection system*

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.

•

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

or the 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.

**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 re-ignition does not occur.

Remain with the machine until help arrives.

1.25

Tigercat AD610C Carrier

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.

FIRE PREVENTION 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 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 non-conductive such as CRC Contact Cleaner 2000.

1.26

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.

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.

Tigercat AD610C Carrier

Safety NO RIDERS

SAFETY LABELS SAFETY LABELS CAB LABELS The following safety labels are installed in the cab of the machine. 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 AD610C Carrier

Safety

SAFETY LABELS

READ OPERATOR'S MANUAL

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 AD610C Carrier

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 label is 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 IGNITION KEY and store it in a safe place.

1.29

Tigercat AD610C Carrier

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 AD610C-10

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 AD610C Carrier

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 us‑e 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 serpentine 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 AD610C Carrier

Safety DO NOT LOOSEN CAP UNTIL COOL

SAFETY LABELS DO NOT USE WINCH FOR HOISTING

43225BUNI R0

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

DO NOT use winch for hoisting.

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

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

33952AUNI R0

This label warns of a PRESSURE AND FLUID SPRAY HAZARD when 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.

1.32

Tigercat AD610C Carrier

Safety FLUID SPRAY HAZARD

SAFETY LABELS STORED ENERGY HAZARD

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

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.

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.

The accumulator has stored hydraulic pressure.

Servicing the accumulator or any hydraulic components before releasing pressure could result in death or serious injury.

DO NOT SERVICE ACCUMULATOR BEFORE RELEASING PRESSURE by applying brakes repeatedly with the engine OFF until there is no pedal resistance. This may take a minimum of 150 applications.

1.33

Tigercat AD610C Carrier

Safety

SAFETY LABELS EXPLOSION HAZARD

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

This label warns of an EXPLOSION HAZARD. 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.

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

1.34

Tigercat AD610C Carrier

Safety

AD610C-206

CRUSH HAZARD This label is located on the aerial device beside the lower controls.

This label warns of a CRUSH HAZARD that exists when operating the aerial device from the lower controls.

KEEP CLEAR of potential crush zones between the platform and the aerial device as it moves.

NEVER have any part of your body between aerial device moving parts and the platform.

AD610C-205

KEEP CLEAR OF CRUSH ZONES WHEN OPERATING LOWER CONTROLS

Always take care to position your body clear of the crush zone between the steps and the aerial device as it moves. Particular care should be taken when rotating the aerial device close to the steps on the platform. Stop the aerial device and move carefully from one level of the platform to another as required to safely access the controls and avoid placing any part of your body between the aerial device moving parts and the platform.

FAILURE TO KEEP CLEAR OF THE CRUSH ZONES COULD RESULT IN SERIOUS INJURY OR DEATH.

1.35

Tigercat AD610C Carrier

Safety PRESSURIZED WATER SYSTEM INSIDE HAND TIGHTEN ONLY

SAFETY LABELS

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 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.

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

1.36

Tigercat AD610C Carrier

Safety FIRE EXTINGUISHER ACCESS HOLE

SAFETY LABELS FIRE PREVENTION!

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.

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.

1.37

Tigercat AD610C Carrier

Safety

1.38

Tigercat AD610C Carrier SECTION 2 - CONTROLS & OPERATION

ISSUE 4.0 AUGUST 2015

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................................................................................................ 2.89 ARTICULATION LOCK.............................................................................................................. 2.116 BATTERY DISCONNECT SWITCH............................................................................................ 2.91 CAB CONTROLS........................................................................................................................ 2.10 BRAKE PEDAL ROTATING SEAT & JOYSTICK STEERING........................................................................ 2.10 COMPUTER DISPLAY............................................................................................................2.20 CONTROL PANEL A/C HEATER CONTROLS - AIR CONDITIONER................................................................ 2.17 A/C HEATER CONTROLS - AIR SOURCE.......................................................................... 2.17 A/C HEATER CONTROLS - FAN CONTROL...................................................................... 2.17 A/C HEATER CONTROLS - TEMPERATURE..................................................................... 2.17 FAN CONTROL SWITCH, COOLING.................................................................................. 2.16 HORN, SAFETY ALERT - SWITCH..................................................................................... 2.16 LIGHTS - SWITCH............................................................................................................... 2.14 PARKING BRAKE / UNLOCK-ACTIVATE CRANE SWITCH............................................... 2.14 WINCH CONTROL LEVER.................................................................................................. 2.18 WINCH SELECT SWITCH................................................................................................... 2.18 DIRECTION SELECTION SWITCH ROTATING SEAT & JOYSTICK STEERING.........................................................................2.11 DOZER BLADE CONTROL LEVER........................................................................................2.13 EMERGENCY SHUT-OFF SWITCH........................................................................................2.14 ENGINE SPEED/TRAVEL PEDALS ROTATING SEAT & JOYSTICK STEERING........................................................................ 2.10 FOOT PEDALS, FORWARD FACING AND REAR FACING ROTATING SEAT & JOYSTICK STEERING........................................................................ 2.10 BRAKE PEDAL................................................................................................................. 2.10 TRAVEL/ENGINE SPEED PEDAL................................................................................... 2.10 HORN, SAFETY ALERT - SWITCH.........................................................................................2.16 IGNITION SWITCH..................................................................................................................2.20 INSTRUMENT PANEL.............................................................................................................2.20 ALARM LIGHT..................................................................................................................... 2.20 AUXILIARY POWER OUTLET............................................................................................. 2.21 COMPUTER DISPLAY......................................................................................................... 2.20 COMPUTER USB PLUG...................................................................................................... 2.21 ENGINE DIAGNOSTICS CONNECTION............................................................................. 2.21 IGNITION SWITCH.............................................................................................................. 2.20 LIGHTER.............................................................................................................................. 2.21 MASTER ALARM................................................................................................................. 2.20 STORAGE COMPARTMENT............................................................................................... 2.21

Tigercat AD610C Carrier

Controls and operation

LEFT HAND JOYSTICK (ROTATING SEAT & JOYSTICK STEERING) DIRECTION SELECTION SWITCH......................................................................................2.11 MAXIMUM SPEED CONTROL............................................................................................ 2.12 STEERING............................................................................................................................2.11 MAXIMUM SPEED CONTROL ROTATING SEAT & JOYSTICK STEERING........................................................................ 2.12 ROTATING SEAT KICK LEVER...............................................................................................2.22 SEAT........................................................................................................................................2.23 SEAT, ROTATING SEAT KICK LEVER....................................................................................2.22 SLOPE INDICATOR................................................................................................................2.20 STEERING JOYSTICK.............................................................................................................................2.11 TRAVEL/ENGINE SPEED PEDALS ROTATING SEAT & JOYSTICK STEERING........................................................................ 2.10 WARNING MESSAGES....................................................................................SEE COMPUTER WINCH CONTROL LEVER.....................................................................................................2.18 WINCH SELECT SWITCH.......................................................................................................2.18 CAB VENTILATION AIR VENTS..............................................................................................................................2.84 FILTER, FRESH AIR................................................................................................................2.84 FILTER, RECIRCULATING AIR, A/C UNIT..............................................................................2.84 CARE OF THE MACHINE......................................................................................................... 2.110 CARE OF POLYCARBONATE WINDOWS...........................................................................2.110 CAUTIONS..........................................................................................................................2.112 CLEANING INSTRUCTIONS..............................................................................................2.112 CONCEALING HAIRLINE SCRATCHES............................................................................2.112 FIRE PRECAUTIONS.........................................................................................................2.113 GRAFFITI REMOVAL..........................................................................................................2.113 INSPECTION AND MAINTENANCE...................................................................................2.111 RESISTANCE TO CHEMICALS..........................................................................................2.111 RESISTANCE TO WATER..................................................................................................2.111 CENTER JOINT........................................................................................................................ 2.110 CLEANING A/C CONDENSER AND COOLING ASSEMBLY................................................... 2.114 COLD IDLE OPERATION.......................................................................................................... 2.104 COLD IDLE SPEED ADJUSTMENT......................................................................................... 2.105 COMPUTER................................................................................................................................ 2.24 ADJUSTMENT MENU EXAMPLE ~ ADJUSTMENT MENU NAVIGATION.............................................................. 2.34 ADJUSTMENT MENU - ENGINE SETTINGS.........................................................................2.31 AUTO RPM.......................................................................................................................... 2.31 COLD IDLE SPEED............................................................................................................. 2.31 ENGINE HIGH IDLE ADJUST.............................................................................................. 2.31 ADJUSTMENT MENU - FAN SETTINGS (IF EQUIPPED)......................................................2.32 CLEAN DURATION.............................................................................................................. 2.32 CLEAN FREQUENCY.......................................................................................................... 2.32 FAN AUTO CLEAN............................................................................................................... 2.32 ADJUSTMENT MENU - SERVICE SETTINGS.......................................................................2.32 FRONT TIRE SIZE............................................................................................................... 2.33 HYDRAULIC OIL GRADE.................................................................................................... 2.32 STEER INVERT (JOYSTICK STEERING ONLY)................................................................ 2.33 COMPUTER CONTROL SYSTEM..........................................................................................2.25 COMPUTER CONTROL SYSTEM COMPONENTS...............................................................2.25 ENGINE COOLANT TEMPERATURE GAUGE.......................................................................2.29 ENGINE MENU - ENGINE FUNCTIONS.......................................................................2.27, 2.28

2.2

Tigercat AD610C Carrier

Controls and operation

BOOST................................................................................................................................. 2.30 CHARGE AIR TEMPERATURE........................................................................................... 2.30 COOLANT TEMPERATURE................................................................................................ 2.29 ENGINE HOURS.................................................................................................................. 2.30 ENGINE SPEED.................................................................................................................. 2.29 ENGINE VOLTAGE.............................................................................................................. 2.30 ENG % TORQUE................................................................................................................. 2.29 OIL PRESSURE................................................................................................................... 2.29 ENGINE MENU - FUEL INFORMATION.................................................................................2.28 FUEL RATE.......................................................................................................................... 2.28 TOTAL FUEL USED............................................................................................................. 2.28 TRIP AVERAGE FUEL RATE............................................................................................... 2.28 TRIP FUEL USED................................................................................................................ 2.28 ENGINE TACHOMETER GAUGE...........................................................................................2.29 FUEL GAUGE................................................................................................................2.28, 2.38 HYDRAULIC OIL TEMPERATURE GAUGE............................................................................2.37 INFORMATION MODE MENU.................................................................................................2.36 DRIVE MOTOR SPEED....................................................................................................... 2.37 DRIVE PRESSURE FORWARD.......................................................................................... 2.37 DRIVE PRESSURE REVERSE........................................................................................... 2.37 HYDRAULIC OIL TEMPERATURE...................................................................................... 2.37 MACHINE HOURS............................................................................................................... 2.37 MACHINE VOLTAGE........................................................................................................... 2.38 TRAVEL SPEED.................................................................................................................. 2.38 INFORMATION MODE MENU - FUEL INFORMATION..........................................................2.38 FUEL RATE.......................................................................................................................... 2.38 TOTAL FUEL USED............................................................................................................. 2.38 TRIP AVERAGE FUEL RATE............................................................................................... 2.38 TRIP FUEL USED................................................................................................................ 2.38 MAIN MENU............................................................................................................................2.26 MAIN MENU PAGE..................................................................................................................2.39 MAIN MENU PAGE - ADJUST MENU.....................................................................................2.40 MAIN MENU PAGE - INFO MENU..........................................................................................2.46 LOGS................................................................................................................................... 2.47 MODULES............................................................................................................................ 2.47 MAIN MENU PAGE - MEASURE MENU.................................................................................2.41 MAIN MENU PAGE - PREFERENCES MENU........................................................................2.42 DATE/TIME ADJUSTMENT................................................................................................. 2.44 DISPLAY ADJUSTMENT..................................................................................................... 2.43 LANGUAGE ADJUSTMENT................................................................................................ 2.46 MD3 COMPUTER....................................................................................................................2.24 MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY......................................................2.24 MD3 COMPUTER MAIN MENU..............................................................................................2.26 MESSAGES AND WARNINGS................................................................................................2.48 ALERT MESSAGES (YELLOW).......................................................................................... 2.63 CRITICAL MESSAGES (RED)............................................................................................ 2.49 ERROR MESSAGES (RED)................................................................................................ 2.59 INFORMATION MESSAGES (BLUE).................................................................................. 2.78 MESSAGES AND WARNINGS - ALERT DRIVE CHARGE FILTER BYPASSED................................................................................. 2.66 DRIVE CHARGE SYSTEM PRESSURE LOW.................................................................... 2.68 DRIVE MOTOR SPEED SENSOR NO MOTOR SPEED..................................................... 2.67 ENGINE AIR INTAKE FILTER RESTRICTED...................................................................... 2.65 ENGINE FAULT CODE MESSAGES - ALERT..................................................................... 2.74

