Tigercat C640 CLAMBUNK SKIDDER OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL Tigercat C640 CLAMBUNK SKIDDER Issue 1.1, MARCH 2003

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

C640-OM00

C640 Available Literature Operator's Manual (This Manual) ........ Part No. 11333A Service Manual .................................... Part No. 11334A Parts Catalog ....................................... Part No. 11332A Hydraulic Adapters Book ....................... Part No. 1472A Hose Assemblies Book ......................... Part No. 3707A

Tigercat

®

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

Fax: (519) 442-1855

ii

Tigercat C640 Clambunk Skidder

Introduction

Tigercat C640 Clambunk Skidder

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the C640 Clambunk Skidder.

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

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

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

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

Tigercat Industries Inc.

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Tigercat C640 Clambunk Skidder

Introduction

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

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

Authorization by any other person is unacceptable.

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat C640 Clambunk Skidder

SECTION 1 - SAFETY MARCH 2003

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

Read and understand all manuals for any attachments or accessories.

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

Tigercat C640 CLAMBUNK SKIDDER

Safety

SAFETY SYMBOLS

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

Understanding Signal Words

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

WARNING WARNING denotes a hazard exists which can result in serious injury or death if proper precautions are not taken.

CAUTION CAUTION is used in areas where failure to follow listed procedures may cause personal injury, component damage or subsequent malfunction.

IMPORTANT IMPORTANT is used to focus attention on items that should be checked, controlled, adjusted or cleaned to ensure the efficiency and long term operation of the machine.

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Tigercat C640 Clambunk Skidder

Safety attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition. Repair or replace damaged labels.

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.

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

Prolonged exposure to loud noise can cause permanent hearing loss.

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

Follow all instructions from safety inspector and supervisors.

You must be fully trained to operate this piece of equipment. Know the capabilities and the limitations of the equipment. Learn the most efficient operating techniques.

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

Do not let an untrained person operate the machine.

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

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

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

These safety rules highlight both general and specific measures the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be

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

1.3

Tigercat C640 CLAMBUNK SKIDDER

Safety Maintain a distance of 10 ft. (3m) between any part of the machine or clam and any power line carrying up to 50,000 volts or less.

GENERAL SAFETY PRECAUTIONS continued

Powerlines carrying up to 50,000 volts require a safety distance of 10 ft. (3m) increase this distance by 1/2 inch (10mm) for each additional 1,000 volts above the 50,000 volt level. If State/ Provincial, local or job site regulations require even greater safety distances than stated above, adhere strictly to these regulations for your own protection.

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.

Machine should be washed completely at every major service.

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

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

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

Install articulation lock whenever the machine is to be transported.

Do not carry passengers either in the cab or anywhere else on the machine. The vehicle seating accommodation is for one operator only.

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

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

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.

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.

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

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

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

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.

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.

1.4

Tigercat C640 Clambunk Skidder

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

OPERATING SAFETY PRECAUTIONS

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

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

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

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

Make sure that all of the controls are positioned as specified in the starting instructions the operator's manual.

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

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

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

Sound the machine horn before starting the machine.

Never use the parking brake to slow down or stop the machine except in an emergency. Keep the brake properly adjusted at all times.

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

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

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

Start the engine by following the instructions in this manual.

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

Skidder operations should only be performed from the operator's seat. Secure loose items in cab.

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Tigercat C640 CLAMBUNK SKIDDER

Safety • Do not overload your skidder as this can create

OPERATING SAFETY PRECAUTIONS continued

an unstable condition and cause a roll-over.

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

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

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

When parking the machine:

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

• Park on level ground only and engage parking brake

Use only prearranged and approved signalling practices.

• Do not park on a hillside or incline.

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

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

• Stop the engine and relieve any hydraulic pressure stored in the system by pressing the brake pedal 30 to 40 times.

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.

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.

• Turn the battery disconnect switch off if the

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

vehicle is to be parked for an extended period of time (Example - overnight).

NEVER travel across a STEEP slope or side hill:

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

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

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.

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

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

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

• Do not approach from the downhill side of an unstable log.

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

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

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Tigercat C640 Clambunk Skidder

Safety

SERVICING SAFETY PRECAUTIONS

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.

Never use your bare hand to check for fluid leaks.

Conduct maintenance inspections at least as frequently as recommended in SECTION 3 of THIS MANUAL. When servicing or repairing equipment, shut the engine down, and disconnect the positive (+) battery cable from both batteries.

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.

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

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

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

Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location. Care must be taken in attaching the welding machine grounding clamp so current does not pass through bearings, especially the centre joint bearing. Also, turn off the master disconnect switch and disconnect the positive (+) battery cable from both batteries.

1.7

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower dozer blade to the ground and relieve trapped pressure (from accumulator) by operating brake pedal 30-40 times before performing work on components, or disconnecting any hoses.

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

Tigercat C640 CLAMBUNK SKIDDER

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

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

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

SAFETY CABLE

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

••

302-13

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE

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.

Keep your hands, feet, head, and loose clothing away from power driven parts. Tie long hair behind your head. Remove rings and other jewellery to prevent electrical shorts and entanglement in moving parts.

SUPPORT BRACE

302-16

• TILTED CAB SUPPORTED BY SUPPORT BRACE

CAUTION SAFETY7

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.

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

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

WARNING

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

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

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Tigercat C640 Clambunk Skidder

Safety

SERVICING SAFETY PRECAUTIONS continued

C640-P02

191-5ALT

ARTICLUATION LOCK IN POSITION

Before working in the centre joint area, install the frame articulation lock between the frames to prevent accidental articulation and injury.

REMOVE LOWER PANELS

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.

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

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

HAND KNOBS

••

UPPER DOORS

• LOWER PANELS

••

••

••

••

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

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

HAND KNOBS

••

Dispose of fluids properly.

•

•

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

QUICK ACCESS

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

302-15

ENGINE COMPARTMENT ACCESS PANELS 1.9

Tigercat C640 CLAMBUNK SKIDDER

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

FIRE PREVENTION

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

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

5.

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

6.

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

7.

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

8.

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

9.

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

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

1.

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

2.

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

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

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

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

3.

4.

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

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

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

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

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

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

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

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Tigercat C640 Clambunk Skidder

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued

•

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

•

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

•

Shut the engine off.

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

•

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

•

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

WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE

•

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

•

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

•

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

•

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

•

Use the PASS method with most extinguishers.

•

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

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

•

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

•

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

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

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

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

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

•

•

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

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

You should have a dry chemical extinguisher rated ABC and a pressurized water extinguisher rated A.

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

Prevent the fire from happening by ensuring that the machine is cleaned regularly and all systems are well maintained.

Continued on page 12

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

1.11

Tigercat C640 CLAMBUNK SKIDDER

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued Continued from page 11

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

•

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

1.12

•

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

•

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

•

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

•

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

Tigercat C640 Clambunk Skidder SECTION 2 - CONTROLS & OPERATION MARCH 2001

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

CONTENTS - SECTION 2 AIR CONDITIONER/HEATER ......................................................................... 2.34 AIR VENTS ..................................................................................................... 2.35 ARTICULATION LOCK .................................................................................... 2.58 BATTERY DISCONNECT SWITCH ................................................................ 2.37 BRAKE PEDAL .................................................................................................. 2.5 CARE OF THE MACHINE ............................................................................... 2.52 CENTER JOINT .............................................................................................. 2.49 CLAMBUNK CONTROLS CLAM CONSTANT PRESSURE, SWITCH .................................................... 2.7 CLAM OPEN/CLOSE, SWITCH ..................................................................... 2.7 JOYSTICK ..................................................................................................... 2.7 CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR .................... 2.54 CLEANING INSTRUCTIONS FOR LEXAN WINDOWS .................................. 2.52 DIFFERENTIAL LOCK, FRONT AXLE, SWITCH ............................................. 2.7 DIFFERENTIAL LOCK, REAR (BOGIE) AXLE, SWITCH ................................. 2.7 DOORS AND ACCESS PANELS .................................................................... 2.36 DOZER BLADE CONTROL LEVER .................................................................. 2.8 DRIVE PEDAL CONTROL ................................................................................ 2.5 ENGINE AIR CLEANER AIR CLEANER ............................................................................................. 2.38 AIR CLEANER UNLOADER VALVE ............................................................. 2.39 AIR PRECLEANER ...................................................................................... 2.38 FAN CONTROL (LATER DESIGN) .................................................................... 2.9 FAN CONTROL LEVER (EARLIER DESIGN) ................................................. 2.10 FILTER, FRESH AIR ....................................................................................... 2.35 FILTER, RECIRCULATING AIR, A/C UNIT ..................................................... 2.35 FUEL TANK ..................................................................................................... 2.37 HOT WATER SHUT OFF VALVE ..................................................................... 2.35 HYDRAULIC FILTERS .................................................................................... 2.40 HYDRAULIC HAND FILL PUMP ..................................................................... 2.41 HYDRAULIC OIL RESERVOIR ....................................................................... 2.40 INSTRUMENT PANEL (6401001 TO 6401010) ............................................... 2.14 BULB TEST - SWITCH ................................................................................ 2.15 CLAM PRESSURE, LIGHT .......................................................................... 2.15 DIFF. LOCK FRONT, LIGHT ......................................................................... 2.15 DIFF. LOCK REAR, LIGHT .......................................................................... 2.15 ENGINE AIR FILTER, LIGHT ....................................................................... 2.15 ENGINE COOLANT LEVEL, LIGHT ............................................................ 2.15 ENGINE COOLANT TEMP, GAUGE ............................................................ 2.17 ENGINE COOLANT TEMP, LIGHT/HORN ................................................... 2.14 ENGINE OIL PRESS, LIGHT/HORN ........................................................... 2.15

Tigercat C640 Clambunk Skidder SECTION 2 - CONTROLS & OPERATION INSTRUMENT PANEL (6401001 TO 6401010) CONTINUED ENGINE OIL PRESSURE, GAUGE ............................................................. 2.17 ETHER START AID, SWITCH ...................................................................... 2.16 FILTER BYPASS, LIGHT .............................................................................. 2.15 FUEL HEATER, SWITCH ............................................................................. 2.17 FUSE PANEL ............................................................................................... 2.17 HOURMETER .............................................................................................. 2.18 HYDRAULIC OIL LEVEL, LIGHT/HORN ...................................................... 2.14 HYDRAULIC OIL TEMPERATURE, GAUGE ................................................ 2.18 IGNITION, SWITCH ..................................................................................... 2.17 LIGHTER ..................................................................................................... 2.17 LIGHTS,WORKING ..................................................................................... 2.15 MAIN PUMP UNLOADING VALVE, LIGHT .................................................. 2.15 MAIN PUMP UNLOADING VALVE,SWITCH ................................................ 2.16 PARKING BRAKE, LIGHT ............................................................................ 2.15 TACHOMETER ............................................................................................ 2.18 VOLT METER .............................................................................................. 2.18 INSTRUMENT PANEL (6401011 TO 6401020) ............................................... 2.19 BULB TEST,SWITCH ................................................................................... 2.21 CLAM PRESSURE, LIGHT .......................................................................... 2.20 DIFFERENTIAL LOCK FRONT, LIGHT ....................................................... 2.20 DIFFERENTIAL LOCK REAR (BOGIE), LIGHT ........................................... 2.20 ENGINE AIR FILTER, LIGHT ....................................................................... 2.20 ENGINE COOLANT LEVEL, LIGHT ............................................................ 2.20 ENGINE COOLANT TEMP, GAUGE ............................................................ 2.23 ENGINE COOLANT TEMP, LIGHT/HORN ................................................... 2.19 ENGINE OIL PRESS, LIGHT/HORN ........................................................... 2.20 ENGINE OIL PRESSURE,GAUGE .............................................................. 2.22 ETHER STARTING AID, SWITCH ............................................................... 2.21 FILTER BYPASS, LIGHT ............................................................................. 2.20 FUEL HEATER, SWITCH ............................................................................. 2.22 FUSE PANEL ............................................................................................... 2.22 HOURMETER .............................................................................................. 2.23 HYDRAULIC OIL LOW, LIGHT/HORN ......................................................... 2.19 HYDRAULIC OIL TEMPERATURE, LIGHT/HORN ...................................... 2.20 HYDRAULIC OIL TEMPERATURE,GAUGE ................................................. 2.23 IGNITION,SWITCH ...................................................................................... 2.22 LIGHT ENGINE SERVICE,SWITCH ............................................................ 2.21 LIGHTER ..................................................................................................... 2.22 LIGHTS,WORKING ..................................................................................... 2.21 MAIN PUMP UNLOADING VALVE, LIGHT .................................................. 2.20 MAIN PUMP UNLOADING VALVE,SWITCH ................................................ 2.21 PARKING BRAKE, LIGHT ............................................................................ 2.20 TACHOMETER ............................................................................................ 2.23 VOLT METER, GAUGE/LIGHT .................................................................... 2.23 INSTRUMENT PANEL (6401021 TO 6401030) ............................................... 2.24 BULB TEST,SWITCH ................................................................................... 2.27 CLAM PRESSURE, LIGHT .......................................................................... 2.25 DIFFERENTIAL LOCK FRONT, LIGHT ...................................................... 2.25 DIFFERENTIAL LOCK REAR(BOGIE), LIGHT ............................................ 2.25 ENGINE AIR FILTER, LIGHT ....................................................................... 2.25 2.2