2.3

Tigercat AD610C Carrier

Controls and operation

ENGINE VOLTAGE HIGH.................................................................................................... 2.73 ENGINE VOLTAGE LOW..................................................................................................... 2.73 FUEL LEVEL LOW............................................................................................................... 2.65 FUEL - WATER IN FUEL...................................................................................................... 2.69 HARDWARE FAILURE - COUT........................................................................................... 2.72 HARDWARE FAILURE - DIN............................................................................................... 2.71 HARDWARE FAILURE - DOUT........................................................................................... 2.72 HARDWARE FAILURE - VIN............................................................................................... 2.71 HARDWARE FAULT - MD3.................................................................................................. 2.69 HARDWARE FAULT - XA2................................................................................................... 2.70 HARDWARE FAULT - XS2................................................................................................... 2.70 MACHINE VOLTAGE HIGH................................................................................................. 2.67 MACHINE VOLTAGE LOW.................................................................................................. 2.66 MODULE HIGH SUPPLY VOLTAGE - ALERT..................................................................... 2.76 MODULE HIGH TEMPERATURE - ALERT.......................................................................... 2.75 MODULE LOW SUPPLY VOLTAGE - ALERT...................................................................... 2.77 SERVICE BRAKE PRESSURE LOW.................................................................................. 2.68 MESSAGES AND WARNINGS - CRITICAL DRIVE MOTOR CLUTCH PRESSURE LOW...................................................................... 2.50 DRIVE MOTOR OVERSPEED............................................................................................. 2.51 ENGINE COOLANT LEVEL LOW........................................................................................ 2.56 ENGINE COOLANT TEMPERATURE HIGH....................................................................... 2.56 ENGINE FAULT CODE MESSAGES - CRITICAL................................................................ 2.58 ENGINE OIL PRESSURE LOW........................................................................................... 2.57 ENGINE STOP..................................................................................................................... 2.53 HARDWARE FAULT - ENGINE............................................................................................ 2.54 HARDWARE FAULT - MD3.................................................................................................. 2.54 HARDWARE FAULT - XA2................................................................................................... 2.55 HARDWARE FAULT - XS2................................................................................................... 2.55 HYDRAULIC OIL LEVEL LOW............................................................................................. 2.50 HYDRAULIC OIL TEMPERATURE HIGH............................................................................ 2.52 INTAKE MANIFOLD TEMPERATURE HIGH....................................................................... 2.57 INTERLOCK SYSTEM............................................................................ 2.53, 2.78, 2.82, 2.83 MESSAGES AND WARNINGS - ERROR CURRENT OUTPUT ERROR (COUT)................................................................................ 2.62 DIGITAL INPUT ERROR (DIN)............................................................................................ 2.62 DIGITAL OUTPUT ERROR (DOUT).................................................................................... 2.62 MODULE NO CONTACT ERROR....................................................................................... 2.60 MODULE VREF ERROR..................................................................................................... 2.61 VOLTAGE INPUT ERROR (VIN).......................................................................................... 2.62 MESSAGES AND WARNINGS - INFORMATION INTERLOCK SYSTEM-CRANE NOT STOWED-MACHINE DRIVE DISABLED................. 2.82 INTERLOCK SYSTEM-CRANE NOT STOWED-MACHINE HYDRAULICS DISABLED..... 2.83 INTERLOCK SYSTEM PARK BRAKE ON..................................................................2.78, 2.83 MACHINE STEERING INVERT DISABLED........................................................................ 2.82 SETUP MODE - DRIVE MOTOR SETUP............................................................................ 2.79 SETUP MODE - DRIVE PUMP POR SETUP...................................................................... 2.79 SETUP MODE - DRIVE PUMP REGULATION SETUP....................................................... 2.79 SETUP MODE - ENGINE HP TEST..................................................................................... 2.79 SETUP MODE - FUNCTION SETUP................................................................................... 2.79 SETUP MODE - MAX CURRENT SETUP MODE............................................................... 2.79 DOORS AND ACCESS PANELS................................................................................................ 2.89

2.4

Tigercat AD610C Carrier

Controls and operation

EMERGENCY SHUT-OFF SWITCH........................................................................................... 2.14 ENGINE AIR CLEANER AIR CLEANER.........................................................................................................................2.92 AIR CLEANER UNLOADER VALVE........................................................................................2.93 AIR PRECLEANER.................................................................................................................2.92 ENGINE FAULT CODE MESSAGES - ALERT............................................................................ 2.74 ENGINE FAULT CODE MESSAGES - CRITICAL....................................................................... 2.58 FIRE EXTINGUISHER, PORTABLE........................................................................................... 2.85 FIRE PREVENTION FIRE EXTINGUISHER, PORTABLE........................................................................................2.85 PRESSURIZED WATER SYSTEM..........................................................................................2.91 FUEL TANK................................................................................................................................. 2.90 FUSE AND RELAY PANELS CAB.........................................................................................................................................2.86 HYDRAULIC OIL TANK, MAIN.................................................................................................... 2.94 HYDRAULIC FILTERS.............................................................................................................2.94 HYDRAULIC HAND FILL PUMP.............................................................................................2.95 HYDRAULIC OIL TANK, SECONDARY (IF EQUIPPED)............................................................ 2.96 HYDRAULIC FILTERS.............................................................................................................2.96 HYDRAULIC HAND FILL PUMP.............................................................................................2.97 MOVING INSTRUCTIONS.................................................................... SEE SEPARATE BOOKLET OPERATING MACHINE.............................................................................................................. 2.98 CENTER JOINT.....................................................................................................................2.110 COLD IDLE OPERATION......................................................................................................2.104 COLD IDLE SPEED ADJUSTMENT......................................................................................2.105 OPERATING WINCH.............................................................................................................2.110 PRE-START CHECKS.............................................................................................................2.98 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.........................................................................................................................2.109 PARKING BRAKE / UNLOCK-ACTIVATE CRANE SWITCH...................................................... 2.14 PICTOGRAM DESCRIPTIONS..................................................................................... 2.7, 2.8, 2.9 PRE-START CHECKS................................................................................................................ 2.98 RADIO, AM/FM CD...................................................................................................................... 2.85 RADIO, CB (IF EQUIPPED)........................................................................................................ 2.85 RETRIEVAL POINTS................................................................................................................ 2.117 ROTATING SEAT KICK LEVER.................................................................................................. 2.22 STARTING ENGINE.................................................................................................................. 2.102 STEERING JOYSTICK STEERING............................................................................................................2.11 STEREO, AM/FM CD.................................................................................................................. 2.85 STOPPING ENGINE................................................................................................................. 2.108 SYSTEM TEST AND WARM-UP............................................................................................... 2.107 SYSTEM WARNING MESSAGES........................................................................ SEE COMPUTER

2.5

Tigercat AD610C Carrier

Controls and operation

TILT CAB.................................................................................................................SEE SECTION 3 TOWING INSTRUCTIONS........................................................................................................ 2.120 TOWING INSTRUCTIONS - EHS TRANSMISSION................................................................. 2.122 TRANSMISSION DIPSTICK........................................................................................................ 2.91 TRANSMISSION OIL FILL LOCATION....................................................................................... 2.91 TRANSPORTING INSTRUCTIONS.......................................................................................... 2.118 LIFTING POINTS...................................................................................................................2.119 TIE DOWN POINTS...............................................................................................................2.119 WINCH, OPERATING................................................................................................................. 2.19

2.6

Tigercat AD610C Carrier

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:

OR

= Adjustment Menu Icon

= Brake

=Cigarette Lighter, 24 Volt

= Aerial Device UNLOCK

= Air Conditioner ON

= Control lever, multidirectional = Control lever, dual direction

= Air Conditioner OFF

= Critical Message Symbol (Display)

= Air Source, Fresh Air

= Differential Locks (ON/OFF)

= Air Source, Recirculate

= Differential Lock, Front

= Alert Message Symbol

= Auxiliary Power Outlet 12 V

= Differential Locks, Front and Rear

= Battery CONNECT

= Differential Lock, Rear

= Battery DISCONNECT

= Dozer Blade DOWN

= Dozer Blade UP 2.7

Tigercat AD610C Carrier PICTOGRAM DESCRIPTIONS CONTINUED

Controls and operation

= Fuel Diesel

= Engine Cold Idle

= Fuel Reset

= Engine Coolant Temperature

= Hand tighten only = Engine Fan, Variable Pitch, Full On = Horn = Engine Fan, Variable Pitch, Auto = Hydraulic oil level = Engine Fan, Variable Pitch, Clean = Hydraulic Oil Temperature = Engine Menu Icon = Imperial/Metric Toggle Symbol = Engine Run = Information Menu Icon = Engine Start = Information Message Symbol = Engine Stop = Light, Beacon = Engine speed/travel = Lights, Hazard = Engine Wait to start = Lights, Work = Error Message Symbol = Maximum speed control

= Foot Pedal Control

= Fuel Information, Computer

= OFF

= Fuel = ON

2.8

Tigercat AD610C Carrier PICTOGRAM DESCRIPTIONS CONTINUED

P

= Parking Brake ON

Controls and operation

= Volume, EMPTY

= Parking Brake OFF

= Winch

= Speed FAST or HIGH = Winch Freespool = Speed SLOW or LOW = Winch IN = Steer Left = Windshield Wiper/Washer = Steer Right

= Stop, Emergency Button (Label)

= Temperature

= Travel Direction

= Travel FORWARD

= Travel REVERSE

= Turn Signals (Turn signal/ Hazard light indicators) = Ventilation Blower Fan

= Volume, FULL

2.9

Tigercat AD610C Carrier

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

REAR FACING FOOT PEDALS (SEAT FACING REAR OF MACHINE)

FORWARD FACING PEDALS AND REAR FACING PEDALS (ROTATING SEAT & JOYSTICK STEERING)

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 rotating seat cab is equipped with two sets of pedals one set forward facing and the other set rear facing.

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

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.

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.

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.

2. BRAKE PEDAL (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.

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.

Check service brake for proper operation daily.

Refer to SERVICE BRAKE ~ CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3 of THIS MANUAL. 2.10

Tigercat AD610C Carrier 3a

Controls and operation 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.

3b

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.

E625C-11

LEFT HAND JOYSTICK

3. LEFT HAND JOYSTICK

(ROTATING SEAT & JOYSTICK STEERING) Steering Move the joystick to the RIGHT* to articulate the machine to the RIGHT* .

3a. DIRECTION SELECTION SWITCH (ROTATING SEAT & JOYSTICK STEERING)

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

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

*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 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.

Place switch in the rear position to travel in a REVERSE* direction .

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.

*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.

2.11

Tigercat AD610C Carrier

E625C-11

Controls and operation

LEFT HAND JOYSTICK

3b. MAXIMUM SPEED CONTROL (ROTATING SEAT & JOYSTICK STEERING) 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.

Push control forward to increase the maximum travel speed.

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

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.

2.12

Tigercat AD610C Carrier

Controls and operation 7. DIFFERENTIAL LOCK SWITCH - REAR

8

This momentary switch activates differential locks in the rear axle. The rear axle is locked to provide torque to both wheels.

7 6

Press this switch to activate rear differential lock. The rear differential lock will engage only when drive motor rpm falls below 125 rpm.

Press a second time to deactivate. The rear differential locks can be disengaged while machine is in motion.

AD610C-01

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

RIGHT HAND ARM REST

6. DIFFERENTIAL LOCK SWITCH - FRONT

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

This momentary switch activates the differential locks in the front axle. The front axle is locked to provide torque to both wheels.

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

Press this switch to activate front differential lock.

Press a second time to deactivate.

8. DOZER BLADE CONTROL LEVER

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

Pull the lever BACK to RAISE blade.

the dozer

Push the lever FORWARD to LOWER dozer blade.

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

the

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

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

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

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

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

If leaving the machine unattended, also remove the ignition key and switch the battery disconnect switch to the OFF position .

2.13

Tigercat AD610C Carrier

Controls and operation 3

2

1

5

6

AD610C-02

4

7

9

10

8

11

13

12

14

15

CONTROL PANEL

CONTROL PANEL

6. PARKING BRAKE / UNLOCK-ACTIVATE CRANE SWITCH / P /

1. LIGHTS FRONT - SWITCH

This is a three position switch, labelled / P / (UNLOCK-ACTIVATE CRANE/PARKING BRAKE ON/PARKING BRAKE OFF).

This switch turns on working lights.

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

Place in the UNLOCK-ACTIVATE CRANE position to unlock the crane from its stowed position and activate the crane hydraulic controls. In addition the parking brake will engage, the front axle oscillation lock will be activated and the full main pump pressure will be available to the crane functions.

3. 4-WAY HAZARD SWITCH This switch turns on hazard lights.

4. SAFETY BEACON SWITCH This switch turns on the safety beacon.

5. EMERGENCY SHUT-OFF SWITCH When the emergency shut-off switch is pressed DOWN, it immediately turns OFF electrical power to all functions within the cab including the computer system which, in turn shuts down the engine and hydraulic systems.

WARNING Always park the machine on level stable ground, lower outriggers (if equipped) and lower the dozer blade to the ground before activating the crane. The lowered dozer blade will increase stability of the carrier when operating the crane.

To allow the power to return to the cab, turn clockwise to allow it to pop back up.

IMPORTANT! The emergency shut-off switch should only be used in emergencies. Error codes will accumulate in the engine computer when the emergency shut-off switch is used.

In addition, always read, understand and folllow all operating and safety instructions in attachment manufacturer's instructions before operating the crane attachment.

2.14

Tigercat AD610C Carrier

Controls and operation

Machines with an optional digger derrick are equipped with throttle pedals located on the derrick operation platforms on both sides of the crane base and digger derrick controls include an engine start/stop switch. When this switch is in the UNLOCK-ACTIVATE CRANE these pedals and switches are activated. Refer to attachment manufacturer's instructions for full safety and operation instructions. Read, understand and follow all general safety precautions specified by attachment manufacturer.

ENGINE THROTTLE PEDAL

Note also that when the crane is activated machine drive, steering and dozer functions are locked out. Attempting to activate any of these functions will trigger a message on the computer control system. Refer to COMPUTER ~ MESSAGES AND WARNINGS - INFORMATION ~ INTERLOCK SYSTEM - CRANE NOT STOWED in THIS SECTION.

AD610C-025

IMPORTANT !

Whenever the crane is activated any computer messages and warnings which include alarms will sound both the master alarm (inside the cab) and the backup alarm to alert operators outside the cab that a warning message is on the computer screen which requires their attention.

AD610C-026

Place in the P PARKING BRAKE ON position 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. Note that only margin pressure is available from the main pump when the parking brake switch is in this position.

DIGGER DERRICK PEDAL (LEFT SIDE SHOWN)

DIGGER DERRICK CONTROLS (LEFT SIDE SHOWN)

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 cab controls from anywhere but the operator's seat.

SWITCH

ACTUATOR ON DOOR

Place in the PARKING BRAKE OFF position to DISENGAGE the parking brake.

NOTE: The parking brake must be DISENGAGED to DRIVE the machine. If the engine is started with the parking brake/ unlock-activate crane switch is not in the parking brake ON position an interlock will be triggered to prevent accidental movement of the machine, the switch must be cycled to release the interlock.

E625C-108

INTERLOCK SWITCHES ON CAB DOORS

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

NOTE ALSO: The interlock system prevents the machine from being driven and function controls from being operated while the parking brake is ENGAGED.

2.15

Tigercat AD610C Carrier

Controls and operation 3

2

1

5

4

7

6

AD610C-02

9

10

8

11

13

12

14

15

CONTROL PANEL engine coolant and hydraulic oil. The computer system automatically adjusts fan air flow to the minimum required level to maintain optimal operating conditions.

7. HORN, SAFETY ALERT - SWITCH This is a two position "momentary" switch.

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

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.

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

8. FAN CONTROL - SWITCH (IF EQUIPPED - VARIABLE PITCH FAN) This is a three position switch, labelled / / (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 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,

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

2.16

Tigercat AD610C Carrier

Controls and operation 10. AIR SOURCE

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.

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

In the cab.

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.

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

Refer also to CAB VENTILATION in THIS SECTION. 11. 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.

CLEAN Position - Momentarily pressing the switch to the CLEAN position will manually start the automatic clean cycle, reversing the flow of air (there is no need to hold the switch down). The pitch of the fan blades is changed and the direction of airflow through the engine enclosure is reversed. This change in airflow blows debris from the machines engine enclosure to eliminate potential overheating and poor machine performance caused by overheating. Ensure that there are no personnel standing directly to the sides of the machine when performing this operation, as dust and debris will fly out.

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.

ENGINE

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

SHUT-OFF VALVE

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.

HOSE TO A/C HEATER UNIT

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.

610C-07

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.

This is a two position rocker switch used to turn the air conditioner ON or OFF. position the air condition is ON.

In the

position the air conditioner is OFF.

HOT WATER SHUT OFF VALVE

12. FAN CONTROL

9. AIR CONDITIONER

In the

position fresh air is brought into the

2.17

Tigercat AD610C Carrier

Controls and operation 3

2

1

5

6

AD610C-02

4

7

9

8

11

13

12

14

15

CONTROL PANEL

13. WINCH SELECT SWITCH This is a three position switch, O / I /

10

14. WINCH CONTROL LEVER Place the winch select switch (to the left of the lever) in the I (ON) position.

.

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

Pull and hold the winch control lever BACK to spool the winch cable IN. Push and hold the winch control lever FORWARD to spool the winch cable OUT.

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.

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

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

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 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.

Refer also to WINCH SELECT SWITCH in THIS SECTION.

NOTE: The winch freespool function cannot be activated when the winch cable is under load. The cable must be slack to activate winch freespool.

Refer also to WINCH CONTROL LEVER in THIS SECTION .

2.18

Tigercat AD610C Carrier OPERATING WINCH:

Controls and operation 15. WINDSHIELD WIPER/WASHER The wiper/washer rotary switch controls the windshield wiper. Turning the dial one setting clockwise, operates wiper on low speed.

Place the carrier in a safe, stable location, in line with the load.

Lower the dozer blade to the ground to anchor the machine. Engage the parking brake.

Turning the dial a setting further clockwise sets the wiper to high speed. To slow or turn off the wiper, turn the dial counterclockwise until the desired setting is reached.

Place the winch select switch in the (freespool) position. The winch freespool icon on the main menu of the computer display will be illuminated.

To operate the washer function press the dial. This function sprays washer fluid on the windshield.

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

In cold climates, fill with anti-freeze washer fluid. To avoid scratching NEVER operate the wipers on a dry windshield

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

NOTE: The winch freespool function cannot be activated when the winch cable is under load. The cable must be slack to activate winch freespool.

WINDSHIELD WASHER FLUID

Avoid winching at an angle to the carrier.

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.

LOCATED ON THE BACK OF THE CAB

Pull and hold the winch control lever BACK to spool the winch cable IN.

AD610C-09

Push and hold the winch control lever FORWARD to spool the winch cable OUT. 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.

2.19

Tigercat AD610C Carrier 1

2

Controls and operation 4

3

5

11

12

13

6

7

9 61322B

10

8

INSTRUMENT PANEL

INSTRUMENT PANEL

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.

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

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

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

4. MASTER ALARM This alarm will sound 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. Refer to the COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION.

Refer also to STARTING ENGINE in THIS SECTION. 2. COMPUTER DISPLAY The computer display is the operator interface with the computer control system.

5.

Refer to COMPUTER in THIS SECTION for complete operating details.

SLOPE INDICATORS The slope indicators provide the operator with machine side slope angle in 5° increments up to 45°. One is mounted on or above the instrument panel (side to side) and one is mounted on the right side of the cab above the door (fore/aft).

2.20

Tigercat AD610C Carrier

Controls and operation Placing the switch in the center position turns OFF the turn signal.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

12. BACKUP CAMERA-MONITOR (IF EQUIPPED)

6. LIGHTER 24V Cigarette lighter is supplied.

See the manufacturer's owners manual for complete operation instructions for the backup camera system. Camera is mounted at the rear of the machine for use as a backup camera.

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

8. STORAGE COMPARTMENT 9

13. DIESEL HEATER CONTROLS - OPTIONAL This digital timer is used only if the machine is equipped with the optional diesel heater.

10

Consult the manufacture’s instruction manual for additional information. Refer also to HOT WATER SHUT OFF VALVE in THIS SECTION for more related information.

630D-04

REMOVE COVER TO ACCESS

9. COMPUTER USB PLUG 1075-089

Plug a laptop with appropriate IQAN software for software updates, diagnostics and some adjustments.

Refer also to COMPUTER in THIS SECTION and SECTION 6 of the SERVICE MANUAL for more information.

10. 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.

1075-087B

NOTE: During warm weather seasons, remove the Diesel Heater electrical fuse (30 Amp) to prevent accidental operation of the Diesel Heater.

The inline fuse is located beside the battery disconnect switch.

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

11. TURN SIGNAL SWITCH (IF EQUIPPED) This is a three position switch (LEFT/OFF/ RIGHT).

When the TURN SIGNAL switch is placed in the LEFT position, the left turn signals will flash, as will the indicator on the computer display.

When the TURN SIGNAL switch is placed in the RIGHT position, the right turn signals will flash, , as will the indicator on the computer display.

DIESEL HEATER FUSE LOCATION

AD610C-208

2.21

Tigercat AD610C Carrier 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 2.22

Tigercat AD610C Carrier 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.

2.23

Tigercat AD610C Carrier

Controls and operation MD3 COMPUTER

COLOUR DISPLAY

MD3 COMPUTER, ELECTRONIC CONTROL AND DISPLAY

AD610C-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

.

.

2.24

Tigercat AD610C Carrier MD3 COMPUTER MODULE

Controls and operation XS2 EXPANSION MODULE CAB

9 PIN ENGINE DIAGNOSTIC CONNECTOR 615C-001

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

XA2-A0 EXPANSION MODULE FRONT CHASSIS

ENGINE ELECTRONIC CONTROL MODULE

*IF EQUIPPED

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 IN CAB BEHIND LEFT KICK PANEL

630D-14

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.

XS2-A0 MODULE - CAB

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

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.

XA2-A0 FRONT CHASSIS

XA2-A1 FRONT CHASSIS 2 (*IF EQUIPPED)

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.

615C-007

2.25

XA2 MODULES

Tigercat AD610C Carrier 1

2

Controls and operation

3A 3B

4

5A

5B

6

15

14 13 7

8

9

10

11

12

MAIN MENU

AD610C-28

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

10. ENGINE COOLANT TEMPERATURE GAUGE

2. * TURN SIGNAL/HAZARD LIGHT INDICATORS

11. INFORMATION MENU - Press F3 to select

3A. ** REAR DIFFERENTIAL LOCK - ENGAGED/DISENGAGED

12. ALARM INDICATORS - Press F4 to select

3B. ** FRONT DIFFERENTIAL LOCK - ENGAGED/DISENGAGED

14. HYDRAULIC OIL TEMPERATURE GAUGE

13. HYDRAULIC OIL GRADE INDICATOR 15. FUEL LEVEL GAUGE

4. *UNLOCK-ACTIVATE CRANE 5A. * WINCH ON/OFF (

* When the icon is illuminated, function is ON.

)

5B. * WINCH FREE SPOOL (

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

)

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

2.26

Tigercat AD610C Carrier

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

2.27

Tigercat AD610C Carrier

Controls and operation

FUEL INFORMATION (EARLIER PROGRAMS)

ENGINE FUNCTIONS (LATER 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 back button to return 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.

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

Press the back button 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.

2.28

Tigercat AD610C Carrier

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.

DO NOT continue to operate machine.

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

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

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

temperature gauge shown on the main menu.

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)

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

This display indicates engine oil pressure.

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

2. Eng % Torque (%)

If oil pressure falls too low, an alarm will sound. Refer to the COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION.

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.

2.29

Tigercat AD610C Carrier

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.

2.30

Tigercat AD610C Carrier

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.

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.

2.31

Tigercat AD610C Carrier

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.

2.32

Tigercat AD610C Carrier

Controls and operation Steer Adjust (Joystick steering only)

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

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.

2.33

Tigercat AD610C Carrier

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

2.34

Tigercat AD610C Carrier

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.

2.35

button again to return to the

Tigercat AD610C Carrier

Controls and operation

INFORMATION MODE MENU

The information functions on display are as follows: 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.

•

Hydraulic Oil Temp -°F or °C

•

Drive Pressure Forward - psi or bar

•

Drive Pressure Reverse - psi or bar

•

Drive Motor Speed - rpm

•

Machine Hours - h

•

Aerial Device Hours - h

•

Machine Voltage - V

•

Travel Speed - mph or km/h Press the F1 button to toggle between imperial and metric units of measure.

Press the back button to return to the main menu.

2.36

Tigercat AD610C Carrier

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

6. Aerial Device Hours - h

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

This display indicates the total number of hours the aerial device has operated.

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.

2.37

Tigercat AD610C Carrier

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.

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

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 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.

2.38

Tigercat AD610C Carrier

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.

2.39

Tigercat AD610C Carrier 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.

2.40

Tigercat AD610C Carrier 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.

2.41

Tigercat AD610C Carrier 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.

2.42

Tigercat AD610C Carrier

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.

2.43

Tigercat AD610C Carrier

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.

2.44

Tigercat AD610C Carrier

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.

2.45

Tigercat AD610C Carrier

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.

2.46

Tigercat AD610C Carrier

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.

2.47

Tigercat AD610C Carrier 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.

2.48

Tigercat AD610C Carrier 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.

IMPORTANT !

Whenever the crane is activated any computer messages and warnings which include alarms will sound both the master alarm (inside the cab) and the backup alarm to alert operators outside the cab that a warning message is on the computer screen which requires their attention.

2.49

Tigercat AD610C Carrier 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 the crane stowed and the dozer blade on the ground.

Restart engine and inspect for leaks.

Drive Motor Clutch Pressure Low.

DRIVE MOTOR CLUTCH PRESSURE LOW ( IF EQUIPPED WITH 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.

2.50

Tigercat AD610C Carrier

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.

2.51

Tigercat AD610C Carrier

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.

2.52

Tigercat AD610C Carrier

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. In addtion this machine automatically engages the parking brake whenever a cab door is open.

This message indicates that the parking brake was engaged, by the parking brake switch 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.

2.53

Tigercat AD610C Carrier

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.

2.54

Tigercat AD610C Carrier

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.

2.55

Tigercat AD610C Carrier

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.

2.56

Tigercat AD610C Carrier

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.

2.57

Tigercat AD610C Carrier

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.

2.58

Tigercat AD610C Carrier 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

IMPORTANT !

Whenever the crane is activated any computer messages and warnings which include alarms will sound both the master alarm (inside the cab) and the backup alarm to alert operators outside the cab that a warning message is on the computer screen which requires their attention.

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.