Tigercat C640 Clambunk Skidder SECTION 2 - CONTROLS & OPERATION ENGINE COOLANT LEVEL, LIGHT ............................................................ 2.25 ENGINE COOLANT TEMP, GAUGE ............................................................ 2.27 ENGINE COOLANT TEMP, LIGHT/HORN ................................................... 2.24 ENGINE OIL PRESS, LIGHT/HORN ........................................................... 2.25 ENGINE OIL PRESSURE,GAUGE .............................................................. 2.27 ETHER STARTING AID, SWITCH ............................................................... 2.26 FILTER BYPASS, LIGHT ............................................................................. 2.25 FUEL HEATER, SWITCH ............................................................................. 2.27 FUSE PANEL ............................................................................................... 2.28 HOURMETER .............................................................................................. 2.28 HYDRAULIC OIL LOW, LIGHT/HORN ......................................................... 2.24 HYDRAULIC OIL TEMPERATURE, LIGHT/HORN ..................................... 2.25 HYDRAULIC OIL TEMPERATURE,GAUGE ................................................. 2.28 IGNITION,SWITCH ...................................................................................... 2.27 LIGHT ENGINE SERVICE,SWITCH ............................................................ 2.26 LIGHTER ..................................................................................................... 2.28 LIGHTS,WORKING ..................................................................................... 2.26 MAIN PUMP UNLOADING VALVE, LIGHT .................................................. 2.25 MAIN PUMP UNLOADING VALVE,SWITCH ................................................ 2.27 PARKING BRAKE, LIGHT ............................................................................ 2.25 TACHOMETER ............................................................................................ 2.28 VOLT METER, GAUGE/LIGHT .................................................................... 2.28 INSTRUMENT PANEL (6401031 AND UP) ..................................................... 2.29 BULB TEST/ENGINE START, SWITCH ....................................................... 2.32 CLAM PRESSURE, LIGHT .......................................................................... 2.30 DIFFERENTIAL LOCK FRONT, LIGHT ...................................................... 2.30 DIFFERENTIAL LOCK REAR(BOGIE), LIGHT ............................................ 2.30 ENGINE AIR FILTER,LIGHT ........................................................................ 2.30 ENGINE COOLANT LEVEL, LIGHT ............................................................ 2.30 ENGINE COOLANT TEMP, GAUGE ............................................................ 2.32 ENGINE COOLANT TEMP, LIGHT/HORN ................................................... 2.29 ENGINE OIL PRESS, LIGHT/HORN ........................................................... 2.30 ENGINE OIL PRESSURE,GAUGE .............................................................. 2.32 ETHER STARTING AID, SWITCH ............................................................... 2.31 FILTER BYPASS, LIGHT ............................................................................. 2.30 FUEL HEATER, SWITCH ............................................................................. 2.32 FUSE PANEL ............................................................................................... 2.33 HOURMETER .............................................................................................. 2.33 HYDRAULIC OIL LOW, LIGHT/HORN ......................................................... 2.29 HYDRAULIC OIL TEMPERATURE, LIGHT/HORN ..................................... 2.30 HYDRAULIC OIL TEMPERATURE,GAUGE ................................................. 2.33 IGNITION,SWITCH ...................................................................................... 2.32 LIGHT ENGINE SERVICE,SWITCH ............................................................ 2.31 LIGHTER ..................................................................................................... 2.33 LIGHTS,WORKING ..................................................................................... 2.31 MAIN PUMP UNLOADING VALVE, LIGHT .................................................. 2.30 MAIN PUMP UNLOADING VALVE,SWITCH ................................................ 2.32 PARKING BRAKE, LIGHT ............................................................................ 2.30 TACHOMETER ............................................................................................ 2.33 VOLT METER, GAUGE/LIGHT .................................................................... 2.33 2.3

Tigercat C640 Clambunk Skidder

Controls and operation

SECTION 2 - CONTROLS & OPERATION JOYSTICK ......................................................................................................... 2.7 OPERATING MACHINE CENTER JOINT ........................................................................................... 2.49 OPERATING CLAM ..................................................................................... 2.48 PRE-START CHECKS ................................................................................. 2.42 RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL ....................... 2.46 STARTING ENGINE..................................................................................... 2.45 STARTING IN COLD WEATHER .................................................................. 2.46 STOPPING ENGINE .................................................................................... 2.49 SYSTEM TEST AND WARM-UP .................................................................. 2.47 TRAVELLING WITHOUT A LOAD ............................................................... 2.48 OPERATOR'S SEAT ........................................................................................ 2.12 PARKING BRAKE ............................................................................................. 2.6 PRE-START CHECKS ..................................................................................... 2.42 PRESSURIZED WATER SYSTEM .................................................................. 2.39 SKIDDING ....................................................................................................... 2.50 CLAM SKIDDING ......................................................................................... 2.51 SAFETY ....................................................................................................... 2.50 SKIDDING TECHNIQUE .............................................................................. 2.50 SPEED CONTROL LEVER ............................................................................... 2.8 STARTING ENGINE ........................................................................................ 2.45 STEERING WHEEL .......................................................................................... 2.5 STEREO, AM/FM CASSETTE ........................................................................ 2.11 STOPPING ENGINE ....................................................................................... 2.49 SYSTEM TEST AND WARM-UP ..................................................................... 2.47 TEST PORTS .................................................................................................. 2.37 TOWING INSTRUCTIONS .............................................................................. 2.56 TRANSMISSION DIPSTICK ........................................................................... 2.37 TRANSMISSION OIL FILL .............................................................................. 2.37 TRANSPORTING INSTRUCTIONS ................................................................ 2.57

2.4

Tigercat C640 Clambunk Skidder

Controls and operation IMPORTANT

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

CONTROLS-CAB

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

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139-4

1.

DRIVE PEDAL CONTROL

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Press the RIGHT foot pedal to drive FORWARD.

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

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

139-3

2

3.

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

•

139-7

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

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

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

2.5

Tigercat C640 Clambunk Skidder

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

21-2AA

• Resistance is encountered half way through the brake lever's free travel.

PARKING BRAKE ~ ENGAGED POSITION

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

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

21-3A

4.

PARKING BRAKE ~ DISENGAGED POSITION

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

PARKING BRAKE PULL up on handle to ENGAGE parking brake.

PUSH down on the handle to DISENGAGE parking brake.

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

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

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

The drive prevent circuit prevents the machine from being driven when the parking brake is ON. A proximity switch is attached to the brake lever housing. When the brake lever is in the ON position a pin on the lever CLOSES the proximity sensor contacts. When the lever is in the fully OFF position, the contacts are OPEN. Keep the brake properly adjusted at all times.

2.6

Tigercat C640 Clambunk Skidder 6.

Controls and operation

JOYSTICK

6

A. LEVER (FORWARD - BACK) Clam Right Tong Only Move the joystick BACK to OPEN the right tong independently of the left tong.

Move the joystick FORWARD to CLOSE the right tong independently of the left tong.

B. LEVER (LEFT - RIGHT) Clam Left Tong Only Move the joystick LEFT to OPEN the left tong independently of the right tong.

290-20X

Move the joystick RIGHT to CLOSE the left tong independently of the right tong.

JOYSTICK MOUNTED ON ARMREST

IMPORTANT

CONSTANT PRESSURE

Use differential locks sparingly for brief periods and ONLY when additional traction is required, or serious damage to the axles may occur.

Do not continuously drive the machine with the differential locks on.

FRONT REAR

F. TWO PUSH BUTTONS (TOP RIGHT) LEFT BUTTON Front Differential Lock Press button to activate front axle differential lock.

Push button a second time to deactivate.

The front differential lock locks up the front axle to provide torque to both front wheels when traction is poor.

14017BX.PDF

Note: Front axle differential locks can be engaged while the machine is in motion.

C. TWO PUSH BUTTONS (TOP LEFT) Not used for this application.

RIGHT BUTTON Rear Differential Lock (Bogie Axle) Bring the machine to a complete stop before activating the rear (bogie) axle differential locks. Press and hold button to activate rear (bogie) axle differential locks.

D. TWO PUSH BUTTONS (BOTTOM) Clam Open/Close Push RIGHT BUTTON to OPEN clam.

Push LEFT BUTTON to CLOSE clam.

E. TRIGGER SWITCH

Release button to deactivate.

Constant Pressure, Clam Push this switch IN and release it to maintain a constant pressure HOLD on the load and help prevent slipping.

Deactivated by pressing clam open thumbswitch on the joystick.

The rear differential lock locks up the rear (bogie) axle to provide torque to all four rear wheels when traction is poor.

CAUTION

Also refer to OPERATING CLAM in THIS SECTION.

Do not engage rear (bogie) axle differential locks while machine is in motion.

2.7

Tigercat C640 Clambunk Skidder

Controls and operation

SIDE INSTRUMENT PANEL •

8. SPEED CONTROL LEVER The speed control lever is used to control the maximum speed of the machine. Setting this lever allows the operator to maintain a given speed without having to feather the drive pedals.

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Push the lever forward to increase the maximum speed.

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

•

341-1X2

SIDE INSTRUMENT PANEL (EARLIER DESIGN)

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

7. DOZER BLADE CONTROL LEVER

9. THROTTLE CONTROL SWITCH

Pull the lever BACK to RAISE the dozer blade.

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

Push the lever FORWARD to LOWER the blade.

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

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.

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

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

Maintaining Correct Engine RPM It is most important that the engine speeds be correct at all times:

WARNING

Cummins 'C' Series Engine

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

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

C640 Low Idle 1100 to 1200 RPM (No Load) C640 High Idle 2400 to 2450 RPM (No Load) NOTE: The above values are with the hydraulic and engine oil at normal operating temperatures and no functions activated.

When setting low idle pressures the throttle control should be adjusted to 1100 RPM. The engine RPM should be checked regularly with a calibrated hand tachometer.

2.8

Tigercat C640 Clambunk Skidder

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

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C640-P06

•

SIDE INSTRUMENT PANEL (LATER DESIGN)

10. FAN CONTROL (LATER DESIGN - 6401031 & UP)

WARNING When the fan control switch is in the AUTOMATIC position (6401031 & UP only), the fan may begin to operate at any time when engine is running. Stay clear of fan at all times.

On later machines, the hydraulic fan is controlled by the fan control switch located on the side instrument panel.

This is a three position switch labeled FULL ON / AUTOMATIC / PURGE. FULL ON Position - This position by-passes the automatic fan controls. The fan will run at full speed continuously when the fan control switch is in this position. 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 automatic control system.

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

AUTOMATIC Position - This position activates the automatic fan control system.

AUTOMATIC is the normal operating position for the fan control switch. The automatic fan control system monitors engine coolant temperature, hydraulic oil temperature and A/C operation and adjusts fan speed to the minimum required level to maintain optimal operating conditions.

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

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

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

NOTE: In the event of an engine coolant temperature and/or hydraulic oil temperature alarm: 1. Stop the machine.

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

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

6. Return the fan control switch to AUTOMATIC and check for proper operation of the fan. In the event of a problem with the automatic control system the fan control switch should be placed in the FULL ON position while the machine is operating until the fan control can be properly repaired.

2.9

Tigercat C640 Clambunk Skidder

Controls and operation

11. FAN CONTROL LEVER (EARLIER DESIGN 6401001 TO 6401030) On earlier machines, the hydraulic fan control lever is located adjacent to the left arm rest in the cab and is used to control fan speed and direction. Fan speed is infinitely adjustable.

When the lever is in the center (neutral) position the fan is stopped. As the lever is moved outward in either direction (forward or reverse) fan speed increases. Push the lever forward to operate the fan in the "forward", cooling, direction. Pull the lever back to operate the purge function of the fan in the "reverse", cleaning, direction.

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

303-6

FAN CONTROL LEVER (EARLIER DESIGN)

NOTE: In the event of an engine coolant temperature and/or hydraulic oil temperature alarm: 1. Stop the machine.

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

Fan direction control is used operate the purge function which cleans the radiator, oil cooler, A/C condenser and air intake door screens . By “reversing” the flow of the fan with the control lever, air flow is propelled in the opposite direction, thereby forcing dust and debris off of the radiator, oil cooler, A/C condenser and air intake door screens. This operation can be done while operating the machine. Ensure that there are no personnel standing directly to the right of the machine when performing this operation, as dust and debris will fly out. Care should be taken not to leave the fan in the reverse position for long periods of time as this will decrease the cooling ability of the radiator, oil cooler and A/C condenser.

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

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

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

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

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

2.10

Tigercat C640 Clambunk Skidder

Controls and operation

290-22

13. AM/FM STEREO CASSETTE With two front mounted speakers. Refer to component manufacturer's manual.

2.11

Tigercat C640 Clambunk Skidder

Controls and operation

14. OPERATOR'S SEAT (SEATS INC.)

SEAT ADJUSTMENTS

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

4-WAY LUMBAR VERTICAL ADJUSTMENT

••

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

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

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

BACK ANGLE ADJUSTMENT KNOB

•

•

To Raise Firmly lift up on the height adjustment lever.

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

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

•• • RIDE ADJUSTMENT KNOB

To Lower Firmly lift up on the height adjustment lever.

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

332-1

••

HEIGHT ADJUSTMENT LEVER FORE/AFT SLIDE LEVER

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

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

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

RIDES TOO SOFT OR BOTTOMS OUT AND PINCHES OPERATOR The seat ride adjustment knob has not been tightened (turned counter-clockwise) enough.

Insufficient ride adjustment exaggerates the kneeaction movement of the seat. This usually happens because the operator is trying to lower the seat by decreasing the amount of ride adjustment instead of using the Height Adjustment lever. Refer to HEIGHT ADJUSTMENT.

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

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

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

2.12

Tigercat C640 Clambunk Skidder

Controls and operation

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

•• •• •• ARMREST ADJUSTMENT 332-6

VIEW FROM RIGHT REAR OF SEAT

SEAT TOO HIGH/SEAT TOO LOW There are several things which can cause improper seat height. Refer to the HEIGHT ADJUSTMENT and adjust seat to the desired position. If the proper height cannot be reached using one of the four height adjustment settings, it may be necessary to install the seat on a higher base.

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

2.13

Tigercat C640 Clambunk Skidder 21

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2441DILX

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INSTRUMENT PANEL (6401001 TO 6401010)

INSTRUMENT PANEL (6401001 TO 6401010) 21. HYDRAULIC OIL LOW RED LIGHT AND HORN This light will come ON and a horn will SOUND when the hydraulic oil level falls approx. 10 gal.

US (38L) below the FULL mark.

SIGHT GAUGE

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

LOW LEVEL SENDER

••

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

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

2.14

••

257-4

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

Tigercat C640 Clambunk Skidder

Controls and operation

23. ENGINE OIL PRESS - RED LIGHT AND HORN

28. ENGINE AIR FILTER - YELLOW LIGHT

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

Stop the engine when this alarm is activated.

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

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

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

24. MAIN PUMP UNLOADING VALVE - RED LIGHT

29. CLAM PRESSURE - GREEN LIGHT

This light will come ON when the main pump unloading valve switch is turned ON.

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

Deactivated the clam open thumbswitch on the joystick.

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

30. NOT USED FOR THIS APPLICATION

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

31. DIFFERENTIAL LOCK FRONT - GREEN LIGHT

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

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

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

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

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

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

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

27. LOW COOLANT - YELLOW LIGHT

35. AUX (OPTIONAL)

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

Applicable to optional light packages.

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

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

WARNING 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.

2.15

Tigercat C640 Clambunk Skidder 21

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Controls and operation

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2441DILX

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INSTRUMENT PANEL (6401001 TO 6401010) 38. MAIN PUMP UNLOADING VALVE - SWITCH The parking brake must be engaged in order to activate the main pump unloading valve with this switch. The main pump unloading valve reduces the pump pressure from 3000 psi to 250 psi. This removes some of the load from the engine in order to improve cold weather starting ability. The machine can be operated with this switch in the on position and the parking brake disengaged.

CANISTER

•

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

284-5A

ETHER STARTING AID CANISTER

TO INSTALL A NEW CAN OF STARTING FLUID

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

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

Remove the protective cap from the new canister of starting fluid and screw the can (hand-tight) onto the solenoid assembly. Retighten the band clamp to hold the can in place.

IMPORTANT: To prevent dust from being

2.16

Tigercat C640 Clambunk Skidder

Controls and operation

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

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

DANGER

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

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

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

43. LIGHTER Cigarette lighter is supplied.

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

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

If the pressure drops below 15 psi, shut the machine down immediately.

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

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

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

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

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

WARNING Ether starting fluid is highly flammable.

Do not use near fire, sparks or flames.

Read the warning label on the container.

40. FUEL HEATER SWITCH (OPTIONAL) This switch manually turns on the fuel heater element in the fuel filter/water separator. An automatic thermostat turns the fuel heater on when the fuel temperature drops below 45°F and off when the fuel temperature reaches 75°F. 41. FUSE PANEL The fuses and relays are protected beneath a panel which can be opened by removing two screws.

2.17

Tigercat C640 Clambunk Skidder 21

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INSTRUMENT PANEL (6401001 TO 6401010) 46. HYDRAULIC OIL TEMPERATURE - GAUGE

48. HOURMETER

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

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

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

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

The LOW IDLE reading should be 900 to 1000 rpm and the HIGH IDLE (full throttle) reading should be 2450 to 2460 rpm. These readings are with no hydraulic load on the engine. See also TACHOMETER SET-UP INSTRUCTIONS in SECTION 7 of the SERVICE MANUAL.

• Plugged oil cooler • Malfunction in a hydraulic system • High loads on the hydraulic system • Low hydraulic oil level Operation above 180°F will shorten hydraulic component life.

If the temperature reaches 185°F DO NOT continue to operate the machine.

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

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

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

2.18

Tigercat C640 Clambunk Skidder 21

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INSTRUMENT PANEL (6401011 TO 6401020)

INSTRUMENT PANEL (6401011 TO 6401020) 21. HYDRAULIC OIL LOW RED LIGHT AND HORN This light will come ON and a horn will SOUND when the hydraulic oil level falls approx. 10 gal. US (38L) below the FULL mark.

SIGHT GAUGE

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

LOW LEVEL SENDER

••

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

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

••

257-4

2.19

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

Tigercat C640 Clambunk Skidder

Controls and operation

23. ENGINE OIL PRESS - RED LIGHT AND HORN

WARNING

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

Stop the engine when this alarm is activated.

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

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

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

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

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

28. ENGINE AIR FILTER - RED LIGHT

25. PARKING BRAKE - RED LIGHT

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

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

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

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

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

29. FILTER BYPASS - YELLOW LIGHT

26. HYDRAULIC OIL TEMPERATURE - RED LIGHT AND HORN

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

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

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

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

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

30. CLAM PRESSURE - GREEN LIGHT

Operation above 180°F will shorten hydraulic component life.

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

Deactivated the clam open thumbswitch on the joystick.

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

31. DIFFERENTIAL LOCK FRONT - GREEN LIGHT

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

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

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

2.20

Tigercat C640 Clambunk Skidder 21

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INSTRUMENT PANEL (6401011 TO 6401020) 33. LIGHTS - SWITCH

39. MAIN PUMP UNLOADING VALVE - SWITCH

This switch turns on working lights.

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

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

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

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

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

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

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

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

TO INSTALL A NEW CAN OF STARTING FLUID Clean the area around the valve before removing the canister. Loosen the band clamp

2.21

Tigercat C640 Clambunk Skidder

Controls and operation DANGER

CANISTER

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

•

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

ETHER STARTING AID CANISTER that holds the empty canister, unscrew the can from the solenoid assembly and discard properly. Check the valve gasket under the cylinder and replace if damaged or missing.

Remove the protective cap from the new canister of starting fluid and screw the can (hand-tight) onto the solenoid assembly. Retighten the band clamp to hold the can in place.

284-5A

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

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

DANGER

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

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

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

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

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

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

44. LIGHTER Cigarette lighter is supplied.

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

If the pressure drops below 15 psi, shut the machine down immediately.

WARNING Ether starting fluid is highly flammable.

Do not use near fire, sparks or flames.

Read the warning label on the container.

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

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

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

2.22

Tigercat C640 Clambunk Skidder 21

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Controls and operation

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INSTRUMENT PANEL (6401011 TO 6401020) 46. COOLANT TEMPERATURE - GAUGE

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

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

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

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

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

47. HYDRAULIC OIL TEMPERATURE - GAUGE

49. HOURMETER

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

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

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

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

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

• Plugged oil cooler • Malfunction in a hydraulic system • High loads on the hydraulic system • Low hydraulic oil level Operation above 180°F will shorten hydraulic component life.

2.23

Tigercat C640 Clambunk Skidder 21 33

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2541DILX1

INSTRUMENT PANEL (6401021 TO 6401030)

INSTRUMENT PANEL (6401021 TO 6401030) 21. HYDRAULIC OIL LOW RED LIGHT AND HORN This light will come ON and a horn will SOUND when the hydraulic oil level falls approx. 10 gal. US (38L) below the FULL mark.

SIGHT GAUGE

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

LOW LEVEL SENDER

••

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

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

••

257-4

2.24

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

Tigercat C640 Clambunk Skidder

Controls and operation

23. ENGINE OIL PRESS - RED LIGHT AND HORN

WARNING

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

Stop the engine when this alarm is activated.

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

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

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

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

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

28. ENGINE AIR FILTER - RED LIGHT

25. PARKING BRAKE - RED LIGHT

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

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

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

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

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

29. FILTER BYPASS - YELLOW LIGHT

26. HYDRAULIC OIL TEMPERATURE - RED LIGHT AND HORN

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

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

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

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

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

30. CLAM PRESSURE - GREEN LIGHT

Operation above 180°F will shorten hydraulic component life.

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

Deactivated the clam open thumbswitch on the joystick.

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

31. DIFFERENTIAL LOCK FRONT - GREEN LIGHT

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

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

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

2.25

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2541DILX1

INSTRUMENT PANEL (6401021 TO 6401030) 33. LIGHTS - SWITCH This switch turns on working lights.

CANISTER

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

•

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

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

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

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

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

Remove the protective cap from the new canister of starting fluid and screw the can (hand-tight) onto the solenoid assembly. Retighten the band clamp to hold the can in place.

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

2.26

Tigercat C640 Clambunk Skidder

Controls and operation

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

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

DANGER

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

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

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

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

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

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

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

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

WARNING

43. COOLANT TEMPERATURE - GAUGE

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

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

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

37. FUEL HEATER SWITCH (OPTIONAL)

44. ENGINE OIL PRESSURE - GAUGE

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

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

If the pressure drops below 15 psi, shut the machine down immediately.

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

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

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

2.27

Tigercat C640 Clambunk Skidder 21 33

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2541DILX1

INSTRUMENT PANEL (6401021 TO 6401030) 45. HYDRAULIC OIL TEMPERATURE - GAUGE

47. VOLT METER - GAUGE/LIGHT

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

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

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

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

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

• Plugged oil cooler • Malfunction in a hydraulic system

48. HOURMETER

• High loads on the hydraulic system

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

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

49. LIGHTER Cigarette lighter is supplied.

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

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

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

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

2.28

Tigercat C640 Clambunk Skidder 21 33

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2541DILX2

INSTRUMENT PANEL (6401031 AND UP)

INSTRUMENT PANEL (6401031 AND UP) 21. HYDRAULIC OIL LOW RED LIGHT AND HORN This light will come ON and a horn will SOUND when the hydraulic oil level falls approx. 10 gal. US (38L) below the FULL mark.

SIGHT GAUGE

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

LOW LEVEL SENDER

••

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

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

••

257-4

2.29

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

Tigercat C640 Clambunk Skidder

Controls and operation

23. ENGINE OIL PRESS - RED LIGHT AND HORN

WARNING

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

Note that later machines (6401031 & UP) are equipped with an automatic engine shutdown feature which is activated when engine pressure falls below 10 psi. Check engine oil levels. See OPERATING MACHINE in this SECTION for more information.

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

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

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

24. MAIN PUMP UNLOADING VALVE - RED LIGHT

28. ENGINE AIR FILTER - RED LIGHT

This light will come ON when the main pump unloading valve switch is turned ON.

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

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

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

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

29. FILTER BYPASS - YELLOW LIGHT

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

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

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

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

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

30. CLAM PRESSURE - GREEN LIGHT

• High loads on the hydraulic system

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

Deactivated the clam open thumbswitch on the joystick.

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

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

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

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

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

2.30

Tigercat C640 Clambunk Skidder 21 33

34

22

23

35

25

24 37

36

Controls and operation

38

• • • •

45

• •

44

26

28

39

40

• • • •

• •

• •

27

•

29 41

30

31

32

42

46

• • • • • •

•

43 48

•

•

•

47

•

•

•

50

•

49

•

2541DILX2

INSTRUMENT PANEL(6401031 AND UP) 33. LIGHTS - SWITCH

CANISTER

This switch turns on working lights.

34. LIGHTS - SWITCH

•

This switch turns on working lights.

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

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

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

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

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

Remove the protective cap from the new canister of starting fluid and screw the can (hand-tight) onto the solenoid assembly. Retighten the band clamp to hold the can in place.

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

2.31

Tigercat C640 Clambunk Skidder

Controls and operation

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

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

DANGER

START position - This position energizes the starter motor. The BULB TEST/ENGINE START switch must be pressed while starting in order to override the automatic engine shut-down system and crank over the engine.

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

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

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

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

40. BULB TEST / ENGINE START - SWITCH This momentary switch is used to perform two functions: First, it tests warning light bulbs on the instrument panel. Replace burnt out light bulbs immediately to ensure that all warning lights are in working order at all times.

Second, it is used at engine start to override automatic engine shut-down system on this machine. This switch must be pressed while starting the engine to allow the engine to crank over when the ignition switch is placed in the START position. Note that if this switch is released before the engine oil pressure rises above 10 psi the engine will automatically shut down.

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

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

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

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

37. FUEL HEATER SWITCH (OPTIONAL)

43. COOLANT TEMPERATURE - GAUGE

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

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

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

44. ENGINE OIL PRESSURE - GAUGE The oil pressure should be greatest after starting a cold engine. It should operate between 35 and 70 psi when the engine is running at rated speed, with SAE 10W30 oil and at operating temperature. If the gauge 2.32

Tigercat C640 Clambunk Skidder 21 33

34

22

23

35

25

24 37

36

Controls and operation

38

• • • •

45

• •

44

26 39

•

28 40

• • • •

• •

• •

27

•

29 41

30

31

32

42

• • • •

46

• •

43 48

•

•

•

47

•

•

•

50

•

49

•

2541DILX2

INSTRUMENT PANEL(6401031 AND UP) registers less than the above with engine running at high idle, check the engine oil level.

If the pressure drops below 15 psi, shut the machine down immediately.

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

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

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

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

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

45. HYDRAULIC OIL TEMPERATURE - GAUGE

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

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

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

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

49. LIGHTER

• Malfunction in a hydraulic system

Cigarette lighter is supplied.