2.59

Tigercat AD610C Carrier ERROR MESSAGES

Controls and operation XS2-A0

Cab Module No contact

MODULE NO CONTACT ERROR The module no contact error message will be displayed to indicate a loss of communication with or power to a module. The module is identified on the display screen.

When a module 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.

2.60

Tigercat AD610C Carrier

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.

2.61

Tigercat AD610C Carrier

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.

2.62

Tigercat AD610C Carrier 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 master 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.

When a system generated alert message is displayed he master 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.

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.

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.

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.

IMPORTANT !

Whenever the crane is activated any computer messages and warnings which include alarms will sound both the master alarm (inside the cab) and the backup alarm to alert operators outside the cab that a warning message is on the computer screen which requires their attention.

2.63

Tigercat AD610C Carrier

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.

2.64

Tigercat AD610C Carrier 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.

2.65

Tigercat AD610C Carrier

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.

2.66

Tigercat AD610C Carrier

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 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.

2.67

Tigercat AD610C Carrier

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.

2.68

Tigercat AD610C Carrier

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.

2.69

Tigercat AD610C Carrier

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.

2.70

Tigercat AD610C Carrier

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.

2.71

Tigercat AD610C Carrier

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.

2.72

Tigercat AD610C Carrier

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.

2.73

Tigercat AD610C Carrier

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.

2.74

Tigercat AD610C Carrier

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.

2.75

Tigercat AD610C Carrier

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.

2.76

Tigercat AD610C Carrier

Controls and operation MD3

Display Low supply voltage

MODULE LOW SUPPLY VOLTAGE - ALERT 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.

2.77

Tigercat AD610C Carrier 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 Interlock System - Crane Not Stowed. Machine drive disabled.

Interlock System - Crane Not Stowed. Machine hydraulics disabled.

Interlock System - Park Brake On. Cycle switch to disengage.

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.

2.78

Tigercat AD610C Carrier 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 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 Drive Motor Setup for service use only. Return to Normal Mode to operate machine.

2.79

Tigercat AD610C Carrier

Controls and operation

Setup Mode Engine HP Test Mode for service use only.

Return to Normal Mode to operate machine.

Setup Mode Drive Pump POR Setup 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.

2.80

Tigercat AD610C Carrier

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.

2.81

Tigercat AD610C Carrier

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 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.

Interlock System Crane Not Stowed. Machine drive disabled.

INTERLOCK SYSTEM CRANE NOT STOWED. MACHINE DRIVE DISABLED This message will be will be displayed when attempted is made drive the machine while the crane is not stowed.

Check that the crane is properly stowed and locked and the sensor is functioning correctly.

The interlock system prevents accidental activation of the drive controls while the crane is not stowed.

2.82

Tigercat AD610C Carrier

Controls and operation

Interlock System Crane Not Stowed. Machine hydraulics disabled.

INTERLOCK SYSTEM CRANE NOT STOWED - MACHINE HYDRAULICS DISABLED This message will be displayed when an attempt is made to operate a machine hydraulic function while the crane is not stowed.

Check that the crane is properly stowed and locked and the sensor is functioning correctly.

The interlock system prevents accidental operation of machine hydraulic functions not related to the operation of the crane from being operated while the crane is not stowed.

Interlock System Park brake on. Cycle switch to disengage.

Interlock SPN: 168 System FMI: 16 1 of 1

Park brake on. high Cycle Engine voltage - switch to disengage.

Above normal, severe

INTERLOCK SYSTEM PARK BRAKE ON. CYCLE SWITCH TO DISENGAGE This message will be will be displayed when the engine is started with the parking brake/unlockactivate crane switch is not in the parking brake ON position.

Place the parking brake/unlock-activate crane switch in the parking brake ON position and then choose either the parking brake OFF (drive) position or the activate-unlock crane position to proceed.

This interlock prevents accidental machine movement when starting the machine.

2.83

Tigercat AD610C Carrier CAB VENTILATION

Controls and operation

1. AIR VENTS

1

The Air Conditioner/Heater package has 10 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

RH 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.

AD610C-201

2.84

FRESH AIR FILTER

Tigercat AD610C Carrier

Controls and operation

LOCATED IN OPERATOR'S CAB

E625C-105

CHARGE GAUGE

E625C-107

FIRE EXTINGUISHER, PORTABLE

FIRE EXTINGUISHER, PORTABLE

AM/FM STEREO CD

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.

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.

2.85

Tigercat AD610C Carrier 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

FUSE AND RELAY PANEL

CAB FUSE AND RELAY PANEL (6109001 TO 6109070, 6109081 TO 6109250) 2.86

Tigercat AD610C Carrier

Controls and operation

CAB FUSE AND RELAY PANEL (6109071 TO 6109250) 2.87

Tigercat AD610C Carrier

Controls and operation

FUSES AND RELAYS (ELECTRICAL BOX) IMPORTANT 24 VOLT ELECTRICAL SYSTEM

625C-95

ELECTRICAL BOX (LEFT SIDE FRONT CHASSIS)

ELECTRICAL BOX FUSES AND RELAYS 2.88

Tigercat AD610C Carrier

Controls and operation

CHASSIS

BOLT ON ACCESS PANELS

MAINTENANCE ACCESS DOORS

BOLTS E620C-15

620C-02

ACCESS PANELS LEFT SIDE

DOOR PROP

FRONT DOOR

DOORS AND ACCESS PANELS FRONT DOOR

E620C-14

TO OPEN:

MAINTENANCE ACCESS DOOR (LEFT SIDE SHOWN)

ACCESS PANELS

Park machine on level ground and lower the dozer to the ground.

This machine is equipped with bolt on access panels to provide service access. Each panel is 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.

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.

Always ensure that all access panels are secured in place and all access doors are closed and secured before operating the machine.

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 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.

CAUTION Park on level ground to prevent unexpected door closing.

2.89

Tigercat AD610C Carrier

Controls and operation REFUELING Park machine on level ground, shut off engine and allow machine to cool.

AD610C-07

DO NOT refuel while smoking or near an open flame or sparks.

FUEL TANK

FUEL TANK

Clear obstructions from steps and handles needed to access fuel tank.

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

Open cover on top of fuel tank (if equipped)and clear any debris from around the fill cap.

Remove filler cap slowly to allow pressure to escape from tank.

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

Inspect fill cap gasket.

Inspect fuel strainer located under the fill cap for debris or damage.

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

A sending unit is installed and connected to the computer display on the instrument panel.

The standard fuel tank has a capacity of 80 US gal (302 L).

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.

Machines with an optional digger derrick are equpped with a non-standard fuel tank, capacity 55 USgal (210 L).

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.

2.90

Tigercat AD610C Carrier

Controls and operation PRESSURIZED WATER SYSTEM WATER TANK

BATTERY DISCONNECT SWITCH

604C-207

SHUT-OFF VALVE IN CLOSED POSITION

BATTERY DISCONNECT SWITCH

620C-41

Located in the engine compartment on the left side of the machine, this switch is wired to the positive side of the battery.

PRESSURIZED WATER SYSTEM

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

604C-209

DOZER BLADE

HOSE STORAGE COMPARTMENT

BATTERY DISCONNECT SWITCH LEFT SIDE ENGINE COMPARTMENT

TRANSMISSION OIL FILL LOCATION

WATER CONTROL VALVE

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 DIPSTICK

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 AND FILL LOCATION

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. 2.91

Tigercat AD610C Carrier

Controls and operation

ENGINE AIR CLEANER ENGINE AIR PRECLEANER

3

3 AIR CLEANER

4

2 1 AIR CLEANER UNLOADER VALVE

610C-08

5

ENGINE AIR CLEANER

630C-19

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.

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.

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.

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.

2.92

Tigercat AD610C Carrier

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.

FILTER RESTRICTION SWITCH (IF EQUIPPED)

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

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.

AIR CLEANER 610C-10

ENGINE AIR PRECLEANER

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.

2.93

Tigercat AD610C Carrier MAIN HYDRAULIC OIL TANK

Controls and operation DOUBLE ELEMENT FILTER

Located at the rear of the engine compartment, the hydraulic tank has a capacity of 23.5 US gal (89 L).

BREATHER BLUE ELEMENT

A sight gauge accessible through the right rear access panel, indicates the HIGH and LOW level of the main hydraulic oil tank.

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

SIGHT GAUGE

Check hydraulic oil level with crane stowed and the 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 (5 to 7.5 cm) when all cylinders are extended.

HYDRAULIC TANK

CHARGE PRESSURE FILTER

A hydraulic oil level switch is connected to the computer control system. This switch triggers the hydraulic oil level low warning.

Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HYDRAULIC OIL LEVEL LOW in THIS SECTION.

604C-215

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (EARLIER DESIGN)

DOUBLE ELEMENT FILTER

SIGHT GAUGE

BREATHER BLUE ELEMENT

EHS TRANSMISSION FILTER

615C-016

MAIN HYDRAULIC OIL SIGHT GAUGE (LATER DESIGN)

SIGHT GAUGE

HYDRAULIC FILTERS

CHARGE PRESSURE FILTER HYDRAULIC TANK

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:

615C-013

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (LATER DESIGN)

full flow, Tigercat hydraulic filter with a restriction indicator sending unit and a third port bypass valve.

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

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

For additional information on these filters refer to FILTERS and SERVICE AND LUBRICATION POINTS in SECTION 3.

The charge circuit contains a single element, 2.94

Tigercat AD610C Carrier

Controls and operation

TO TANK VIA FILTERS

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION SHUT-OFF VALVE IN OFF POSITION

610C-34

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.

HAND FILL PUMP QUICK CONNECT TO SUCTION HOSE

615C-014

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION BELOW LEFT HAND CAB DOOR

HYDRAULIC HAND FILL PUMP

HYDRAULIC HAND FILL PUMP

Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

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.

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.

TO ADD OIL TO THE MAIN HYDRAULIC TANK: Park machine on level ground and lower dozer blade 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.

2.95

Tigercat AD610C Carrier SECONDARY HYDRAULIC OIL TANK (IF EQUIPPED)

Controls and operation DOUBLE ELEMENT FILTER

Machines equipped with an optional digger derrick have a secondary hydraulic tank. Located on the rear chassis to the rear of the digger derrick base, the secondary hydraulic tank has a capacity of 58 US gal (220 L).

BLUE ELEMENT

SINGLE ELEMENT FILTER

SIGHT GAUGE

Two sight gauges are mounted on the front and rear of the secondary hydraulic tank, indicate the HIGH and LOW level of the main hydraulic oil tank. The front sight gauge is accessible during normal operation. The rear sight gauge is located above the fill pump for use when filling the tank.

Both sight gauges incorporate a temperature gauge for monitoring hydraulic oil temperature in the secondary tank.

TEMPERATURE GAUGE

SECONDARY HYDRAULIC TANK AD610C-020

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

Check hydraulic oil level with crane stowed and the dozer blade on the ground. Fill tank until hydraulic oil level reaches the sight gauge full mark. Note that the oil level will drop when all cylinders are extended.

Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HYDRAULIC OIL LEVEL LOW in THIS SECTION. HYDRAULIC FILTERS The secondary hydraulic circuit contains a two element, full flow, 7 micron filter with a built in 25 psi (1.7 bar) bypass valve.

The secondary hydraulic circuit also contains a single element full flow 7 micron filter with a built in 5 psi (0.34 bar) bypass valve. This filter is used as a case drain strainer for the secondary hydraulic ciruit.

It is recommended that all machines use two different filter elements: 1 blue, Tigercat water absorbing, full flow hydraulic oil filter element.

2 white, Tigercat high performance, full flow hydraulic oil filter element.

For additional information on these filters refer to FILTERS and SERVICE AND LUBRICATION POINTS in SECTION 3.

2.96

SECONDARY HYDRAULIC OIL TANK

Tigercat AD610C Carrier

Controls and operation

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION

SIGHT GAUGE QUICK CONNECT TO SUCTION HOSE SHUT-OFF VALVE IN OFF POSITION

HAND FILL PUMP 610C-34 AD610C-022

HYDRAULIC HAND FILL PUMP

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION BELOW LEFT HAND CAB DOOR

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 HAND FILL PUMP SECONDARY TANK (IF EQUIPPED) The hydraulic hand fill pump, located on the rear of the secondary hydraulic tank (open cover to access), is used to add oil to the secondary hydraulic oil tank. Refer to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL.

Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

TO ADD OIL TO THE SECONDARY HYDRAULIC TANK:

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.

Park machine on level ground park crane and lower dozer blade onto the ground. Open the cover at the rear of the secondary hydraulic tank to access fill pump. Get the hydraulic oil fill suction hose from its storage location. 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 secondary hydraulic tank via the double element filter. The pump should always be operated at a medium speed with a steady motion.

2.97

Tigercat AD610C Carrier

Controls and operation

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

3. When computer checks are complete place ignition switch in the OFF position.

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:

AD610C-07

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.

SIGHT GAUGE

ICON ILLUMINATED (RED) WHEN PARKING BRAKE IS ENGAGED

615C-016

E625C-118

2. Check parking brake for proper operation and engage parking brake.

MAIN HYDRAULIC OIL SIGHT GAUGE

5. Check hydraulic oil level with crane stowed and the 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 (5 to 7.5 cm) when all cylinders are extended.