• High loads on the hydraulic system

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

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

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

If the temperature reaches 185°F DO NOT continue to operate the machine. Refer to FAN CONTROL in THIS SECTION. 2.33

Tigercat C640 Clambunk Skidder

Controls and operation

AIR CONDITIONER/HEATER

A/C HEATER CONTROL PANEL (6401011 AND UP)

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

7

A/C HEATER CONTROL PANEL (6401001 TO 6401010) 2

5

1

4

• 6

3

• •

• 350-4A

272-24AC

1.

A/C-HEATER CONTROL PANEL (6401001 TO 6401010)

6.

A/C ON/OFF SWITCH - LIGHT

FAN SPEED - OFF/LOW/MED/HIGH This is a rotary, four position switch for the fan speed.

3.

AIR SOURCE - 2 POSITION This is a rotary, two position switch to used to add fresh air to the cab.

4.

HEAT - VARIABLE

A/C AND FAN CONTROL

7. TEMPERATURE CONTROL

This is a variable, rotary dial to adjust the amount of heated air for the cab. Make sure this control is off, when using the air conditioning.

5.

A/C-HEATER CONTROL PANEL (6401011 AND UP)

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

This is push/on push/off power switch with an indicator light.

2.

•

•

•

•

8

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

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

AIR CONDITIONING - VARIABLE This is a variable, rotary dial to adjust the amount of cooled air for the cab.

NOTE: To maximize the efficiency of the air conditioning, the heat control dial on the control panel must be rotated to the "OFF" position. Also refer to HOT WATER SHUT OFF VALVE in THIS SECTION.

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

8.

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

2.34

Tigercat C640 Clambunk Skidder

9

•

Controls and operation •

• ENGINE

•

HOSE TO A/C HEATER UNIT

SHUT-OFF VALVE

274-5 193-8

HOT WATER SHUT OFF VALVE

6. HOT WATER SHUT OFF VALVE (ENGINE)

R.H. DOOR POST VENTS - 2

•

•

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

9

•

12 151-11

REAR DASH VENTS - 2

• 10

•

•

9 303-20 FRESH AIR FILTER 7. FILTER - FRESH AIR 151-9

4.

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

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

VENTS BEHIND SEAT - 2

AIR VENTS 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.

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

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

2.35

Tigercat C640 Clambunk Skidder

Controls and operation

CHASSIS DOOR

••

••

191-5ALT

DOOR PIN

REMOVE LOWER PANELS

NUT AND BOLT

HAND KNOBS

•• ••

UPPER DOORS

LOWER PANELS

•

••

••

••

•

HAND KNOBS

•• ••

• QUICK ACCESS

272-21

FRONT DOOR

302-15

DOORS AND ACCESS PANELS

ENGINE COMPARTMENT ACCESS PANELS

FRONT DOOR

CAUTION

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

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

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

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

Do not operate DOZER with door open.

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

CAUTION Park on level ground to prevent unexpected door closing.

2.36

Tigercat C640 Clambunk Skidder

Controls and operation

FUEL TANK

TEST PORT COMPARTMENT 1

••

DIPSTICK

•

4

3

2

• •

• FILLER SCREEN

••

275-3

TEST PORT COMPARTMENT BELOW LEFT CAB DOOR

1. BATTERY DISCONNECT SWITCH

••

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

FUEL SIGHT GAUGE

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.

C640-P01

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

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

3. TRANSMISSION OIL FILL LOCATION

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

4. TEST PORTS

The transmission oil fill is located in the test port compartment below the left hand cab door.

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

A fuel sight gauge is provided to indicate fuel level in the tank. The fuel tank has a capacity of 83 (US) gallons total.

2.37

Tigercat C640 Clambunk Skidder

Controls and operation

ENGINE AIR CLEANER ENGINE AIR PRECLEANER

AIR CLEANER

•

••

SENDING UNIT FOR WARNING LIGHT IN CAB

FILTER RESTRICTION INDICATOR

ENGINE AIR CLEANER

••

•• ••

291-3

ENGINE AIR CLEANER

AIR PRECLEANER 303-8

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

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

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

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

EXHAUST PORT AREA

284-25A

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

REAR VIEW OF PRECLEANER

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

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

• • • •

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

ENGINE AIR CLEANER

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

TURBO II PRECLEANER OPERATION

2.38

Tigercat C640 Clambunk Skidder

Controls and operation PRESSURIZED WATER SYSTEM DOZER BLADE

UNLOADER VALVE

•

WATER TANK

•

••

•

•

WATER CONTROL VALVE 303-7

AIR CLEANER UNLOADER VALVE HOSE STORAGE COMPARTMENT

AIR CLEANER UNLOADER VALVE 150-3AA

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

PRESSURIZED WATER SYSTEM

An 11 gal. water tank is incorporated into the dozer blade and is pressurized to 60 psi. A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade.

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.

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

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

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

Refer to SCHEDULED MAINTENANCE and AIR CLEANER MAINTENANCE in SECTION 3 of THIS MANUAL.

2.39

Tigercat C640 Clambunk Skidder

Controls and operation

HYDRAULIC OIL RESERVOIR

HYDRAULIC FILTERS

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

The cooling circuit contains a double element, full flow, 7 micron filter with a built in restriction indicator and a 25 psi bypass valve.

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

The drive pump charge circuit contains a single element, full flow, 10 micron filter with a restriction indicator sending unit and a third port bypass valve. The restriction indicator sending unit is connected to the filter bypass warning light on the instrument panel.

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

The fan drive circuit contains a single element, full flow, 10 micron filter with a restriction indicator sending unit and a third port bypass valve. The restriction indicator sending unit for this filter is not connected to a warning light.

For additional information on these filters, refer to FILTER BYPASS LIGHT in THIS SECTION. Also refer to FILTERS and SERVICE AND LUBRICATION POINTS CHART in SECTION 3.

SIGHT GAUGE

LOW LEVEL SENDER

••

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

••

257-4

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

LEFT SIDE BELOW COOLING FAN

333-3

2.40

COOLING FAN PRESSURE FILTER ELEMENT

Tigercat C640 Clambunk Skidder

Controls and operation HYDRAULIC HAND FILL PUMP

DOUBLE ELEMENT FILTER

•

•

•

DRIVE PUMP CHARGE PRESSURE FILTER

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

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

••

HYDRAULIC RESERVOIR

IMPORTANT: Close shut-off valve after filling.

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

302-17

HYDRAULIC RESERVOIR

FILTER HAND FILL PUMP

•

SHUT-OFF VALVE IN OFF POSITION

•

•

TO OIL SUPPLY DRUM

•

••

312-18A

HYDRAULIC HAND FILL PUMP (RIGHT SIDE BELOW CAB)

2.41

Tigercat C640 Clambunk Skidder

Controls and operation

OPERATING MACHINE Before operating this machine, ensure that the proper lubrication and maintenance schedule has been performed as outlined in SECTION 3 of THIS MANUAL.

••

For the Diesel Engine supplied with this machine, refer to the engine manufacturer's operating manual.

PRIMER PUMP

FUEL WATER SEPARATOR

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 WATER SEPARATOR BOWL

• DRAIN TAP

•

270-9A

FUEL WATER SEPARATOR

3. Drain water from fuel line water separator.

635-P01

IGNITION IN THE OFF POSITION

1. Ensure ignition switch is in the OFF position and set parking brake ON.

••

SIGHT GAUGE

DIPSTICK

LOW LEVEL SENDER

FILLER SCREEN

••

• • C640-P01

••

• FUEL SIGHT GAUGE

FUEL TANK

257-4

2. Check fuel sight gauge. Refer to FUEL TANK in THIS SECTION for standard tank capacity information.

HYDRAULIC OIL SIGHT GAUGE/ LOW LEVEL SENDER

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

2.42

Tigercat C640 Clambunk Skidder

Controls and operation DIPSTICK

DIPSTICK

•• 270-15A

• TEST PORT COMPARTMENT LEFT SIDE OF CAB

ENGINE OIL LEVEL

275-3 TRANSMISSION OIL LEVEL 7. Check transmission oil level (dipstick).

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

WARNING 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.

DIPSTICK

••

RIGHT SIDE OF ENGINE

FILLER CAP

•• PUMP DRIVE GEARBOX

302-24

••

PUMP DRIVE GEARBOX OIL LEVEL

JUST INSIDE LEFT HAND FRONT UPPER SIDE PANEL DOOR

ENGINE COOLANT LEVEL

302-23

8. Check the engine coolant level.

FILLER/BREATHER DOZER BLADE

•

•

WATER TANK

• •

•

PRESSURE GAUGE

DIG-002

PUMP DRIVE GEARBOX FILLER/BREATHER

HOSE STORAGE COMPARTMENT

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

150-3AA

PRESSURIZED WATER SYSTEM

9. 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.

2.43

Tigercat C640 Clambunk Skidder

Controls and operation

••

••

302-19

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

FAN BELT

A/C COMPRESSOR BELT 635-01

CHECK ENGINE BELT(S)

10. Check tension and condition of all engine belts.

290-11

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

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

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

ENGINE AIR PRECLEANER

AIR CLEANER

•

••

WARNING 291-3

ENGINE AIR CLEANER

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

11. Check air intake precleaner.

13. Perform SCHEDULED MAINTENANCE as shown in SECTION 3 of THIS MANUAL. 14. Inspect machine for leaks , damaged or loose components and any other abnormal conditions.

15. Check tire pressures.

16. Check wheel bolts for tightness.

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

18. Check parking brake for proper operation.

2.44

Tigercat C640 Clambunk Skidder

Controls and operation

STARTING ENGINE

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

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

CAUTION

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

• After engine has started, keep engine speed low until engine oil pressure registers on gauge. If it does not register within 10 seconds, stop engine and investigate cause. Note that later machines (6401031 & UP only ) are equipped with an automatic engine shutdown system which stops the engine immediately if engine oil pressure is below 10 psi.

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

4. Earlier Machines (6401001 to 6401030) Turn ignition switch to the START position to crank engine.

CAUTION

Later Machines (6401031 & UP) Press and hold the bulb test/engine start switch while turning the ignition switch to the START position to crank engine.

5.

• 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.

Earlier Machines (6401001 to 6401030) When engine starts, release ignition key to RUN position.

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.

Later Machines (6401031 & UP) When engine starts, release ignition key to RUN position. When engine oil pressure rises above 10 psi, release the bulb test/engine start switch.

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

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

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

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

2.45

Tigercat C640 Clambunk Skidder

Controls and operation

RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL

STARTING IN COLD WEATHER (WHEN APPLICABLE WITH OPTIONAL STARTING AID KIT)

If the engine runs out of fuel, the fuel line must be primed:

Cold temperatures require the use of the engine block heater and the engine oil pan heater. The use of an optional fuel heater and/ or ether starting aid may also be required.

1. Refill fuel tank completely.

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

3. Bleed the system according to engine manual procedures.

CAUTION Cold startups can result in pump failure, refer to "HYDRAULIC OIL CHART" for recommended oil viscosities and temperature ranges.

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

If a (ether) starting aid is being used; (a) Move throttle control to the FULL position.

NOTE: Later Machines (6401031 & UP) only.

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

Refer to START ENGINE in THIS SECTION.

(b) Crank engine with starter one or two revolutions before injecting starter fluid.

NOTE: Later Machines (6401031 & UP) only.

It is necessary to press and hold the bulb test/engine start switch while turning the ignition switch to the START position to crank engine. Refer to STARTING ENGINE in THIS SECTION.

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

CAUTION 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.

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

Wait 2 minutes between each attempt to start the engine.

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

If engine fails to start, refer to engine manufacturers operator's manual. (c) Momentarily depress ETHER push button switch, using short "bursts" while cranking the engine at the same time. Stop injecting fluid after engine starts. If engine begins to die during the first few minutes, inject another "shot" of fluid. (d) Once the engine is running evenly and the engine oil pressure is at NORMAL, move the throttle control to the IDLE position and allow to run for approx. 5 minutes or until the engine coolant temperature gauge begins to register. If the engine oil pressure does not register on the gauge within 10 seconds stop the engine. (e) Before applying any load to the engine proceed with SYSTEM TEST AND WARM-UP. 2.46

Tigercat C640 Clambunk Skidder

Controls and operation

SYSTEM TEST AND WARM-UP CAUTION

Before commencing skidding operations, follow steps (a) thru (n) 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.

CAUTION

Fluid leaks under pressure may not be visible.

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

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

Ensure that the machine was parked on level ground at last shutdown:

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

(a) Start engine. (b) Ensure gauges and warning lights are indicating normal operating conditions. (c) Check that all personnel are clear of the machine. (d) Increase throttle control to the approximately the MID position. (e) Operate the clam tongs and check for proper operation. (f) Raise and lower dozer blade (g) Steer the machine to the left and right. (h) When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps (e) "thru" (g) several times. As the hydraulic system warms up, engine speed can be increased gradually to the FULL position. (i) 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. (j) Put the parking brake ON. (k) Move the throttle control to the IDLE position.

2.47

Tigercat C640 Clambunk Skidder

Controls and operation

TRAVELLING WITHOUT A LOAD:

OPERATING CLAM:

Close clam and place the dozer blade in the UP position.

DAILY INSPECTION/SERVICE • • • • •

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

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

Lubricate all grease fittings Check all hydraulic fittings Check hoses for wear. Replace as required.

Check for excessive wear at pin points.

Inspect for trash accumulation and clean out.

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

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

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

C640-P05

TYPICAL TIGERCAT CLAMBUNK

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

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

The controls will return to neutral automatically when released.

Refer to JOYSTICK in THIS SECTION for specific information on clam operating controls.

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

Refer to SKIDDING ~ CLAM SKIDDING in THIS SECTION for specific operating instructions.

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

CAUTION

Never attach chains or cables to the clam tongs for any reason. Do not tow this machine or any other object by attaching to the clam tongs. Serious damage to the clam will result.

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

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

In addition for rear (bogie) axle differential locks only, it is necessary to bring the machine to a complete stop before engaging the rear (bogie) axle differential locks.

2.48

Tigercat C640 Clambunk Skidder

Controls and operation

CENTER JOINT:

STOPPING ENGINE:

It is very important that the machine not be operated if there is any looseness in the center joint bearings.

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.

Refer to CENTER JOINT MAINTENANCE 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.

1. Park machine on level ground lower the dozer blade to the ground.

2. Reduce engine speed to LOW IDLE and let run for approximately three minutes to allow gradual dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

3. Do not race engine before shut-off.

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

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

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

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

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

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

2.49

Tigercat C640 Clambunk Skidder

Controls and operation

SKIDDING

SKIDDING TECHNIQUE:

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

WARNING

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

•

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

•

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

•

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

•

Never travel across a STEEP slope or side hill.

•

Never make an uphill turn on a slope

•

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

•

Never approach an unstable log from the downhill side.

•

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

•

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

•

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

•

Wear heavy gloves when handing cables.

•

Ensure that the PARKING BRAKE is engaged.

•

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

•

Keep load low and close to skidder for best stability.

•

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

•

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

•

•

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

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

•

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

•

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

•

Be aware of what is happening around you.

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

•

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

•

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

CAUTION

Never attach chains or cables to the clam tongs for any reason. Do not tow this machine or any other object by attaching to the clam tongs. Serious damage to the clam will result.

2.50

Tigercat C640 Clambunk Skidder

Controls and operation

CLAM SKIDDING:

Avoid overloading, never load the clambunk to a point where the tongs cannot be closed enough to meet at the top of the load.

Overloading the clambunk can cause serious damage to the clam and other machine components.

1. Timber is loaded onto the clambunk skidder using a shovel logger or track mounted loader.

2. Logs should always be placed so that the butt end is behind the headache rack.

C640-05

CORRECT LOADING

C640-04

Avoid overloading, never place logs with the butt end extending past the headache rack.

INCORRECT LOADING

4. Use the clam OPEN/CLOSE thumbswitches and the joystick control lever to adjust the load as needed. Refer to JOYSTICK in THIS SECTION for more information about these controls and their operation.

5. When the machine is fully loaded activate the clam constant pressure switch to maintain a constant pressure hold on the load while the machine is in motion.

C640-06

INCORRECT LOADING

6. It may be necessary to adjust the load during travel. Note that the joystick control lever functions which independently operate the clam tongs are not available while the clam constant pressure switch is activated. To deactivate the clam constant pressure switch press and release the clam OPEN thumbswitch. After adjusting the load activate the clam constant pressure switch again.

Overloading the clambunk can cause serious damage to the clam and other machine components.

3. When fully loaded the clam tongs should appear to meet or overlap one another.

WARNING Backup carefully. If a log strikes an object, it could be pushed forward through the clam and into the operator's cab.

When running empty, always keep clam tongs closed to prevent damage to the machine.

C640-02

7. To unload the clambunk: Open the clam tongs and drive forward using the clam tongs to direct the load.

C640-03

OR

CORRECT LOADING

Unload using a loader.

2.51

Tigercat C640 Clambunk Skidder

Controls and operation

CARE OF THE MACHINE

CLEANING INSTRUCTIONS FOR LEXAN WINDOWS

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

1. Rinse with lukewarm water.

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

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

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

3. Rinse with clean lukewarm water.

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

4. Do not apply load to a cold engine.

5. Close and secure all doors and access covers.

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.

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

Clean frequently but at least once daily.

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

WINDOW SCREEN HANDKNOB

7. Always lower the dozer blade to the ground when parking and before servicing the machine.

•• 173-25

SIDE WINDOW SCREEN

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.

2.52

Tigercat C640 Clambunk Skidder

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

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

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

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

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

Top Job

Freon T.F.

VM&P grade Naphtha

Joy Windex with Ammonia D Palmolive Liquid

284-10A

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

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

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

(B) To remove labels, stickers, etc., the use of kerosene, VM&P Naphtha, or petroleum spirits is generally effective. When the solvent will not penetrate sticker material, apply heat (hair dryer) to soften the adhesive and promote removal. GASOLINE SHOULD NOT BE USED.

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

2.53

Tigercat C640 Clambunk Skidder

Controls and operation

CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR

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

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

Always use personal protective equipment to guard against flying debris

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. If an oil leak has occurred in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed. The presence of oil will cause dust and dirt to cling to surfaces impair the reversible fan's ability to remove dust and dirt particles. Care must be taken when cleaning this assembly, as the components can be damaged by careless handling and cleaning.

302-21

RIGHT SIDE - A/C CONDENSER AND OIL COOLER

The A/C condenser core, engine radiator and oil cooler should be manually checked every 8 hours (every shift) for accumulation of twigs, leaves, pine needles and dust.

WARNING When the fan control switch is in the AUTOMATIC position (6401031 & UP only), the fan may begin to operate at any time when engine is running. Stay clear of fan at all times.

290-11

2.54

LEFT SIDE - CROSS-FLOW FAN

Tigercat C640 Clambunk Skidder

302-19

Controls and operation

A/C CONDENSER SWINGS DOWN FOR CLEANING

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

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

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

2.55

Tigercat C640 Clambunk Skidder

Controls and operation

TOWING INSTRUCTIONS DISCONNECT LEVER

A malfunction of the machines equipment may make towing necessary.

•

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

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

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

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

STEERING CYLINDERS

342-1

TRANSMISSION DISCONNECT LEVER SHOWN IN NEUTRAL

CAUTION

STEERING CYLINDERS

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.

SM47

NORMAL HOSE CONNECTIONS

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

HOSES ON ONE CYLINDER CROSS CONNECTED FOR TOWING

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

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

CAUTION

4. 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.

Never attach chains or cables to the clam tongs for any reason. Do not tow this machine or any other object by attaching to the clam tongs. Serious damage to the clam will result.

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

2.56

Tigercat C640 Clambunk Skidder

Controls and operation

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

CAUTION Do not use the center joint to chain the machine to the truck. This can damage the center joint The dozer blade must be down on the truck bed.

The clam must be closed during transport.

The articulation lock bar must be installed.

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

Chains must be attached to the clam to prevent movement.

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

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

CAUTION

Never attach chains or cables to the clam tongs for any reason. Do not tow this machine or any other object by attaching to the clam tongs. Serious damage to the clam will result.

2.57

Tigercat C640 Clambunk Skidder

Controls and operation

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

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

WARNING To prevent movement of machine and possible injury, install articulation lock bar before performing any work in the center joint area.

REAR CHASSIS ARTICULATION LOCK

•• C640-P03

•

••

RETAINING PINS

ARTICULATION LOCK STORED POSITION

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

C640-P02

ARTICULATION LOCK IN LOCKED POSITION

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

2.58

Tigercat C640 Clambunk Skidder SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3 AIR CONDITIONING SYSTEM, CHECKING ................................................ 3.18 APPROVED HYDRAULIC OILS ..................................................................... 3.7 CENTER JOINT LUBRICATION .......................................................................................... 3.16 MAINTENANCE ........................................................................................ 3.16 ENGINE AIR CLEANER MAINTENANCE .................................................... 3.14 FILTERS - REMOVE AND REPLACE CHARGE PRESSURE FILTER - DRIVE PUMP ....................................... 3.13 CHARGE PRESSURE FILTER - FAN DRIVE PUMP ............................... 3.13 FUEL FILTER/WATER SEPARATOR ....................................................... 3.10 FUEL TANK STRAINER ........................................................................... 3.10 HYDRAULIC OIL DOUBLE ELEMENT FILTERS ..................................... 3.11 FRONT AXLE ............................................................................................... 3.24 ALTERNATIVE METHOD FOR FILLING FRONT AXLE .......................... 3.25 CAPACITY ................................................................................................ 3.24 DIFFERENTIAL LUBRICATION ............................................................... 3.24 DRAINING THE FRONT AXLE ................................................................. 3.24 FILLING THE FRONT AXLE ..................................................................... 3.24 GENERAL MAINTENANCE ........................................................................... 3.3 HOUR METER ~ MAINTENANCE ................................................................. 3.2 NEW MACHINE MAINTENANCE ................................................................... 3.2 INITIAL PRE-DELIVERY INSPECTION ...................................................... 3.2 FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................. 3.2 TIGHTENING POINTS ............................................................................... 3.2 PRESSURIZED WATER SYSTEM MAINTENANCE .................................... 3.16 FILL AND CHARGE .................................................................................. 3.17 PURGING ................................................................................................. 3.17 SYSTEM TEST ......................................................................................... 3.16 REAR (BOGIE) AXLE ................................................................................... 3.22 BOGIE HOUSINGS (2 FILLING POINTS) ................................................ 3.23 DIFFERENTIAL (1 FILLING POINT) ......................................................... 3.22 DRAINING AND REFILLING BOGIE AXLE .............................................. 3.22 PLANETARY DRIVES (4 FILLING POINTS) ............................................ 3.23 REPLACING THE ENGINE SERPENTINE BELT ........................................ 3.28 SCHEDULED MAINTENANCE ...................................................... 3.4, 3.5, 3.6 FREQUENTLY ............................................................................................ 3.4 8 HOURS .................................................................................................... 3.4 125 HOURS ................................................................................................ 3.4 250 HOURS ................................................................................................ 3.5 500 HOURS ................................................................................................ 3.5 1000 HOURS .............................................................................................. 3.5 SEASONAL ................................................................................................ 3.6 SERVICE AND LUBRICATION POINTS CHART ........................................... 3.9 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE ........................ 3.26 TILTING THE CAB ....................................................................................... 3.20 TORQUE CHART ......................................................................................... 3.29 TORQUE CHART, GENERAL ...................................................................... 3.30 WHEELS, INSTALLING .................................................................................. 3.2

MARCH 2001

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR C640 CLAMBUNK SKIDDER _______________________________________________________________________________________

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

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

TIGHTENING POINTS FOR:THE FIRST 50-100 HOUR INSPECTION REPORT:~

IMPORTANT! __________________________________________

WHEELS:

All hydraulic connections

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.

Hose clamps Center joint pin securing bolts Transmission securing bolts

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

Engine mounting bolts Pump drive gearbox securing bolts

__________________________________________

Axle mounting bolts

HOUR METER ~ MAINTENANCE:

Wheel retaining bolts

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

Cab securing bolts Pin retainers

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

Any other loose nut, bolt or fitting

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

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

__________________________________________

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

OIL LOST FROM LEAKAGE

_______________________________________________________________________________________

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

3.2

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

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

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

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

Plug or cap immediately Clean up spills as soon as possible Always use clean oil and containers Drain dirty oil while still warm Do not exceed recommended fluid levels Service all hydraulic filters after the failure of a pump, motor, cylinder or valve. Failures of this nature could contaminate the entire hydraulic system Top up diesel fuel at end of each shift to reduce contamination by condensation Clean up oil spills on walking surfaces and top of engine enclosure immediately Before welding on machine be sure master switch is disconnected When welding secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings Clean away all branches, bark and chips.

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

3.3

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE • Lubricate Clam, 10-fittings, purge

FREQUENTLY:~

• Lubricate Clam Swing Bearing, 1-fitting, 10 shots

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

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

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

______________________________________________

• Clean potentially damaging limbs or sticks from machine

EVERY 8 HOURS (EVERY SHIFT):~

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

• Perform "frequently" maintenance check, And in addition:~ • Check engine coolant level • Check engine oil level • Drain fuel/water separator

• Check for leakage around hydraulic components and flexible hoses

• Check air intake precleaner, clean as required

• Check for loose nuts, bolts and fittings

• Check air cleaner unloader valve • Check engine air filter restriction indicator

• Check condition and tension of all engine belts.

• Check hydraulic oil level

• Conduct an overall visual inspection.

• Check pump drive gearbox oil level with dipstick

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

• Check transmission oil level with dipstick

______________________________________________

• Lubricate front axle pivot, 2-fittings, purge • In submerged or snow conditions perform the following every shift (otherwise every 125 hrs)

EVERY 125 HOURS:~ • Perform "frequently" maintenance

Lubricate front axle - outer bearings 1-fitting; 2-places; lubricate until grease flows out past the outer seals.

• Perform 8 hour maintenance And in addition:~ • Check fuel tank filler screen

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

• Lubricate front axle - outer bearings 1-fitting; 2-places; lubricate until grease flows out past the outer seals. (Note: In submerged or snow conditions axles should be lubricated every shift)

• Lubricate mid drive shaft, 1-fitting, purge Note: Lubrication of the mid drive shaft slip joint should be done with machine fully articulated.

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

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

• Lubricate front drive shaft, 1-fitting, purge • Test for proper operation of pressurized water system. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

• Lubricate center joint bearings, 2-fittings, purge

Check:~ • Fluid level in batteries unless maintenance free

• Lubricate steering cylinder ends, 4-fittings, purge

• Engine rpm.

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

• All hydraulic pressures 3.4

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE immediately. Refer also to CENTER JOINT in SECTION 11 of the SERVICE MANUAL for more detailed checking and adjustment procedures.