2.98

Tigercat AD610C Carrier

Controls and operation FUEL FILTER

SIGHT GAUGE

FUEL FILTER/ WATER SEPARATOR

FUEL WATER SEPARATOR 8. Drain water from fuel line water separator.

604C-204

TEMPERATURE GAUGE

AD610C-021

SECONDARY HYDRAULIC OIL TANK FRONT SIGHT GAUGE

If equipped with a secondary hydraulic tank check hydraulic oil level. Fill tank until hydraulic oil level reaches the sight gauge full mark.

DIPSTICK

LEFT SIDE OF ENGINE

ENGINE OIL LEVEL

604C-207

33952AUNI R0

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

FILLER CAP

BELOW RIGHT HAND CAB DOOR

TRANSMISSION OIL FILL LOCATION

604C-209

TRANSMISSION DIPSTICK

TRANSMISSION DIPSTICK AND FILL LOCATION

620C-36

ENGINE COOLANT LEVEL

9. Check the engine coolant level.

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

2.99

Tigercat AD610C Carrier

Controls and operation ENGINE AIR PRECLEANER AIR CLEANER

A/C COMPRESSOR BELT

SERPENTINE BELT

AIR CLEANER UNLOADER VALVE

ENGINE AIR CLEANER

610C-08

11. Check air intake precleaner for foreign material build-up in air intake area or discharge louver area.

12. Check air cleaner unloader valve 610C-13

FILTER RESTRICTION INDICATOR

CHECK CONDITION OF ENGINE BELTS

10. Check tension and condition of all engine belts.

FILTER RESTRICTION SWITCH (IF EQUIPPED)

AIR CLEANER 610C-10

ENGINE AIR PRECLEANER

ENGINE AIR CLEANER

13. Check engine air cleaner restriction indicator.

2.100

Tigercat AD610C Carrier

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.

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.

610-03

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 AD610C Carrier 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. 3. Turn ignition key to RUN position and observe computer display.

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.

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.

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

NOTE: For cold weather conditions refer to COLD IDLE OPERATION on the following pages.

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 AD610C Carrier 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 AD610C Carrier

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 AD610C Carrier

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 AD610C Carrier 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 settings menu.

button again to return to the

Press the back main menu.

button again to return to the

2.106

Tigercat AD610C Carrier SYSTEM TEST AND WARM-UP

Controls and operation CAUTION

Before commencing skidding operations, follow steps (a) through (k) to accomplish the following: • Warm up the hydraulic system.

• Test all systems for proper operation.

• Inspect for hydraulic oil leaks.

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.

Ensure that the machine was parked on level ground at last shutdown: (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 dozer blade, check for proper operation. (e) Steer the machine to the left and right. (f) When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps (d) through (e) several times. As the hydraulic system warms up, engine speed can be increased gradually to the HIGH IDLE. In cold weather conditions the COLD IDLE function can be turned on. Refer to COLD IDLE OPERATION in THIS SECTION. (g) 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 to the ground. (h) Check service brake for proper operation.

Refer to SERVICE BRAKE ~ CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3 of THIS MANUAL. (i) Engage the parking brake. (j) Decrease engine idle speed to LOW IDLE. (k) Leave the cab and visually check hose connections and cylinders for leaks. Check under the machine for oil leaks.

2.107

Tigercat AD610C Carrier

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 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 dozer blade to the ground and engage parking brake.

Never work behind, in front of, or below a machine 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 machine unattended, also remove the ignition key and switch the battery disconnect switch to OFF

.

2.108

Tigercat AD610C Carrier TRAVELLING: Move the crane to its parked position. 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 or the crane is not in the park position.

Controls and operation (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.

(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.

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.

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.

(3) 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.

(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.

Refer to STEERING in THIS SECTION for more detailed steering control information.

2.109

Tigercat AD610C Carrier 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 dozer blade are resting on the ground before servicing or parking the machine.

Controls and operation

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 AD610C Carrier

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.

•

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.

Other chemicals however can seriously weaken the polycarbonate.

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.

2.111

Tigercat AD610C Carrier

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.

2.112

Tigercat AD610C Carrier

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.

2.113

Tigercat AD610C Carrier

Controls and operation

CLEANING A/C CONDENSER AND COOLING ASSEMBLY 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.

A/C CONDENSER

CHARGE AIR COOLER (CAC)

RADIATOR

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.

610-03

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

HYDRAULIC OIL COOLER

COOLING ASSEMBLY WITH AIR CONDITIONING

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.

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Tigercat AD610C Carrier

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.

2.115

Tigercat AD610C Carrier 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.

Controls and operation ARTICULATION LOCK ~ ARTICULATED LOCKED POSITION 1. Position machine on level ground and steer machine into a fully articulated position to the right.

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

ARTICULATION LOCK

ARTICULATION LOCK ~ STRAIGHT LOCKED POSITION 1. Position machine on level ground and steer machine into a straight ahead position.

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

ARTICULATION LOCK

REAR CHASSIS AD610C-10

RETAINING PINS

ARTICULATION LOCK STORED POSITION

REAR CHASSIS AD610C-10

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.

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-01

630D-03

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

2.116

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

Tigercat AD610C Carrier 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 'H' and 'I' on the machine lifting/ tie-down 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 'F' and 'G' 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.

A E

B

I

G F

H

A B C D E

C

H,I

D

E

F F,G

G H I A,D E

B,C

46640BUNI R0

2.117

Tigercat AD610C Carrier TRANSPORTING INSTRUCTIONS

Controls and operation CAUTION

The carrier 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 crane must be placed in the park position.

•

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.

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.

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.

A E

B

I

G F

H

A B C D E

C

H,I

D

E

F F,G

G H I B,C

A,D E 46640BUNI R0

2.118

Tigercat AD610C Carrier

Controls and operation

TIE DOWN POINTS

LIFTING POINTS

1. When a machine 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.

Lifting of the machine should be done for transportation purposes only.

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.

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.

WARNING 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 'F' and 'G' 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 'H' and 'I' 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.

5. 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 'E' 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.

2.119

Tigercat AD610C Carrier TOWING INSTRUCTIONS

Controls and operation

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.

MANIFOLD 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.

PARKING BRAKE SUPPLY HOSE

Note if equipped with an EHS transmission please refer to TOWING INSTRUCTIONS EHS TRANSMISSION in THIS SECTION. AD610C-08

2. Remove parking brake supply hose from the manifold and connect to a remote power source. Pressurize circuit to 250 psi (17 Bar) to disengage parking brake.

REMOVE PARKING BRAKE SUPPLY HOSE AND CONNECT TO REMOTE POWER SOURCE TO DISENGAGE PARKING BRAKE WHILE TOWING

3. Raise the dozer blade off the ground and turn off the engine.

CAUTION

DISCONNECT LEVER

342-1

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 (3.2 km/h). 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.

TRANSMISSION DISCONNECT LEVER SHOWN IN NEUTRAL

2.120

Tigercat AD610C Carrier STEERING CYLINDERS

SM47

NORMAL HOSE CONNECTIONS

Controls and operation STEERING CYLINDERS

HOSES ON ONE CYLINDER CROSS CONNECTED FOR TOWING

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.

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.

2.121

Tigercat AD610C Carrier

Controls and operation

TOWING INSTRUCTIONS

(IF EQUIPPED WITH EHS TRANSMISSION) 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.

Prior to towing, be sure that the machine is either on level ground, or is secured by the tow vehicle to prevent the machine from rolling unexpectedly.

IMPORTANT! Before towing, the transmission must always be disconnected from the drive wheels.

615C-025

FRONT DRIVE SHAFT

615C-024

MID DRIVE SHAFT

615C-023

MID DRIVE SHAFT

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.

1. To facilitate towing, the drive shafts must be disconnected from the transmission.

2. Disconnect the front drive shaft at the front axle.

3. Remove the mid drive shaft.

4. Raise the dozer blade off the ground and turn off the engine.

5. 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.

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

STEERING CYLINDERS

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

STEERING CYLINDERS

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

7. When towing is completed, reinstall the mid drive shaft, reconnect the front driveshaft and reconnect the steering cylinder hoses in their proper locations.

SM47

2.122

NORMAL HOSE CONNECTIONS

HOSES ON ONE CYLINDER CROSS CONNECTED FOR TOWING

Tigercat AD610C Carrier SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3

ISSUE 4.0 AUGUST 2015

AIR CLEANER MAINTENANCE.................................................................................... 3.33 AIR CONDITIONING SYSTEM, CHECKING................................................................. 3.40 APPROVED HYDRAULIC OILS.................................................................................... 3.13 ARTICULATION LOCK................................................................................................... 3.37 AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS.......................................................................................... 3.45 AXLE PINION SEAL GREASE FITTING........................................................................ 3.45 CAB SAFETY CABLE.................................................................................................... 3.43 CAB SUPPORT BRACE................................................................................................ 3.43 CENTER JOINT LUBRICATION............................................................................................................ 3.36 MAINTENANCE.......................................................................................................... 3.36 DEPRESSURIZING SUSPENDED MACHINE ELEMENTS.......................................... 3.31 DRAINING ENGINE COOLANT..................................................................................... 3.29 DRAINING MAIN HYDRAULIC TANK............................................................................ 3.27 DRAINING PARKING BRAKE OIL................................................................................. 3.30 DRAINING SECONDARY HYDRAULIC TANK (IF EQUIPPED).................................... 3.28 DRAINING THE FUEL TANK......................................................................................... 3.22 DRAINING TRANSMISSION OIL................................................................................... 3.30 EMERGENCY EXITS, CHECK MONTHLY...................................................................... 3.7 FILLING HYDRAULIC TANK................................................................................ 3.27, 3.28 FILTERS CHARGE PRESSURE FILTER................................................................................... 3.26 EHS TRANSMISSION FILTER (6109071 TO 6109080)............................................. 3.26 FUEL FILTER/WATER SEPARATOR.......................................................................... 3.20 FUEL TANK STRAINER............................................................................................. 3.20 HYDRAULIC OIL FILTERS............................................................................... 3.23, 3.24 SERVICING GUIDELINES FOR OIL FILTERS........................................................... 3.25 FIRE PREVENTION......................................................................................................... 3.8 GENERAL MAINTENANCE..................................................................................... 3.7, 3.8 HOUR METER ~ MAINTENANCE................................................................................... 3.3 LUBRICATION AND SERVICE POINTS 6109001 TO 6109020................................................................................................. 3.15 6109021 TO 6109070, 6109081 TO 9109250............................................................ 3.17 6109071 TO 6109080................................................................................................. 3.19 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 PRESSURIZED WATER SYSTEM MAINTENANCE..................................................... 3.38

Tigercat AD610C Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE 8 HOURS...................................................................................................................... 3.9 48 HOURS.................................................................................................................... 3.9 125 HOURS................................................................................................................ 3.10 250 HOURS................................................................................................................ 3.10 500 HOURS................................................................................................................ 3.11 1000 HOURS.............................................................................................................. 3.11 2000 HOURS.............................................................................................................. 3.12 SEASONAL................................................................................................................. 3.12 SERVICE AND LUBRICATION POINTS 6109001 TO 6109020................................................................................................. 3.15 6109021 TO 6109070, 6109081 TO 9109250............................................................ 3.17 6109071 TO 6109080................................................................................................. 3.19 SERVICE BRAKE CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION................ 3.32 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE............................................................................................ 3.46 TILTING THE CAB......................................................................................................... 3.42 LOWERING THE CAB................................................................................................ 3.43 RAISING THE CAB..................................................................................................... 3.42 TIRE PRESSURES........................................................................................................ 3.54 TORQUE, FLUID CONNECTIONS................................................................................ 3.50 TORQUE SPECIFICATIONS - GENERAL..................................................................... 3.49 WEIGHTS OF COMMERCIAL WOOD........................................................................... 3.53 WHEELS, INSTALLING.................................................................................................... 3.3 WINCH MAINTENANCE................................................................................................ 3.44

3.2

Tigercat AD610C Carrier

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR AD610C Carrier 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 AD610C Carrier

Lubrication and Maintenance

TIGERCAT OIL ANALYSIS PROGRAM Using the Tigercat Advanced Oil Analysis Program on a regular basis is an excellent preventative maintenance tool.

Studies have shown that it is possible to receive a 10 to 1 payback when looking at the amount saved on repair costs to the amount invested in a scheduled oil analysis program. Some of the benefits of a sampling program include: •

Detect problems early before they become major catastrophic failures.

•

Better ability to schedule downtime and forecast cost of repairs.

•

Monitor maintenance schedules and practices and confirm that the required maintenance is being done on time.

•

Increase used equipment value by providing proof of proper maintenance.

This Program uses the most modern technology available to analyze all oil samples. Most test results are available within 24 hours after receipt of the sample and are supplied in an easy to understand report, which calls for specific action and makes detailed recommendations. This report is available as a mailed or faxed hardcopy, sent via e-mail or can be viewed on the internet.

This program will provide Tigercat machine owners access to an Advanced Oil Analysis Program for all major machine components including Engines, Hydraulic Circuits, Axles, Final Drives, Gearboxes, etc.

Location Hydraulic Oil Transmission Axles – Front & Rear

600 Series Utility Vehicle Models

First Sample Follow-up Samples 125 Hours Every 1000 Hours or 6 Months 125 Hours Every Oil Change (500 Hours or 3 Months) 125 Hours Every Oil Change (1000 Hours or 6 Months)

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 AD610C Carrier

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:

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.

3.5

•

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.

Tigercat AD610C Carrier

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.

MACHIINES 6109001 TO 6109020

SAMPLE LOCATION / TRANSMISSION DRAIN 630C-100

TRANSMISSION OIL

AXLE LEVEL CHECK AND FILL

AXLE DRAIN

AXLE DRAIN 610-01

SAMPLE LOCATION AXLE DRAIN

REFER ALSO TO AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS IN THIS SECTION FOR MORE INFORMATION.

AXLE DRAIN AND FILL LOCATIONS (REAR AXLE SHOWN) AXLE LEVEL CHECK AND FILL (FAR SIDE)

MACHIINES 6109021 TO 6109250

AXLE LEVEL CHECK AND FILL

SAMPLE LOCATION AXLE DRAIN

S610-01

AXLE DRAIN AND FILL LOCATIONS 3.6

REFER ALSO TO AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS IN THIS SECTION FOR MORE INFORMATION.

Tigercat AD610C Carrier

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 dozer blade to the ground

Clean up oil spills on walking surfaces and top of engine enclosure immediately

For safety, always block or support attachment 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 AD610C Carrier

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 AD610C Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE FREQUENTLY:~

Check:~ • Service brake for proper operation. Refer to SERVICE BRAKE ~ CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in THIS SECTION.

• Check engine cooling air intake screens for possible restriction.

• 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.

EVERY 8 HOURS (EVERY SHIFT):~ • Perform "frequently" maintenance check, and in addition:~ • Check engine coolant level • Check engine oil level

• 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.

• 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.

• For loose nuts, bolts and fittings

Replace secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

• Condition and tension of fan belts.

• Exhaust system for leaks.

• Water pressure (60 psi [4 Bar]) for pressurized water system.

• Check hydraulic oil level with crane stowed and dozer blade on the ground

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

• On machines equipped with a secondary hydraulic tank, check hydraulic oil level with crane stowed • Check winch sump oil level

• Conduct an overall visual inspection.

• Check transmission oil level with dipstick

• Inspect winch, control valve, and connecting hoses for damage or hydraulic oil leakage.

Check that the wire cable is in good condition.

If any problems are found, they should be corrected before operating the winch.

• Lubricate front axle pivot, 2-fittings, purge • Lubricate mid drive shaft 1-fitting, purge 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.

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

• Lubricate center joint bearings, 2-fittings, purge • Lubricate steering cylinder ends, 4-fittings, purge

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

• Lubricate dozer blade cylinders and pivots, 6-fittings, purge Clean:~ • Potentially damaging limbs or sticks from machine • A/C condenser, oil cooler, radiator refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR'S MANUAL. 3.9

Tigercat AD610C Carrier

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:~ • Carry out A/C system inspection; Refer to AIR CONDITIONING SYSTEM, CHECKING in THIS SECTION

• Perform 125 hour maintenance And in addition:~ • Replace primary fuel filter and secondary fuel filter/water separator

Check:~ • Check oil level in front and rear axles. Refer to AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION.

• Check parking brake oil level

• Fluid level in batteries unless maintenance free

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

• 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:• Front and rear frame • Center joint area • Attachment Make repairs immediately Visually inspect for:• Frayed electrical wiring and hydraulic hose • Wear in any other components • 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.

3.10

Tigercat AD610C Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 500 HOURS:~

EVERY 1000 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• 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.

• 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.

• Replace charge pressure filter † • On machines 6109071 to 6109080, replace EHS transmission filter † • On machines equipped with a secondary hydraulic tank, replace hydraulic oil double element filters and single element filter (3 elements) †

• Replace oil in winch sump.

• Replace oil in parking brake.

2 white, high performance element.

1 blue, water absorbing element.

• Drain and refill front and rear axles. Refer to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils.

Refer also to AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION.

• Replace oil in transmission.

• Lubricate front drive shaft 1-fitting, purge • Lubricate rear drive shaft bearing, 1-fitting, purge

• Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

• Lubricate door hinges, 12-fittings, purge • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

• Lubricate front axle pinion grease seal (if equipped (6109021 to 6109250) • Lubricate rear axle pinion grease seal (if equipped (6109021 to 6109250) • 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 AD610C Carrier

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

SEASONAL:~ • Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Fill tank with crane stowed and the 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 (5 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 s 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.

• On machines equipped with a secondary hydraulic tank, drain and refill secondary hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

3.12

• Drain and refill front and rear axles. Refer to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils.

Refer also to AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION. • Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

Tigercat AD610C Carrier

Lubrication and Maintenance

APPROVED HYDRAULIC OILS Use only one of the following oils to fill or replenish the MAIN HYDRAULIC SYSTEM.

3.13

Tigercat AD610C Carrier

Lubrication and Maintenance

MACHINES 6109001 TO 61009020

3.14

Tigercat AD610C Carrier

Lubrication and Maintenance

MACHINES 6109001 TO 61009020 Tigercat® Model AD610C SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

CHK

2

ENGINE OIL/FILTER CUMMINS QSB SERIES

CHK

3 3A

•

PRIMARY FUEL FILTER SECONDARY FUEL FILTER/WATER SEPARATOR

DRN

34.4

9.1

•

•

QTY

2000 6

1000 6

500 6

CHANGE COOLANT EVERY 2 YEARS

DESCRIPTION USG

COOLING SYSTEM

CAPACITY LITERS

1

250 6

86

ITEM

125 6

SERVICE POINT NO.

SERVICE EVERY

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 1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENCE FOR DETAILS.

1

REFER TO SECTION 3 IN MANUAL

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)

6

CHK

1

AIR INTAKE SAFETY ELEMENT

CHK

7

AIR CLEANER UNLOADER VALVE

CHK

8

AIR INTAKE CONNECTIONS

CHK

9

HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10

HYDRAULIC FILTER, FULL FLOW, INCLUDES: 1 BLUE WATER ABSORBING ELEMENT * 1 WHITE HIGH PERFORMANCE FILTER

REP †

2

*NOTE: MUST USE: 1 BLUE FILTER ELEMENT 1 WHITE FILTER ELEMENT

11

CHARGE PRESSURE FILTER

REP †

1

CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW

12

WINCH: DP

CHK

13

PRESSURIZED WATER SYSTEM

CHK

14

TRANSMISSION

CHK

15

AXLES: FRONT REAR

16

AXLE-PIVOT (FRONT ONLY)

CAST

REP REP

89

TEST

MID DRIVE SHAFT

1.89

0.5

REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL

D/R

52

13.7

SEASONAL DRAIN AND REFILL

6

1.6

1

36 36

9.5 9.5

1 1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10ºF(-23ºC) USE 75W-90 UP TO 100ºF(38ºC) USE 80W-90 ABOVE 100ºF(38ºC) USE 85W-140

PURGE

2

LITHIUM BASE EP2 GREASE u

PURGE

1

LITHIUM BASE EP2 GREASE u

PURGE

2

D/R ***

LUB

FRONT DRIVE SHAFT 17

D/R

D/R

CHK

23.5

LUB LUB **

REAR DRIVE SHAFT

LUB

CENTER JOINT

LUB

CENTER JOINT BEARING PRELOAD

CHK 48 6

19

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE u

20

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE u

21

AERIAL DEVICE

18

22

PARKING BRAKE

LUBECHART-46651BENG R0A.PDF

LITHIUM BASE EP2 GREASE u REFER TO SECTION 3 OF THE MANUAL FOR DETAILS

CHK

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

CHK

3.15

D/R

0.5

0.1

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

Tigercat AD610C Carrier

Lubrication and Maintenance

MACHINES 6109021 TO 6109070, 6109081 TO 61090250 DOOR HINGES

MID DRIVE SHAFT

4 FTG/500

12

1 FTG/8

REAR DRIVE SHAFT

1 FTG/500

12

20

AXLE-PIVOT, FRONT

STEER CYLINDERS

2 FTG/8

4 FTG/8

17

2

1

13

DOOR HINGES

8 FTG/500

4

22

3

3A

11

10

23

18

18

9

10 11

6 7

1

5

8

19

15 16

AXLE PINION

1 FTG/1000

18

CENTER JOINT

2 FTG/8

14

FRONT DRIVE SHAFT

1 FTG/500

16

AXLE PINION

1 FTG/1000

DOZER

6 FTG/8

15

21

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).

2 FTG/125

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2FTG) AND HOURS BETWEEN 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 AD610C Carrier

Lubrication and Maintenance

MACHINES 6109021 TO 6109070, 6109081 TO 61090250 Tigercat Model AD610C 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 MAINTENCE 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

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

REP †

2

*NOTE: MUST USE: 1 BLUE FILTER ELEMENT 1 WHITE FILTER ELEMENT

11

CHARGE PRESSURE FILTER

REP †

1

CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW

12

WINCH: DP

CHK

13

PRESSURIZED WATER SYSTEM

CHK

6

14

TRANSMISSION

CAST

15

AXLES: FRONT REAR

16

PINION GREASE SEAL - FRONT AND REAR AXLE

17

AXLE-PIVOT (FRONT ONLY)

CHK

1

REP REP

89

D/R TEST

D/R

CHK

D/R

D/R ***

LUB LUB

FRONT DRIVE SHAFT 18

MID DRIVE SHAFT

52

13.7

SEASONAL DRAIN AND REFILL

1.6

1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE 75W-90

6.5 7.0

1 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

PURGE

2

ONE FITTING PER AXLE LITHIUM BASE EP2 GREASE 

PURGE

2

LITHIUM BASE EP2 GREASE 

PURGE

1

LITHIUM BASE EP2 GREASE 

PURGE

2

24.6 26.5

LUB LUB **

REAR DRIVE SHAFT 19

REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL

1.89 0.5

6

CHK

23.5

LUB

CENTER JOINT

LUB

LITHIUM BASE EP2 GREASE  REFER TO SECTION 3 OF THE MANUAL FOR DETAILS

CENTER JOINT BEARING PRELOAD

CHK 48 

20

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

21

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE 

22

AERIAL DEVICE

23

PARKING BRAKE

CHK

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

CHK

D/R

LUBECHART-49232BENG R3.PDF

3.17

0.5

0.1

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

Tigercat AD610C Carrier

Lubrication and Maintenance

MACHINES 6109071 TO 6109080 DOOR HINGES

MID DRIVE SHAFT

4 FTG/500

13

1 FTG/8

11

24

19

REAR DRIVE SHAFT

13

23

3

3A

12

10

AXLE-PIVOT, FRONT 2 FTG/8 18 DOOR HINGES

STEER CYLINDERS 21 4 FTG/8

1 FTG/500

19

2

1

14

8 FTG/500

4

9

10 12

6 7

1

5

8

20

16 17

AXLE PINION

1 FTG/1000

19

CENTER JOINT

2 FTG/8

11 15

FRONT DRIVE SHAFT

1 FTG/500

17

AXLE PINION

1 FTG/1000

DOZER

6 FTG/8

16

22

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).

2 FTG/125

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2FTG) AND HOURS BETWEEN 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 AD610C Carrier

Lubrication and Maintenance

MACHINES 6109071 TO 6109080 Tigercat Model AD610C SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

1

COOLING SYSTEM

CHK

2

ENGINE OIL/FILTER CUMMINS QSB SERIES

CHK

3 3A

QTY

34.4 9.1

•

•

DRN

DESCRIPTION USG

LITERS

2000 

1000 

500 

CAPACITY

CHANGE COOLANT EVERY 2 YEARS

PRIMARY FUEL FILTER SECONDARY FUEL FILTER/WATER SEPARATOR

250 

8

ITEM

125 

SERVICE POINT NO.

SERVICE EVERY

60/40 ANTIFREEZE *

• SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS

•

REP

1

REP

1

4

FUEL TANK FILLER SCREEN

CHK

5

AIR INTAKE PRECLEANER/INLET HOOD

CHK

1 1

CLEAN AS REQUIRED

AIR INTAKE PRIMARY ELEMENT

CHK

1 1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENCE FOR DETAILS.

1

REFER TO SECTION 3 IN MANUAL

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)

REP †

2

*NOTE: MUST USE: 1 BLUE FILTER ELEMENT 1 WHITE FILTER ELEMENT

EHS TRANSMISSION FILTER

REP †

1

12

CHARGE PRESSURE FILTER

REP †

1

13

WINCH: DP

CHK

14

PRESSURIZED WATER SYSTEM

CHK

15

EHS TRANSMISSION

CHK

16

AXLES: FRONT REAR

17

PINION GREASE SEAL - FRONT AND REAR AXLE

18

AXLE-PIVOT (FRONT ONLY)

6

AIR INTAKE SAFETY ELEMENT

CHK

7

AIR CLEANER UNLOADER VALVE

CHK

8

AIR INTAKE CONNECTIONS

CHK

9

HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10

HYDRAULIC FILTER, FULL FLOW, INCLUDES: 1 BLUE WATER ABSORBING ELEMENT * 1 WHITE HIGH PERFORMANCE FILTER

11

REP REP

89

TEST

19

MID DRIVE SHAFT

1.89

0.5

REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL

D/R

52

13.7

SEASONAL DRAIN AND REFILL

10

2.6

1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE 75W-90

24.6 26.5

6.5 7.0

1 1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10ºF(-23ºC) USE 75W-90 UP TO 100ºF(38ºC) USE 80W-90 ABOVE 100ºF(38ºC) USE 85W-140

PURGE

2

ONE FITTING PER AXLE LITHIUM BASE EP2 GREASE 

PURGE

2

LITHIUM BASE EP2 GREASE 

PURGE

1

LITHIUM BASE EP2 GREASE 

PURGE

2

D/R ***

LUB LUB

FRONT DRIVE SHAFT

CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW

D/R

D/R

CHK

23.5

LUB LUB **

REAR DRIVE SHAFT

LUB

CENTER JOINT

LUB

CENTER JOINT BEARING PRELOAD

CHK 48 

21

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

22

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE 

23

AERIAL DEVICE

20

24

PARKING BRAKE

LITHIUM BASE EP2 GREASE  REFER TO SECTION 3 OF THE MANUAL FOR DETAILS

CHK

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

CHK

D/R

LUBECHART-54906BENG R0 MOD.PDF

3.19

0.5

0.1

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

Tigercat AD610C Carrier

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

1. Park machine on level ground, install articulation lock bar, lower dozer 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.