• Hydraulic pump and motor securing bolts • Torque tightening points as per new machine maintenance

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

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

EVERY 500 HOURS:~ • Perform "frequently" maintenance

• Wear in any other components

• Perform 8 hour maintenance

Clean/replace:• Air conditioner re-circulation filter • Cab fresh air filter • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

• Perform 125 hour maintenance • Perform 250 hour maintenance And in addition:~ • Replace air intake safety element • Replace hydraulic oil double element filters (2 elements) † *PREFILL DOUBLE ELEMENT FILTERS WITH CLEAN OIL BEFORE INSTALLATION • Replace charge pressure filter-drive pump †

EVERY 250 HOURS:~

• Replace charge pressure filter-cooling fan pump †

• Perform "frequently" maintenance

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

• Perform 8 hour maintenance • Perform 125 hour maintenance And in addition:~ • Replace engine oil and change oil filter

EVERY 1000 HOURS:~

• Replace engine fuel filter • Replace fuel/water separator filter

• Perform "frequently" maintenance

• Replace air intake primary element

• Perform 8 hour maintenance

• Replace oil in pump drive gearbox

• Perform 125 hour maintenance

• Replace oil in transmission

• Perform 250 hour maintenance

• Check oil level in bogie axle differentials

• Perform 500 hour maintenance

• Check oil level in bogie axle housings, 2 places

And in addition:~ • Replace air cleaner unloader valve • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

• Check oil level in bogie axle planetary drives, 4 places • Lubricate bogie axle slewing rings, 12-fittings; 2-places

______________________________________________

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

• 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

† Use only Genuine Tigercat replacement hydraulic oil filters.

3.5

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE

SEASONAL:~ • Drain and refill hydraulic oil tank and front axle with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Refer also to FRONT AXLE in THIS SECTION. • Replace hydraulic hand fill pump filter. † • Drain and refill bogie axle differential, housings and planetary drives. Refer to REAR (BOGIE) AXLES in THIS SECTION. Refer also to bogie axle service and repair manual for recommended gear oils and service intervals.

• Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. ______________________________________________ † Use only Genuine Tigercat replacement hydraulic oil filters.

3.6

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

APPROVED HYDRAULIC OILS In addition to providing the vehicle with its normal operational functions, hydraulic oil is also used to fill the front axle assembly, apply brakes and operate front differential locks.

Wet disk brakes in the front axle require oil with specific properties to ensure reduced chatter and ensure proper lubrication of mechanical components.

Use only one of the following oils to fill or replenish the hydraulic system.

HYDRAULIC OIL THE FLUID USED TO FILL OR REPLENISH THE HYDRAULIC SYSTEM OF THIS MACHINE MUST MEET JOHN DEERE SPECIFICATIONS TYPE J20C (SUMMER) OR J20D (WINTER).

THE FOLLOWING ARE APPROVED BY Tigercat FOR USE IN THIS MACHINE: CHEVRON CITGO IMPERIAL/ESSO SHELL SUN JOHN DEERE

®

TRACTOR HYDRAULIC FLUID (SUMMER) TRACTOR HYDRAULIC FLUID (33-310) (SUMMER) HYDRAUL 56 (SUMMER) HYDRAUL 50 (LOW VISC) WINTER) DONAX TD (SUMMER) DONAX TDL (WINTER) SUNFLEET TH FLUID (SUMMER) TYPE J20C (HYGARD) (SUMMER) TYPE J20D (HYGARD) WlNTER) 11514A

3.7

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

REAR DRIVE SHAFTS 22 3 FTG/8

19

OUTER AXLE BEARINGS 17 2 FTG/8

4

3

11

18

10

12 BOGIE AXLE SLEWING RINGS 21 24 FTG/250

STEER CYLINDERS

4 FTG/8

SWING BEARING

28

AXLE - PIVOT 24

2 FTG/8

16

27

1 FTG/8

DOOR HINGES

10 FTG /8

8 FTG/500

5

CLAM 26

14

1

7 8

6

DOZER

6 FTG/8 CLAM COVERS

4 FTG/500

CENTER JOINT 23

2 FTG/8 MID DRIVE SHAFT 22

20

1 FTG/8

FRONT DRIVE SHAFT

1 FTG/125

22

15

13

9

LEGEND *

ANTIFREEZE SOLUTION MUST MEET GM 6038M SPECIFICATIONS - SEE MANUFACTURERS MAINTENANCE MANUAL

**

LUBRICATE UNTIL GREASE FLOWS OUT PAST OUTER SEALS. DO NOT USE POWER GREASERS AS IT WILL DAMAGE THE SEALS. SEVERE CONDITIONS (DEEP MUD, WATER OR SNOW) LUBRICATE EVERY 8 HOURS. NORMAL CONDITIONS LUBRICATE EVERY 125 HRS. STEER MACHINE FULLY BEFORE GREASING MID DRIVE SHAFT SLIP YOKE.

*** ****

2 FTG/125

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2 FTG) AND HOURS BETWEEN SERVICING (125 ). JOINT TO BE PURGED. USE LITHIUM BASED GREASE CONTAINING MOLYBDENUM DISULFIDE.

†

Use only Genuine T igercat replacement Hydraulic oil filters.

12735B.PDF

3.8

CHK REP DRN D/R LUB

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

25

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

Tigercat® Model C640 SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

1

COOLING SYSTEM

CHK

2

CHK

REP

3

ENGINE OIL/FILTER CUMMINS C SERIES FUEL FILTER (ENGINE)

REP

1

4

FUEL/WATER SEPARATOR

DRN

REP

1

5

FUEL TANK FILLER SCREEN

6

AIR INTAKE PRECLEANER

7

CHANGE COOLANT EVERY 2 YEARS

40

10.6

18.9

5

QTY

USG

LITERS

CAPACITY

1000

500

250

8

ITEM

125

SERVICE POINT NO.

SERVICE EVERY

CHK

60/40 ANTIFREEZE */DISTILLED WATER SEE ENGINE MANUFACTURERS MAINTENANCE MANUAL

1

CHK

AIR INTAKE PRIMARY ELEMENT

DESCRIPTION

REP

AIR INTAKE SAFETY ELEMENT

REP

CLEAN AS REQUIRED

1 1

CHECK FILTER RESTRICTION INDICATOR WITH ENGINE RUNNING

1

REFER TO SECTION 3 OF THE MANUAL

1

DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE (SEE HYDRAULIC OIL CHART)

8

AIR CLEANER UNLOADER VALVE

CHK

9

HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10

HYDRAULIC FILTER, FULL FLOW

11

14

CHARGE PRESSURE FILTER (DRIVE PUMP) CHARGE PRESSURE FILTER (FAN DRIVE PUMP) PUMP DRIVE GEARBOX CHECK LEVEL WITH DIPSTICK TRANSMISSION CAST

15

FRONT AXLE - DIFFERENTIAL

16

FRONT AXLE - PIVOT

LUB

17

FRONT AXLE-OUTER BEARINGS

LUB ***

18

BOGIE AXLE - DIFFERENTIAL

CHK

14

19

BOGIE AXLE - HOUSINGS

CHK

20

BOGIE AXLE - PLANETARY DRIVES

CHK

21

BOGIE AXLE - SLEWING RINGS

LUB

PURGE

24 LITHIUM BASE EP2 GREASE

PURGE

1

LUB ***

PURGE

1

LUB

PURGE

1

BEARING INTERMEDIATE

LUB

PURGE

1

BEARING DIFFERENTIAL YOKE

LUB

PURGE

1

PURGE

2

12 13

22

23

REAR DRIVE SHAFT: BEARING FRONT

CENTER JOINT

95

25

REP † REP † REP †

2 1 1

CHK

D/R

3

0.8

1

CHK

D/R

6

1.6

1

28

7.4

FRONT DRIVE SHAFT MID DRIVE SHAFT

REP

1

LUB ***

LUB

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

1

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

PURGE

2

LITHIUM BASE EP2 GREASE

** SEE NOTE

2

LITHIUM BASE EP2 GREASE

3.7

1

35

9.2

2

REFER TO BOGIE AXLE SERVICE AND REPAIR MANUAL FOR RECOMMENDED GEAR OILS

5

1.3

4

LITHIUM BASE EP2 GREASE

LUB

CENTER JOINT BEARING PRELOAD

LITHIUM BASE EP2 GREASE REFER TO SECTION 3 OF THE MANUAL

CHK

24

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE

25

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE

10 LITHIUM BASE EP2 GREASE

26

CLAM

LUB

PURGE

27

SWING BEARING

LUB

10 SHOTS

28

PRESSURIZED WATER SYSTEM

CHK

TEST

41.6

C640LUBCHART.XLS/PDF-R3

3.9

11

1

LITHIUM BASE EP2 GREASE SEASONAL DRAIN AND REFILL

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

FILTERS - REMOVE AND REPLACE

FUEL TANK STRAINER

FUEL FILTER/WATER SEPARATOR

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.

This is a combination unit, with a replaceable fuel filter and a removable water sediment bowl on the bottom of the unit. The water sediment bowl is only replaced if it becomes damaged or non-functional. For service and replacement intervals refer to SERVICE AND LUBRICATION POINTS CHART in THIS SECTION. Changing the filter:

Changing or cleaning the strainer: 1. Park machine on level ground, install articulation lock pin, lower dozer blade to the ground , stop engine, pull parking brake ON and block wheels.

2. Drain the fuel tank. (plug in bottom)

1. Park machine on level ground, install articulation lock pin, lower dozer blade to the ground, stop engine, pull parking brake ON and block wheels.

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

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

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).

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

4. Wearing face protection (in case of a fuel spray) turn OFF the fuel shut-off valve on the side of the fuel tank and unscrew the old filter.

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

5. Remove and discard the small 1” I.D. gasket from the threaded extension on the filter head.

7. Reinstall the strainer using the hex on end.

6. Remove the water sediment bowl from the bottom of the old filter. Discard this gasket also. Dispose of old filter and any fuel properly.

7. Clean the water sediment bowl.

8. Reinstall fuel tank cover plate with “O” ring.

9. Refuel and check for leaks. Start the engine and check for leaks again.

8. Check the seating area for the gaskets on the filter head and the water sediment bowl and wipe clean.

IMPORTANT

9. Lubricate gasket for bottom of filter and water sediment bowl with clean engine oil and carefully hand tighten the water sediment bowl onto the new filter. It is plastic and will break if over tightened.

Close the water drain valve.

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.

10. Lubricate the new 1” I.D. gasket with clean engine oil and install onto the threaded extension on the filter head.

11. Lubricate the gasket on top of the new filter with clean engine oil and prefill the filter with clean fuel.

12. Screw the new filter on to the filter head until the gasket makes contact with the seat and then hand tighten an additional 3/4 turn only.

13. Turn the fuel shut-off valve ON, start the engine and check for leaks.

3.10

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 operation and maintenance manual.

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

HYDRAULIC OIL DOUBLE ELEMENT FILTERS

FILTER HEAD

The cooling circuit contains a double element, full flow, 7 micron filter with a built in restriction indicator and a 25 psi bypass valve. In the event of a clogged filter element or thicker oil on cold starts, this bypass filter will open and redirect oil around the filter element. When the filter elements become restricted, the Red pop-up indicator will show RED, indicating that the elements must be changed.

• • GASKET

• FILTR_SEALS 2

Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Prefill filter with clean oil before installation.

Screw on new filter until gasket makes contact.

Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact)

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

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

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

6. Start the engine and check for leaks.

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.

•

'O' RING GASKET INSTALLATION

l 'O' Ring Gasket

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS CHART in THIS SECTION.

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

FILTER ELEMENT

DOUBLE ELEMENT FILTER

•

•

•

FILTER HEAD

• DRIVE PUMP CHARGE PRESSURE FILTER

GASKET

•

FILTER ELEMENT 302-17

SQUARE SECTION GASKET INSTALLATION

HYDRAULIC FILTERS

FILTR_SEALS 2

n Square Section Gasket

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.

Remove used gasket and clean groove in head.

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Prefill filter with clean oil before installation. Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

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

3.11

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

3.12

Tigercat C640 Clambunk Skidder CHARGE PRESSURE FILTERSDRIVE PUMP AND FAN DRIVE PUMP The drive pump charge circuit contains a single element, full flow, 10 micron filter with a restriction indicator sending unit and a 50 psi third port bypass valve. The restriction indicator sending unit turns on the filter bypass warning light when an oil flow restriction in excess of 50 psi is encountered at the filter head. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the drive circuit.

The fan drive circuit contains a single element, full flow, 10 micron filter with a restriction indicator sending unit and a 50 psi third port bypass valve.

The restriction indicator sending unit for this filter is not connected to a warning light. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the fan drive circuit.

Lubrication and Maintenance Changing a pressure filter: 1. Park machine on level ground, install articulation lock pin, lower dozer blade to ground, stop engine, pull parking brake ON and block wheels.

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

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

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

5. Check the seating area for the gasket on the filter head and wipe it clean.

6. The new filter has an attached gasket. Apply hydraulic oil to the gasket surface.

7. Screw on the new filter until the gasket makes contact with the seat in the filter head. DO NOT PREFILL THE NEW PRESSURE FILTER. 8. Hand tighten filter an additional 1/2 turn only.

DOUBLE ELEMENT FILTER

9. Start the engine and check for leaks.

•

•

•• LEFT SIDE BELOW COOLING FAN

DRIVE PUMP CHARGE PRESSURE FILTER

302-17

HYDRAULIC FILTERS

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.

333-3

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

3.13

FAN DRIVE CHARGE PRESSURE FILTER

Tigercat C640 Clambunk Skidder ENGINE AIR CLEANER MAINTENANCE

Lubrication and Maintenance

ENGINE AIR PRECLEANER

AIR CLEANER

••

••

SENDING UNIT FOR WARNING LIGHT IN CAB

FILTER RESTRICTION INDICATOR

ENGINE AIR CLEANER

••

•• ••

ENGINE AIR CLEANER

291-3

303-8

EXHAUST PORT AREA

ENGINE AIR CLEANER

AIR CLEANER

284-25A

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.