SECONDARY FUEL FILTER/ WATER SEPARATOR

8. Prime the fuel system using the hand primer on the secondary fuel filter/water separator before starting the engine.

610C-12

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 AD610C Carrier

Lubrication and Maintenance

Changing the secondary fuel filter/water separator: 1. Park machine on level ground, install articulation lock bar, lower dozer to the ground, stop engine, engage parking brake and block wheels.

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 .

8. Install the water in fuel sensor in the new filter.

(Inspect water in fuel sensor for damage and replace as required.)

9. Check the seating area for the o-ring on the filter head and wipe clean.

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

14. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL.

OUTLET CONNECTION

PLUG HAND PRIMER SECONDARY FUEL FILTER/ WATER SEPARATOR

610C-12

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.

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

FUEL WATER SEPARATOR

DRAIN VALVE WATER IN FUEL SENSOR

610C-15

SECONDARY FUEL FILTER/ WATER SEPARATOR

3.21

Tigercat AD610C Carrier

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.

COVER

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 to the ground , stop engine, engage parking brake and block wheels.

2. Drain the fuel tank. Refer to DRAINING THE FUEL TANK in THIS SECTION.

AD610C-07

FUEL TANK

DRAINING THE FUEL TANK 1. The fuel system is equipped with two standard saddle tanks. A siphon should be used to drain the fuel tanks.

3. Remove the round fuel tank cover plate and “O” ring from the access hole.

4. Before removing the strainer, clean any debris from the bottom of the tank and wipe it clean.

5. Remove the fuel strainer using the hex on the end of strainer. Carefully clean the strainer (it may be damaged by rough handling).

6. Check for a buildup of foreign materials where the strainer threads on to the pipe and elbow.

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.

REAR COVER

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.

RIGHT HAND TANK

LEFT HAND TANK

3. To access the fuel tanks, remove the cover.

Remove the fuel tank filler cap and filler screen on the right hand fuel tank.

Remove the rear cover on the left hand fuel tank. Care should be taken to avoid damaging the fuel level sender mounted on this cover.

Siphon fuel from both the left and right hand tanks into the container.

Once fluid has been drained replace the filler cap, filler screen and cover.

3.22

Tigercat AD610C Carrier

Lubrication and Maintenance

HYDRAULIC OIL DOUBLE ELEMENT FILTERSMAIN HYDRAULIC TANK DOUBLE ELEMENT FILTER

BREATHER

DOUBLE ELEMENT FILTER

BREATHER

BLUE ELEMENT

BLUE ELEMENT

EHS TRANSMISSION FILTER

SIGHT GAUGE

HYDRAULIC TANK

SIGHT GAUGE

CHARGE PRESSURE FILTER

604C-215

CHARGE PRESSURE FILTER HYDRAULIC TANK

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (EARLIER DESIGN)

615C-013

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (LATER DESIGN)

WARNING

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: 1 white, Tigercat high performance, full flow hydraulic oil filter element

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

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

•

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)!

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION AND SERVICE POINTS in THIS SECTION. 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. Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

3.23

Tigercat AD610C Carrier

Lubrication and Maintenance

HYDRAULIC OIL DOUBLE ELEMENT FILTERS SECONDARY HYDRAULIC TANK (IF EQUIPPED)

DOUBLE ELEMENT FILTER

Machines equipped with an optional digger derrick have a secondary hydraulic tank. Located on the rear chassis to the rear of the digger derrick base.

BLUE ELEMENT

SINGLE ELEMENT FILTER

SIGHT GAUGE

The secondary hydraulic circuit contains a two element, full flow, 7 micron filter with a built in 25 psi (1.7 bar) bypass valve.

TEMPERATURE GAUGE

The secondary hydraulic circuit also contains a single element full flow 7 micron filter with a built in 5 psi (0.34 bar) bypass valve. This filter is used as a case drain strainer for the secondary hydraulic ciruit.

SECONDARY HYDRAULIC TANK

It is recommended that all machines use two different filter elements:

AD610C-020

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

2 white, Tigercat high performance, full flow hydraulic oil filter element.

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION AND SERVICE POINTS in THIS SECTION. 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. Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

3.24

SECONDARY HYDRAULIC OIL TANK

Tigercat AD610C Carrier

Lubrication and Maintenance

Changing the filters: 1. Park machine on level ground, install articulation lock bar, lower dozer to ground, stop engine, engage parking brake and block wheels.

BREATHER

DOUBLE ELEMENT FILTER

BLUE ELEMENT

2. Wipe clean the area around the filter and head.

3. Place rags below to catch the spillage of oil.

EHS TRANSMISSION FILTER

4. Wearing face protection (in case of an oil squirt), unscrew the old filter. Dispose of old filter and any oil properly.

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.

FILTER HEAD

SIGHT GAUGE

CHARGE PRESSURE FILTER HYDRAULIC TANK

GASKET

FILTER ELEMENT

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (LATER DESIGN)

615C-013

FILTR_SEALS 2

SQUARE SECTION GASKET INSTALLATION

DOUBLE ELEMENT FILTER

 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.

BLUE ELEMENT

SINGLE ELEMENT FILTER

SIGHT GAUGE

TEMPERATURE GAUGE

FILTER HEAD SECONDARY HYDRAULIC TANK GASKET

FILTR_SEALS 2

AD610C-020

SECONDARY HYDRAULIC OIL TANK

HYDRAULIC FILTER SERVICING GUIDELINES

FILTER ELEMENT

'O' RING GASKET INSTALLATION

 'O' Ring Gasket

Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

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) 6. Start the engine and check for leaks.

3.25

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.

Tigercat AD610C Carrier

Lubrication and Maintenance 9. Hand tighten filter an additional 1/2 turn only.

DOUBLE ELEMENT FILTER

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

BREATHER BLUE ELEMENT

10. Start the engine and check for leaks.

EHS TRANSMISSION FILTER (6109071 TO 6109080)

EHS TRANSMISSION FILTER

SIGHT GAUGE

The EHS transmission circuit is equipped with a full flow pressure filter with a 50 psi (3.5 bar) third port bypass valve. When a restriction is encountered the bypass valve diverts oil back to the transmission circuit reservoir in the transmission to prevent unfiltered oil from entering the transmission circuit.

Refer to SERVICE AND LUBRICATION POINTS for EHS transmission oil specifications.

CHARGE PRESSURE FILTER

Changing a transmission filter: 1. Park machine on level ground, install articulation lock bar, lower dozer to ground, stop engine, engage parking brake and block wheels.

HYDRAULIC TANK

615C-013

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE (LATER DESIGN)

2. Wipe clean the area around the filter and head.

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.

3. Place rags below to catch the spillage of oil.

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.

Changing a pressure filter: 1. Park machine on level ground, install articulation lock bar, lower dozer to ground, stop engine, engage parking brake and block wheels.

7. This filter has an o-ring gasket. Replace o-ring as required and apply transmission oil to the gasket surface.

2. Wipe clean the area around the filter and head.

3. Place rags below to catch the spillage of oil.

8. Screw on the new filter until the gasket makes contact with the seat in the filter head.

9. Hand tighten filter an additional 1/2 turn only.

4. Wearing face protection (in case of an oil squirt), unscrew the old filter.

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

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.

10. Start the engine and check for leaks.

7. This filter has an o-ring gasket. Replace o-ring as required and apply hydraulic oil to the gasket surface.

8. Screw on the new filter until the gasket makes contact with the seat in the filter head.

3.26

Tigercat AD610C Carrier

Lubrication and Maintenance

DRAINING MAIN HYDRAULIC TANK

TO TANK VIA FILTERS

CAUTION Perform the hydraulic tank drain when the hydraulic oil temperature is below 100°F (38°C), but warm enough to be viscous.

SHUT-OFF VALVE IN OFF POSITION

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.

3. The drain hose for the hydraulic tank can be lowered from the belly of the chassis and positioned in a drip pan.

HAND FILL PUMP

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.

QUICK CONNECT TO SUCTION HOSE

FILLING HYDRAULIC TANK 615C-014

Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Refer to SERVICE AND LUBRICATION POINTS chart in THIS SECTION for hydraulic tank capacity.

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 THIS SECTION.

1. Park machine on level ground, lower dozer blade onto the ground.

2. Open right rear engine compartment access panels.

Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

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.

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION

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 crane stowed and the 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 (5 to 7.5 cm) when all cylinders are extended.

610C-34

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.

3.27

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION BELOW LEFT HAND CAB DOOR

Tigercat AD610C Carrier

Lubrication and Maintenance

DRAINING SECONDARY HYDRAULIC TANK (IF EQUIPPED)

DOUBLE ELEMENT FILTER

BLUE ELEMENT

SINGLE ELEMENT FILTER

CAUTION Perform the hydraulic tank drain when the hydraulic oil temperature is below 100°F (38°C), but warm enough to be viscous.

SIGHT GAUGE

1. The secondary hydraulic tank is equipped with a drain plug.

TEMPERATURE GAUGE

2. Remove the plug to drain tank into a suitable container.

SECONDARY HYDRAULIC TANK

3. Once fluid has been drained, replace the drain plug.

FILLING HYDRAULIC TANK

SECONDARY HYDRAULIC OIL TANK

AD610C-020

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 onto the ground.

SIGHT GAUGE

2. Open the cover at the rear of the secondary hydraulic tank to access fill pump.

QUICK CONNECT TO SUCTION HOSE SHUT-OFF VALVE IN OFF POSITION

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.

HAND FILL PUMP

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.

AD610C-022

HYDRAULIC HAND FILL PUMP

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION

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 crane stowed until hydraulic oil level reaches the sight gauge full mark. Note that the oil level will drop 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 cover.

610C-34

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION BELOW LEFT HAND CAB DOOR

IMPORTANT !

Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs.

Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in THIS SECTION. 3.28

Tigercat AD610C Carrier

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.

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.

1. The radiator is equipped with a hose to drain the contents of the radiator system fluid into a storage container.

FILLER CAP 33952AUNI R0

2. Remove the front nose belly pan in the front chassis.

3. Remove the radiator pressure cap.

4. The radiator is located on the right hand side of the heat exchanger.

ENGINE COOLANT FILLER CAP

620C-36

A/C CONDENSER

DRAIN HOSE

630D-06

SHUT-OFF VALVE

CHARGE AIR COOLER (CAC)

RADIATOR

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.

3.29

610-03

COOLING ASSEMBLY

HYDRAULIC OIL COOLER

Tigercat AD610C Carrier

Lubrication and Maintenance

DRAINING PARKING BRAKE OIL

DRAINING TRANSMISSION OIL

1. The parking brake is equipped with a hose to drain the oil contents of the parking brake into a storage container.

1. The transmission is equipped with a plug to drain the contents of the transmission into a storage container.

2. Remove the belly pan in the rear chassis closest to the articulation joint.

2. Remove the belly pan in the front 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.

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 drain hose.

4. Once fluid has been drained, replace the drain plug in the transmission housing once draining has completed.

DRAIN HOSE

TRANSMISSION DRAIN 630D-001

PARKING BRAKE

630C-100

3.30

TRANSMISSION OIL

Tigercat AD610C Carrier

Lubrication and Maintenance

DEPRESSURIZING SUSPENDED MACHINE ELEMENTS

LET DOWN AUXILLIARY POWER CONTROL

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.

CRANE - AERIAL DEVICE The aerial device is equipped with a Let Down Auxilliary Power Control. Refer also to aerial device attachment manufacturer's manual.

1. Press and hold the Let Down Auxilliary Power Control to operate the auxilliary pump.

2. Refer to manufacturer's operator's manual for further instructions.

AD610C-14

DOZER 1. When suspended the dozer blade will tend to extend the hydraulic cylinders supporting them due to gravity.

2. Remove the function valve cover in the rear chassis.

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.

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.

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.

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. Restore spool limiting set screws to their factory setting and secure jam nuts prior to operating the machine.

Factory settings are dozer section 6mm.

AERIAL DEVICE - LET DOWN AUXILLIARY POWER CONTROL

AUXILLIARY PUMP

AD610C-15

SPOOL LIMITING SET SCREW

620D-09

MAIN VALVE SPOOL LIMITING SET SCREWS

A

B DOZER

WINCH

WARNING

ATTACHMENT PRESSURE

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

DO NOT perform work on valves or piping until all suspended elements are are lowered and engine is shut off.

AD610C-02

3.31

MAIN VALVE

Tigercat AD610C Carrier

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.

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 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

Tigercat AD610C Carrier

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 AIR CLEANER

610C-08

3

3

AIR CLEANER UNLOADER VALVE

4

ENGINE AIR CLEANER

2

AIR PRECLEANER

1

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.

5

630C-19

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

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 AD610C Carrier

Lubrication and Maintenance AIR CLEANER UNLOADER VALVE

FILTER RESTRICTION INDICATOR

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.

FILTER RESTRICTION SWITCH (IF EQUIPPED)

AIR CLEANER 610C-10

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 PRECLEANER

ENGINE AIR CLEANER

AIR CLEANER

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

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.

FILTER RESTRICTION INDICATOR

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

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.

Engine Air Intake Filter Restricted. Service Machine to correct.

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.

NOTE: Replace the safety element every third primary filter change.

INTAKE TUBING AND JOINTS 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 and repair or replace immediately.

Replace all air intake rubber components such as elbows and connectors every 2000 hours - High temperatures in this area can cause the rubber to harden.

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.

In addition to the LUBRICATION AND MAINTENANCE SCHEDULE, the following instructions should also be noted.

3.34

Tigercat AD610C Carrier

Lubrication and Maintenance

The most common and damaging servicing problems are:

OUTLET TUBE

OVER SERVICING

PRIMARY ELEMENT

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.

SAFETY ELEMENT

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.

AIRCLEANER

AIR FILTER ELEMENTS

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS 1. Release the cover latch gently to reduce the amount of dust dislodged.

2. Avoid dislodging dust from filter element(s) by gently pulling the element off the outlet tube.

3. Always clean the sealing surface of the outlet tube before inserting a new filter element.

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.

6. Inspect the new filter for damage.

7. Insert the new filter properly. Apply pressure to the outer rim of the filter not the flexible centre.

8. 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.

3.35

Tigercat AD610C Carrier

Lubrication and Maintenance

CENTER JOINT MAINTENANCE OF CENTER JOINT Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint grease fittings to purge the pivot bearings of debris and water. Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint pivot for looseness every 48 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

1. Have operator lift the dozer blade off the ground and then rapidly raise and lower blade several times to "bounce" machine.

2. As machine bounces, check for motion between the front and rear chassis frame lugs. Also check for a "clunking" sound at the center joint area.

3. Movement between front and rear chassis lugs or clunking of the pivot indicates a loose joint and preload must be checked.

Refer SECTION 11 of the SERVICE MANUAL for more information.

REAR CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

DIG-003

FRONT CHASSIS

CENTER JOINT PRE-LOAD CHECK

3.36

Tigercat AD610C Carrier

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 dozer blade to the ground, engage parking brake, stop engine and remove ignition key.

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

ARTICULATION LOCK

REAR CHASSIS AD610C-10

ARTICULATION LOCK

RETAINING PINS

ARTICULATION LOCK STORED POSITION

REAR CHASSIS AD610C-10

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 AD610C Carrier

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 WATER SHUT-OFF VALVE (SHOWN CLOSED) 620C-42

PRESSURIZED WATER SYSTEM

3. Close water shut off valve.

4. Fill tank with clean water.

WATER CONTROL VALVE

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.

Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL. 3.38

Tigercat AD610C Carrier 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.

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.

13. Return the hose to the hose compartment.

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. 3.39

Tigercat AD610C Carrier

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.

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. 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.

CHECK A/C CONDENSER CORE

g. Check air temperature exiting vents in cab. h. Listen to compressor and blower motor for abnormal noises.* i.

610-03

Run air conditioning system for 3 - 5 minutes.

CHECK A/C CONDENSER CORE 3.40

Check to see that compressor clutch will engage.*

Tigercat AD610C Carrier

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.

3.41

Tigercat AD610C Carrier TILTING THE CAB WARNING

Before tilting the cab, ensure that the machine is parked on level ground. Lower the dozer blade 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 machine on level ground.

2. Lower the 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 left side Cab Locking Pins (2 pins). This is done by first removing the locking bolts. (2 bolts) 6. Remove the access panel of the right hand step compartment below the cab door to access the cab tilt hand pump.

PUMP HANDLE

CAB SWEEP BOLTS

PUMP

LOCATED IN THE RIGHT HAND STEP COMPARTMENT BELOW THE CAB DOOR

PUMP LEVER SHOWN IN "RAISE" POSITION 630D-11 AD610C-03

PUMP CONTROL LEVER IN RAISE CAB POSITION

7. Turn the lever on the pump manifold to RAISE (pointing IN, toward 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 630D-12

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 the machine is on level ground.

3.42

Tigercat AD610C Carrier

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.

LOCATED IN THE RIGHT HAND STEP COMPARTMENT BELOW THE CAB DOOR

PUMP HANDLE

PUMP

PUMP LEVER SHOWN IN "LOWER" POSITION

CAB LOCKING PIN

SAFETY CABLE

CAB SUPPORT BRACE (3291B).

MUST USE CAB & CHASSIS LUGS SHOWN

AD610C-04

3. Turn the lever on the pump manifold to LOWER (pointing OUT, away the machine).

CAUTION Keep hands away from the locking pin area as the cab is being lowered.

CAB LOCKING PIN

PARTIAL TILT WITH CAB SUPPORT BRACE

E620C-17

CAB SAFETY CABLE (3361B)

PUMP CONTROL LEVER IN LOWER CAB POSITION

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 IN toward the machine and store the pump handle inside the cab.

8. Reinstall the access panel.

9. Replace the Cab Sweep Bolts. (2 bolts)

AD610C-05

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE CAB SUPPORT BRACE

WARNING

If cab support brace is damaged or lost, it must be replaced immediately with Tigercat brace PART NO. 3291B. DO NOT attempt to work under a raised cab supported only by the hydraulic cylinder or a substitute device.

WARNING

AD610C-203

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 SUPPORT BRACE STORED UNDER PLATFORM 3.43

Tigercat AD610C Carrier

Lubrication and Maintenance

WINCH MAINTENANCE - DP The recovery winch is located in the rear of the carrier.

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 activated is used to spool the winch cable in/out.

Refer to CAB CONTROLS~WINCH CONTROL LEVER , CAB CONTROLS~WINCH SELECT SWITCH in SECTION 2 of the OPERATOR'S MANUAL. Refer also to OPERATING WINCH 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 DP RECOVERY WINCH MODEL 35 Maximum rated line pull bare drum ............................35000 lbs (15876 kg) full drum................................18180 lbs (8246 kg) Maximum cable size.............3/4 in (19.1 mm) Drum Size and Capacities Barrel Diameter....................6.13 in (156 mm) Barrel Width..........................12.12 in (308 mm) Cable Capacity 9/16 in (14.3 mm).................289 ft (80 m) 5/8 in (15.9 mm)...................271 ft (82.6 m) 3/4 in (19.1 mm) ..................188 ft (57.3 m) Winch Ratio DPW-35............40.96:1 Dry Weight ...........................645 lbs (293 kg) Oil supply maximum pressure...............................2750 psi (190 bar) Oil supply maximum flow......30 USgpm(114 L/min)

FILL/LEVEL PLUG

AD610C-06

DRAIN PLUG

RECOVERY WINCH

The winch should be operated once every 30 days to ensure that the cable will freespool and that the winch will pull the machine in the event that it is needed to recover the machine from an unexpected accident or equipment failure.

LUBRICATION Refer to the manufacturer's maintenance and service manual for information on your winch.

The sump holds 0.5 US gal (1.9 L).

The oil level should be checked every day (if the winch is being used) before starting the machine.

Oil should be changed every 1000 hrs, depending on use.

Refer to manufacturer's manual for recommended oil. Use these oils or the equivalent.

The oil level should be up to the oil fill/level plug on the right side of the winch.

In addition fairlead rollers require lubrication on a weekly basis. Refer to manufacturer's service manual.

MAINTENANCE Maintenance of the winch is limited to the hydraulic system maintenance of the machine itself.

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.

3.44

Tigercat AD610C Carrier

Lubrication and Maintenance

AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS It may be necessary to remove axle covers to access the axle level check and fill plugs.

Refer to LUBRICATION AND SERVICE CHART and SCHEDULED MAINTENANCE in THIS SECTION for service intervals and recommended gear oils.

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.

CAUTION

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.

Fluid spray hazard. Contact with fluid under pressure may cause injury.

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.

REAR AXLE - LIMITED SLIP ADDITIVES Rear axles are equipped with brakes. It is permissible to use a limited slip additive in the rear axle to reduce brake chatter noise. Do not MACHIINES 6109001 TO 6109020

AXLE LEVEL CHECK AND FILL

AXLE DRAIN

AXLE DRAIN 610-01

SAMPLE LOCATION AXLE DRAIN

REFER ALSO TO AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS IN THIS SECTION FOR MORE INFORMATION.

AXLE DRAIN AND FILL LOCATIONS (REAR AXLE SHOWN)

MACHIINES 6109021 TO 6109250

AXLE LEVEL CHECK AND FILL (FAR SIDE)

PINION SEAL GREASE FITTING

AXLE LEVEL CHECK AND FILL

SAMPLE LOCATION AXLE DRAIN

S610-01

AXLE DRAIN AND FILL LOCATIONS 3.45

REFER ALSO TO AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS IN THIS SECTION FOR MORE INFORMATION.

Tigercat AD610C Carrier

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, seondary, 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.

1. Ensure the articulation lock bar is installed.

CAUTION

5. Install the articulation lock bar and engage parking brake.

Machine operator must ONLY take directions from the person doing the set-up.

6. Turn differential lock switch to OFF. 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

610C-03

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.

ENGINE 4 PIN POWER CONNECTOR

2. Disconnect 4 pin engine power connector on engine (prevents engine starting).

3. Crank engine for 10 seconds, wait for 10 seconds. Repeat 6 times to pump oil into pumps.

3.46

Tigercat AD610C Carrier 4

Lubrication and Maintenance

Check hydraulic oil levels in the main hydraulic tank and add hydraulic oil as required.

9. Set throttle to IDLE and run each function for 2 minutes to purge air from circuit.

5. Reconnect 4 pin engine power connector on engine.

10. Set throttle to FULL and run each function again for 2 minutes to flush circuit.

6. Start engine.

11. Top up the radiator with clean coolant.

7. Check for leaks.

12. With cylinders fully retracted, top up the main hydraulic oil reservoir with clean hydraulic oil.

CONNECTORS DRIVE PUMP

610C-17

DISCONNECT TWO CONNECTORS ON DRIVE PUMP PRIOR TO BLEEDING BRAKES

NOTE: If the machine was on wheels, the steer and drive functions were not properly purged or flushed. Remove the articulation lock bar and at LOW IDLE, slowly operate the steer function right and left a few times. With the parking brake released and at LOW IDLE, slowly operate the drive function forward and reverse a few times.

NOTE: If possible, allow the machine to stand for 4 to 6 hours before setting any of the operating pressures. This will allow any air bubbles in the oil to escape and is a good time to check for leaks.

8. Bleed brakes (rear 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, engage parking brake, hold foot brake down, bleed brakes in rear axle (both sides). Refer also to AXLES ~ SERVICE BRAKES ~ BRAKE BLEEDING in SECTION 8 of the SERVICE MANUAL. Reconnect two connectors on drive pump.

3.47

Tigercat AD610C Carrier

Lubrication and Maintenance

TORQUE CHART LOCATION

DIAMETER

Cylinders Piston nut, steer cylinder (38087B) Piston nut, dozer cylinder (3267D) Gland, steer cylinder (36597B) Keeper plate bolts Keeper plate bolts

1 3/8" UNF 1 1/4" UNF 3/4" UNC 5/8" UNC

1260 762 550 282 159

1708 1033 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 adapter plate Coolant pump to main pump

3/4" UNC M10 3/8" UNF 5/8" UNC M12

282 40 37 159 73

382 54 50 215 99

5/8" UNF 5/8" UNC

170 159

230 215

1/2" UNF

90

122

1/2" UNF

90

122

3/8" UNC

37

50

Axle mounting bolts Front Rear

3/4" UNC 7/8" UNC

226 364

306 493

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 Yoke retaining bolt, park brake Parking brake retaining bolts Rear drive shaft universal joint bolts Mid. drive shaft universal joint bolts Front drive shaft universal joint bolts

TORQUE (LUBRICATED) lbf-ft Nm

Torque values pertaining to the engine and attachment are provided in the appropriate manuals.

AD610CTORQUECHART.XLS 06/10

3.48

Tigercat AD610C Carrier

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

3.49

Tigercat AD610C Carrier

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

3.50

Tigercat AD610C Carrier

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

3.51

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 AD610C Carrier

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

3.52

Tigercat AD610C Carrier

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.

3.53

Tigercat AD610C Carrier

Lubrication and Maintenance

TIRE PRESSURES (AD610C ONLY) Tigercat Part # BP139 BP039

Manufacturer Goodyear Nokian

Size

Inflation Pressure psi 35 45

30.5L-32 20 PR LOGLUGIII LS2 TL 750/55-26.5 20PR TRS (N)

kPa 240 310

AD610C TIRE PRESSURES R0 02/14

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

3.54

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