REAR VIEW OF PRECLEANER

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

AIR PRECLEANER The engine air precleaner cleans engine air before it reaches the air cleaner filter elements. It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance.

However, it should be checked periodically to make sure that foreign materials have not plugged the intake area or the exhaust port area. For servicing procedures, refer to SECTION 7 of the SERVICE MANUAL.

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

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

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

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

••

• 303-7

• •

TURBO 2

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.

•

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

AIR CLEANER UNLOADER VALVE

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

TURBO II PRECLEANER OPERATION

This valve should be replaced every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. Check and clean the valve. A good valve should be soft and flexible. If it is 3.14

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

plugged, be sure to check the filter elements as they may need replacing as well. Reattach the valve to the tube.

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

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

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

In addition to SCHEDULED MAINTENANCE, the following instructions should also be noted.

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

The most common and damaging servicing problems are:

4. Always clean the inside of the outlet tube and filter housing.

PRIMARY ELEMENT

OUTLET TUBE

••

SAFETY ELEMENT

••

NOTE: Filter elements should never be cleaned and reused. Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media. The dust is then drawn directly into the engine.

••

ENGINE AIR PRECLEANER

171-18A

5. Check your old filter, It can help you detect foreign material on the sealing surface that is causing leakage.

AIR FILTER ELEMENTS

OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that looks dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond engine manufacturer's guidelines, should a filter be replaced.

6. Inspect the new filter for damage.

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

8. Check connections and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points Leaks here send dust directly to the engine.

NOTE: This does not apply to oil filters.

IMPROPER SERVICING Engine exposure to dust during servicing is the largest single reason for engine damage due to dust.

Abrasive dust can easily enter the intake system once the air cleaner cover and protective filter element is removed for replacement. The safety element does reduce this risk but it should also be replaced at every third primary element change.

3.15

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

CENTER JOINT

PRESSURIZED WATER SYSTEM MAINTENANCE

MAINTENANCE OF CENTER JOINT Maintenance in this area is usually limited to:

An 11 gal. water tank is incorporated into the dozer blade and is pressurized to 60 psi. A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade.

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 CHART in THIS SECTION for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide.

The control valve incorporates an air charge valve, a pressure gauge and a relief valve on the outlet side of the valve. A ball valve is installed on the outlet side of the valve and is used to shut off the water supply to the hose.

This ball valve should be in the OFF position when the system is not in use.

b) Visually checking the center joint pivot for looseness every 250 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.

The pressure gauge on the valve should read 60 psi check system pressure daily.

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

DOZER BLADE

•

WATER TANK

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.

• •

•

WATER CONTROL VALVE

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..

HOSE STORAGE COMPARTMENT 150-3AA

PRESSURIZED WATER SYSTEM

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) the system needs to be PURGED. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE ~ PURGING in THIS SECTION.

REAR CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

DIG-003

FRONT CHASSIS

After testing, the tank must be refilled and pressurized to 60 psi. Refer to the following PRESSURIZED WATER SYSTEM MAINTENANCE ~ FILL AND CHARGE procedure. This FILL AND CHARGE procedure should be carried out yearly.

1000 HOUR CHECK

3.16

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

FILL AND CHARGE PRESSURIZED WATER SYSTEM

c.

WATER SHUT-OFF VALVE (SHOWN OFF) PRESSURE GAUGE

•

•

•

OUTLET CONNECTION

•

d. Install fill plug in tank.

AIR CHARGE VALVE 150-1A

WATER CONTROL VALVE a. Completely discharge all water and compressed air from the tank via the hose end nozzle.

CAUTION Never remove fill plug before depressurizing tank or injury may result. This fill plug incorporates a vent hole to release air pressure from the tank before the threads disengage. Do not replace this fill plug with any substitute. b.

Slowly unscrew fill plug two full turns. Any remaining air in the tank will be heard expelling from the special fill plug. Do not remove fill plug until all air has been expelled.

WATER TANK FILL PLUG

•

•

e. Charge water tank with compressed air by connecting an air hose to air charge valve beside the pressure gauge. Pressurize to 60 psi as indicated on pressure gauge.

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. a. Follow procedures (a) and (b) from FILL & CHARGE PRESSURIZED WATER SYSTEM and continue with: b.

Close the water shut off valve and add 2 gallons of CLEAN water to the tank. Reinstall the fill plug and charge the system with 60 lbs. of compressed air through the charging valve.

c.

Open the shut off valve and completely discharge all the water in the tank via the hose end nozzle.

d. 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. e. After the purging operation, fill and charge the system as described in FILL & CHARGE PRESSURIZED WATER SYSTEM.

DOZER BLADE 150-8A

Close water shut off valve and fill tank with water. (Tank capacity is approx. 10.5 gals.)

NOTE: When temperatures below 32°F are anticipated, add a Nontoxic R. V. Antifreeze or other suitable antifreeze solution to the water.

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.

• PRESSURIZED WATER SYSTEM

3.17

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

IMPORTANT

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant only. PAG (polyalkeylene glycol) oil should be present in the system and must be used on 'O' ring fittings during assembly.

It is recommended that during cold weather when the A/C system is not in use, that it be run for a period of 5 minutes every 2 weeks. This will circulate oil to all components of the A/C system.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT 3 LBS. 0 OZ.

CAUTION

PAG OIL (polyalkylene glycol)

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

Always use personal protective equipment to guard against flying debris.

7 OZ.

The compressor and charge valves are accessed from the right side engine compartment. The receiver drier is accessed from the compartment behind the right door, on the outside. The evaporator core is accessed on the right hand side of the machine just inside the cab door.

Use this checklist to maintain system between service intervals. a. Check and adjust compressor drive belt tension. b. Check air intake filters and clean as required. c. Check the condenser core for dirt and debris. Clean as required. Refer to CLEANING A/C Condenser, OIL COOLER AND RADIATOR in THIS SECTION. d. Check the evaporator core and the inside of the A/C housing for dirt and debris.

Clean as required.

302-19

e. Run air conditioning system for 3 - 5 minutes. f.

Check to see that compressor clutch will engage.

3.18

CHECK A/C CONDENSER CORE

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance FRESH AIR FILTER

• ENGINE

SHUT-OFF VALVE

•

•

HOSE TO A/C HEATER UNIT

• 303-20

274-5

HOT WATER SHUT OFF VALVE

FRESH AIR FILTER

FILTER - FRESH AIR

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

RECIRCULATING AIR FILTER

•

When the control switch is in the FRESH AIR position , outside air is drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. To reduce dust in the cab area, use the FRESH AIR option with the A/C on. This pressurizes the cab, forcing dust out and reducing dust coming in. The FRESH AIR filter is accessible from outside of the cab, at the back between the lights. It should be cleaned or replaced every 125 hours. This is done by removing 6 bolts (3/8”) and removing the air inlet cover. Next remove two nuts (1/4”) and remove the filter box cover. This will allow access to the filter.

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

HEAT CONTROL DIAL

VENTS BEHIND SEAT - 2 FILTER, RECIRCULATING AIR - A/C UNIT 151-9

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

• 271-24AC

A/C-HEATER CONTROL PANEL (6401001 TO 6401010) TEMPERATURE CONTROL

•

350-4A

A/C-HEATER CONTROL PANEL (6401011 AND UP)

HEAT - VARIABLE/TEMPERATURE CONTROL This is a variable, rotary dial to adjust the amount of heated air for the cab. Make sure this control is off or at the coolest setting (full counterclockwise), when using the air conditioning. Refer also to HOT WATER SHUT OFF VALVE. 3.19

Tigercat C640 Clambunk Skidder 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.

Lubrication and Maintenance 5. Remove the left side Cab Locking Pins. (2 pins) This is done by first removing the locking bolts. (2 bolts) 6.

Open the lower compartment door in left hand step below the cab door to access the cab tilt hand pump.

PUMP HANDLE

•

•

RAISING THE CAB 1. Position the Skidder on level ground.

PUMP

••

2. Lower the dozer blade to the ground.

3. Apply parking brake and turn ignition off.

4. Remove the sweep mounting bolts at the cab.

(4 bolts) CANOPY SWEEP BOLTS

•• 302-14

PUMP HANDLE STORAGE BRACKETS

HAND PUMP FOR CAB TILT

7. Turn the lever on the pump manifold to RAISE (pointing in).

•

PUMP HANDLE

•

PUMP LEVER SHOWN IN "RAISE" POSITION

•• PUMP LEVER SHOWN IN "LOWER" POSITION

••

••

303-14

138-8AX

PUMP CONTROL LEVER

8. Insert handle into pump and pump in a steady manner to raise the cab to the tilt position. The pump handle is stored on the inside of the battery access door located below the test port compartment.

CAUTION 303-M2

Keep hands away from the locking pin area.

As the cab passes "top dead center" it will slowly move on its own to the full extent of the safety cable. DO NOT PUMP BEYOND LIMIT OF SAFETY CABLE.

•

303-12

•

CAB LOCKING PINS

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 center of gravity.

The cab will stay at this limit provided Skidder is on level ground.

3.20

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

LOWERING THE CAB 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.

CAB SUPPORT BRACE (3291B).

MUST USE CAB & CHASSIS LUGS SHOWN

•

SAFETY CABLE

CAB LOCKING PINS

3. Turn the lever on the pump manifold to LOWER (pointing out)

••

4. Pump the handle on the pump to lower the cab.

5. Watch closely for pinching of hydraulic lines and wires.

302-16

••

••

PARTIAL TILT WITH CAB SUPPORT BRACE

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

6. When fully lowered, insert Cab Locking Pins and tighten locking bolts (2 pins) (2 bolts) 7. Turn the lever on the pump manifold inwards and store the pump handle on the lower door.

8. Close and lock the lower door.

9. Replace the Canopy Sweep Bolts. (4 bolts)

WARNING

••

Before working under cab; Machine must be parked on level ground.

Cab must be fully tilted with safety cable completely tight, or cab support brace must be installed.

CAB SAFETY CABLE (3361B)

302-13

CAB AT FULL TILT SUPPORTED SUPPORTED BY SAFETY CABLE

WARNING If cab support brace is damaged or lost, it must be replaced immediately with Tigercat brace part number 3291B. DO NOT attempt to work under a raised cab supported only by the hydraulic cylinder or a substitute device.

WARNING

311-13

If cab safety cable is damaged or lost, it must be replaced immediately with Tigercat part number 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 SEAT

3.21

Tigercat C640 Clambunk Skidder REAR (BOGIE) AXLE

Lubrication and Maintenance DIFFERENTIAL (1 FILLING POINT)

The bogie axle has 7 separate oil reservoirs.

Each reservoir must be filled separately to get the proper level of lubrication in the bogie axle.

1. Remove the DIFFERENTIAL FILL/LEVEL PLUG 2. Remove the DIFFERENTIAL DRAIN PLUG and drain the oil into a suitable container for disposal.

Refer to SERVICE AND LUBRICATION POINTS CHART in THIS SECTION for differential oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

3. Clean any filings from the magnet on the oil drain plug.

DRAINING AND REFILLING BOGIE AXLE

4. Replace the DIFFERENTIAL DRAIN PLUG.

•

Park the machine on level ground.

•

Stop the engine and place the parking brake in the ON position.

•

The bogie axle must be level in order to drain and refill it properly.

•

Note that it will be necessary to reposition the wheel hubs when draining and refilling the planetary drives.

•

The oil must be warm before draining and refilling.

•

Clean around all fill, level and drain plugs before removing them.

5. Refill the differential with new oil until the level reaches the bottom of the DIFFERENTIAL FILL/LEVEL PLUG. Refer to SERVICE AND LUBRICATION POINTS CHART in THIS SECTION for differential oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

6. Replace the DIFFERENTIAL FILL/LEVEL PLUG.

DIFFERENTIAL FILL/LEVEL PLUG * (1 PLACE)

BOGIE HOUSING LEVEL PLUG (4 PLACES)

DIFFERENTIAL DRAIN PLUG (1 PLACE)

•

BOGIE HOUSING FILL PLUG (2 PLACES)

• •

•• BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

BM018

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

3.22

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

•

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

PLANETARY DRIVES (4 FILLING POINTS)

19. Clean any fillings from the four drain plugs.

7. Position the wheel hub for draining the planetary, with the drain plug in the lowest possible position as shown.

20. Replace the four drain plugs.

21. Remove the BOGIE HOUSING LEVEL PLUGS (2 per housing).

8. Remove the PLANETARY FILL PLUG.

22. Refill the housing through the BOGIE HOUSING FILL PLUG, using first the reusable portion of the oil drained from the bogie housing and then new oil, until the oil level reaches the bottom of the BOGIE HOUSING OIL FILL PLUG.

9. Remove the PLANETARY DRAIN/LEVEL PLUG and drain the oil into a suitable container for disposal.

10. Reposition the wheel hub for filling the planetary, with the PLANETARY DRAIN/ LEVEL PLUG at 9 o’clock and the fill plug at 1 o’clock as shown.

Refer to SERVICE AND LUBRICATION POINTS CHART in THIS SECTION for differential oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

11. Refill the planetary with new oil until the level reaches the bottom of the PLANETARY DRAIN/LEVEL PLUG. (Note: To get a correct filling level the wheel hub must be in the planetary fill position as shown.)

23. Replace the BOGIE HOUSING FILL PLUG and BOGIE HOUSING LEVEL PLUGS.

Refer to SERVICE AND LUBRICATION POINTS CHART in THIS SECTION for differential oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

24. Repeat steps 12 to 23 for the second bogie housing.

AFTER DRAINING AND REFILLING 25. Check all drain, fill and level plugs for leaks.

12. Repeat steps 7 to 11 for each of the four planetary drives.

BOGIE HOUSINGS (2 FILLING POINTS) 13. Note that the bogie housing must be level to drain and refill it properly.

14. Before draining the oil from the bogie housings, the axle should sit for at least 30 minutes so that contaminants in the oil can settle in the oil pan.

15. Remove the BOGIE HOUSING FILL PLUG. 16. A portion of the oil drained from the housing can be reused. To drain the reusable oil remove the BOGIE HOUSING DRAIN PLUGS (2 per housing – upper plugs) and drain the oil into a clean container, as this part of the oil can be reused.

17. Set aside the reusable oil.

18. The remaining oil is contaminated and must be discarded. To drain the contaminated oil remove the BOGIE HOUSING CONTAMINATED OIL DRAIN PLUGS (2 per housing – lower plugs) and drain the remaining oil into a second container for disposal.

3.23

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

FRONT AXLE

FILLING THE FRONT AXLE The front axle is filled by pumping oil in through the case drain plug port on the top right of the front axle. A vent plug also at the top of the axle should be removed to allow air to vent out and to allow oil to exit when the axle is full of oil.

DIFFERENTIAL LUBRICATION The front axle is allowed to completely fill with oil to the top of the differential case. This hydraulic oil buildup inside the differential case is due to normal internal leakage from the differential locks and is used as lubricant for the differential. The excess oil drains back to the hydraulic tank via the axle drain line.

Access to the vent plug (1 1/4") on the back, right side, near the top, of the front axle. Tilt the right side of the axle down for easier access.

DRAINING THE FRONT AXLE Care should be taken when draining the hydraulic oil from the front axle, not to also drain the oil from the hydraulic tank. To prevent oil from siphoning from the tank, first remove the hydraulic drain line from the top of the axle to allow air to vent into the axle when the bottom drain plug is removed and oil drains out. The line that is removed must be capped to prevent draining from the hydraulic tank.

• •

The time to schedule an oil change in the front axle is when doing the seasonal oil change on the hydraulic oil tank, as they are part of the overall system and use the same oil.

CASE DRAIN PLUG

VENT PLUG

IMPORTANT Care should be taken to refill the axle before moving the machine after draining.

635-P06

FRONT AXLE (RIGHT SIDE OF MACHINE)

Note: If ONLY the front axle was drained and not the entire hydraulic system, the port from which the drainline was removed will provide the vent and oil will exit from this port when the axle is full of oil. The drainline should remain capped until it is reinstalled.

Care must be taken to ensure that the front axle is completely full of oil and that all plugs, fittings and lines are tight.

CAPACITY For front axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION POINTS CHART in SECTION 3 of THIS MANUAL.

3.24

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

ALTERNATIVE METHOD FOR FILLING FRONT AXLE The following alternative method of filling the front axle is suitable for refilling the drained axle only. If you have done major service, a rebuild, replaced any major component or drained the machine of hydraulic oil refer to STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE in THIS SECTION. 1. Ensure the articulation lock pin is installed.

2. With engine at IDLE, parking brake ON, hold foot brake down, bleed brakes in front axle.

3. Turn front differential lock ON and run engine at IDLE for 30 minutes to purge air and fill front axle with oil (axle fills with leakage from diff. lock). If wheels have been removed, operate forward and reverse pedals very slowly to fill front axle with oil.

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

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

6.

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

NOTE:If the machine was on wheels, the steer and drive functions were not properly purged or flushed. Remove the articulation lock pin 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.

3.25

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE •

This procedure should be followed: •

after major service or a rebuild.

•

whenever the machine has been drained of hydraulic oil.

•

when any major component has been removed, repaired or replaced.

Loosen plug on the outside of the main pump.

•

PRE-STARTUP AND FILLING

LOOSEN PLUG OUTSIDE OF MAIN PUMP

1. Ensure all filters are in place. Pre-fill only the hydraulic oil double element filters. Do not prefill the charge pressure filters.

2. Check oil levels in the engine, the pump drive gearbox and the transmission.

3. Check coolant level in the radiator.

630-D30

•

Loosen plugs on both motors.

4. Do a final inspection of all fittings and clamps to make sure they are tight and will not leak.

5. Install the articulation lock pin and apply the parking brake.

•

LOOSEN PLUGS ON BOTH MOTORS

6. Turn both differential lock switches to OFF. 7. Do not start engine. Purge air from hydraulic system by adding oil as follows; •

•

•

Prepare the hand fill pump on the machine to add hydraulic oil. Clean the fill line pipe, remove cap on end of pipe and insert pipe into oil supply drum.

Pre-fill the cases of the hydrostatic pump and any other components that have been drained of oil.

Loosen plug on the top center of hydrostatic drive pump servo

LOOSEN PLUG ON TOP CENTER OF HYDROSTATIC DRIVE PUMP SERVO

•

•

630-D31

•

Operate the hand fill pump at medium speed, using a steady motion.

•

Watch for oil leaking from each plug previously loosened and tighten each plug when oil leaks out.

•

Continue pumping slowly and watch the oil sight gauge on the reservoir. Continue pumping slowly until the hydraulic tank is full.

NOTE: If the front axle was drained of oil, refer to FRONT AXLE ~ FILLING THE FRONT AXLE in THIS SECTION.

630-D35

3.26

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

MACHINE STARTUP

11. Top up the radiator with clean coolant. With cylinders fully retracted, top up the hydraulic oil reservoir with clean hydraulic oil.

Before beginning this procedure, perform the PRE-STARTUP AND FILLING steps.

NOTE: If the machine was on wheels, the steer and drive functions were not properly purged or flushed. Remove the articulation lock pin 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.

1. Ensure the articulation lock pin is installed.

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

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.

2. Disconnect red and white wires on injector pump solenoid (prevents engine starting).

3. Crank engine for 10 seconds, wait for 10 seconds. Repeat 6 times to pump oil into pumps. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL for starting instructions for your machine serial number.

4. Reconnect wires on injector pump solenoid.

Do not start engine.

5. Install a 0-1000 psi. gauge on drive pump to check charge pressure at ‘G’ ( TEE fitting).

Watch gauge closely during startup.

6. Start engine. If charge pressure does not rise within 5 to 10 seconds, TURN ENGINE OFF. If charge pressure is between 260 and 450 psi., run engine at IDLE for 20 minutes.

Check engine oil pressure in cab. Do not operate any functions. Remove gauge from 'G'.

7. With engine at IDLE, parking brake ON, hold foot brake down, bleed brakes in front axle.

8. Turn front differential lock ON and run engine at IDLE for 30 minutes to purge air and fill front axle with oil (axle fills with leakage from diff. lock). If wheels have been removed, operate forward and reverse pedals very slowly to fill front axle with oil.

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

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

3.27

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

REPLACING THE ENGINE SERPENTINE BELT

A/C COMPRESSOR BELT

BELT GUARD BOLT LOCATIONS

In order to replace the engine serpentine belt it is necessary to disassemble the fan drive pump coupling.

•

•

1. Park the machine on level ground. Parking brake ON, grapple and dozer down and engine off.

2. Remove the belt guard (4 bolts).

3. Remove the A/C compressor belt.

•

•

4. Remove the fasteners that hold the pump drive coupler together (8 bolts - 1/4"). Note the engine will have to be 'jogged' to access all of the bolts.

• •

5. Carefully slide the black rubber section of the coupler towards the fan pump. This will provide enough clearance to replace the serpentine belt.

SERPENTINE BELT

•

COUPLER

6. Replace the serpentine belt. Ensure that all of the ribs on the serpentine belt align with the grooves on the engine pulleys.

• FAN DRIVE PUMP

•

7. Reassemble the pump drive coupler, using the original bolts. Use loctite 242 (temporary) or equivalent. Torque all bolts to 8-10 lbf-ft using an opposing torque pattern.

SHOWN WITH FAN AND SOME HOSES REMOVED FOR CLARITY

BELT GUARD

314-24

8. Reinstall, align and tension the A/C compressor belt.

9. Reinstall the belt guard.

CAUTION

FAN DRIVE PUMP BOLTS

Always install belt guard before running the engine.

COUPLER

• • • COUPLER 1/4" BOLTS

SHOWN WITH FAN AND SOME HOSES REMOVED FOR CLARITY

314-12

3.28

FAN DRIVE PUMP BOLT LOCATIONS

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

TORQUE CHART LOCATION

Cylinders Pin bolts Piston nut, steer cylinder Piston nut, dozer cylinder Piston nut, clam cylinder Gland, steer cylinder Keeper plate bolts Keeper plate bolts Keeper plate bolts

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

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

282-310 1100 1260 1750 550 282-310 159-175 746-821

393-420 1491 1708 1232 745 393-420 216-237 1012-1113

Cab pin keeper plate bolts

3/4" UNC

282-310

393-420

Center joint bearing Bearing retaining bolts Pin retaining bolts

1/2" UNC 3/4" UNC

80-88 282-310

109-119 393-420

Engine mounting Bolts Bolts, brkt. to bell hsg.

7/8" UNC M12

450 80

610 108

Pump drive gearbox Drive plate to flywheel Bell housing to engine Engine mounting bracket

3/8" UNC 10 x 1.5 5/8" UNC

33-36 32 159-175

45-49 43 216-237

1 1/4" x 18 UNEF 3/4" UNC

475-525 282-310

640-711 393-420

1/2" UNF

120-132

163-179

1/2" UNF

120-132

163-179

1/2" UNF

120-132

163-179

3/4" UNC 1" UNC M27

300 682-750 1000

406 925-1016 1350

Wheel bolts

7/8" UNF

501-550

679-745

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

5/8"UNC 7/8" UNC

159-175 450

216-237 610

Drive shafts Yoke retaining nut, rear shaft Pillow block retaining bolts Rear drive shaft assembly universal joint bolts Mid. drive shaft universal joint bolts Front drive shaft universal joint bolts Axle mounting bolts Front Axle Rear (Bogie) Axle

REV0 02/2001

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

3.29

Tigercat C640 Clambunk Skidder

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS The torque values listed below are for general use only.

DO NOT use these values if a different torque value or tightening procedure is shown for a specific application.

IMPERIAL

GRADE 5 BOLTS

GRADE 8 BOLTS COARSE THREADS 1/4" - 20 5/16" - 18 3/8" - 16 7/16" - 14 1/2" - 13 9/16" - 12 5/8" - 11 3/4" - 10 7/8" - 9 1" - 8 1 1/8" - 7 1 1/4" - 7 FINE THREADS 1/4" - 28 5/16" - 24 3/8" - 24 7/16" - 20 1/2" - 20 9/16" - 18 5/8" - 18 3/4" - 16 7/8" - 14 1" - 12 1 1/8" - 12 1 1/4" - 12

DRY lbf-ft Nm 11 - 12 15 - 16 20 - 28 27 - 38 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

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 26 - 30 35 - 40 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250

COARSE DRY THREADS lbf-ft Nm 1/4" - 20 7- 8 10 - 11 5/16" - 18 14 - 18 19 - 24 3/8" - 16 31 - 34 42 - 46 7/16" - 14 49 - 54 66 - 73 1/2" - 13 75 - 83 102 - 112 9/16" - 12 109 - 120 148 - 162 5/8" - 11 150 - 165 204 - 223 3/4" - 10 266 - 293 360 - 397 7/8" - 9 394 - 433 535 - 586 1" - 8 591 - 649 802 - 879 1 1/8" - 7 794 - 873 1077 - 1183 1 1/4" - 7 1120 - 1232 1519 - 1670 FINE DRY THREADS lbf-ft Nm 1/4" - 28 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 3/8" - 24 35 - 39 48 - 53 7/16" - 20 55 - 61 75 - 83 1/2" - 20 85 - 94 116 - 127 9/16" - 18 121 - 133 164 - 180 5/8" - 18 170 - 187 231 - 253 3/4" - 16 297 - 327 403 - 443 7/8" - 14 434 - 477 589 - 646 1" - 12 646 - 711 876 - 965 1 1/8" - 12 891 - 980 1208 - 1328 1 1/4" - 12 1240 - 1364 1682 - 1849

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 10 - 15 13 - 20 23 - 25 31 - 34 37 - 41 50 - 55 57 - 63 77 - 85 82 - 90 111 - 122 113 - 124 152 - 168 200 - 220 271 - 298 296 - 326 402 - 441 443 - 489 601 - 663 596 - 656 808 - 889 840 - 924 1139 - 1252 LUBRICATED lbf-ft Nm 9 - 10 12 - 13 16 - 20 21 - 27 26 - 29 35 - 39 41 - 45 56 - 61 64 - 70 87 - 95 91 - 100 124 - 135 128 - 141 174 - 191 223 - 245 303 - 332 326 - 359 442 - 486 484 - 534 657 - 724 668 - 735 906 - 996 931 - 1024 1262 - 1387

METRIC

SIZE

M6 M8 M10

CLASS 4.8 LUBRICATED DRY Nm lbf-ft Nm lbf-ft 4.8 3.5 6 4.5 12 8.5 15 11 23 17 29 21

CLASS 8.8 OR 9.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft 9 6.5 11 8.5 22 16 28 20 43 32 55 40

CLASS 10.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft 13 9.5 17 12 32 24 40 30 63 47 80 60

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft 15 11.5 19 14.5 37 28 47 35 75 55 95 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 1000 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

3.30