Tigercat C640C CLAMBUNK SKIDDER SERVICE MANUAL – PDF DOWNLOAD

Description

Tigercat C640C CLAMBUNK SKIDDER SERVICE MANUAL – PDF DOWNLOAD

DESCRIPTION:

Tigercat C640C CLAMBUNK SKIDDER SERVICE MANUAL – PDF DOWNLOAD

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 C640C Clambunk Skidder serial
  numbers 6401601 to 6401999.
• 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 phrase “and up” appearing in this manual after the serial number implies that the related
  information is current for any machine serial number HIGHER than the serial number preceding the “and
  up”.
• Tigercat reserves the right to make changes to the machine after this manual release date that may not
  immediately appear in this manual.

TABLE OF CONTENTS:

Tigercat C640C CLAMBUNK SKIDDER SERVICE MANUAL – PDF DOWNLOAD 

C640C SERVICE ISSUE 1.0…………………………………. 1
INTRODUCTION……………………………………….. 3
S.A.E. STANDARDS……………………………………. 4
NON-APPROVED FIELD PRODUCT CHANGES……………………. 5
SECTION 1 – SAFETY……………………………………… 7
battery disconnect switch …………………………… 14
Battery safety …………………………………….. 12
CAB EXITS …………………………………………. 13
CAB SAFETY CABLE …………………………………… 19
CAB SUPPORT BRACE ………………………………….. 19
cooling system …………………………………….. 17
EMERGENCY CAB EXITS ………………………………… 13
exhaust fumes ……………………………………… 19
FIRE PREVENTION…………………………………….. 7
FIRE PREVENTION GUIDELINES ………………………. 20
WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE ………. 21
WHAT TO DO AFTER A FIRE …………………………. 22
WHAT TO DO IN CASE OF A MACHINE FIRE ……………… 21
first aid …………………………………………. 10
Fluid leaks ……………………………………….. 17
Hydraulic Pressure hazard …………………………… 17
loose clothing hazard ………………………………. 17
PARKING THE MACHINE ………………………………… 14
protective clothing ………………………………… 9
SAFETY PRECAUTIONS, GENERAL …………………………. 10
SAFETY PRECAUTIONS, OPERATING ……………………….. 13
SAFETY PRECAUTIONS, SERVICING ……………………….. 16
SAFETY SYMBOLS …………………………………….. 8
SIGNAL WORDS ………………………………………. 8
WELDING, PRIOR TO ………………………………….. 16
Working with oil …………………………………… 10
SECTION 3 – LUBRICATION & MAINTENANCE…………………….. 23
AIR CLEANER MAINTENANCE …………………………….. 38
AIR CONDITIONING SYSTEM, CHECKING ……………………. 42
APPROVED HYDRAULIC OILS……………………………… 23
AXLE CIRCUIT …………………………………… 31
MAIN HYDRAULIC SYSTEM …………………………… 30
ARTICULATION LOCK ………………………………….. 48
CAB SAFETY CABLE …………………………………… 47
CAB SUPPORT BRACE ………………………………….. 47
CENTER JOINT……………………………………….. 49
LUBRICATION ……………………………………. 49
MAINTENANCE ……………………………………. 49
EMERGENCY EXITS, CHECK MONTHLY ………………………. 25
FILTERS……………………………………………. 34
AXLE PRESSURE FILTER ……………………………. 37
CHARGE PRESSURE FILTER ………………………….. 37
FUEL FILTER/WATER SEPARATOR ……………………… 34
FUEL TANK STRAINER ……………………………… 35
HYDRAULIC OIL TRIPLE ELEMENT FILTERS ……………… 36
SECONDARY FUEL FILTER/WATER SEPARATOR …………….. 35
SERVICING GUIDELINES FOR OIL FILTERS ……………… 36
FIRE PREVENTION ……………………………………. 25
FRONT AXLE OIL LEVEL CHECK AND AXLE CIRCUIT FILL ……… 52
GENERAL MAINTENANCE ………………………………… 25
HOUR METER ~ MAINTENANCE ……………………………. 24
LUBRICATION AND SERVICE POINTS ………………………. 33
NEW MACHINE MAINTENANCE …………………………….. 24
FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT ……. 24
INITIAL PRE-DELIVERY INSPECTION ………………….. 24
OIL LOST FROM LEAKAGE ………………………………. 24
PRESSURIZED WATER SYSTEM MAINTENANCE …………………. 40
REAR (BOGIE) AXLE ………………………………….. 50
BOGIE HOUSINGS (2 FILLING POINTS) ………………… 51
DIFFERENTIAL (1 FILLING POINT) …………………… 50
DRAINING AND REFILLING BOGIE AXLE ………………… 50
PLANETARY DRIVES (4 FILLING POINTS) ………………. 51
SCHEDULED MAINTENANCE ………………………………. 26
FREQUENTLY …………………………………….. 26
8 HOURS ……………………………………….. 26
48 HOURS ………………………………………. 26
125 HOURS ……………………………………… 27
250 HOURS ……………………………………… 27
500 HOURS ……………………………………… 28
1000 HOURS …………………………………….. 28
SEASONAL ………………………………………. 29
STARTUP PROCEDURE AFTER MAJOR MAINTENANCE……………… 23
6401601 TO 6401620 ……………………………… 54
6401621 AND UP …………………………………. 56
TILTING THE HOOD AND CAB ……………………………. 44
TILTING THE CAB ………………………………… 46
TILTING THE HOOD ……………………………….. 44
TORQUE CHART ………………………………………. 58
TORQUE SPECIFICATIONS – GENERAL ……………………… 58
WHEELS, INSTALLING …………………………………. 24
SECTION 6 – ELECTRICAL AND COMPUTERS……………………… 61
ALARMS AND GAUGES ………………………………….127
CHANNELS …………………………………………. 94
INPUTS…………………………………………. 61
DIGITAL IN (DIN) …………………………… 94
FREQUENCY IN (FIN) …………………………. 94
VOLTAGE IN (VIN) …………………………… 94
OUTPUTS………………………………………… 61
CURRENT OUT (COUT) …………………………. 94
DIGITAL OUT (DOUT) …………………………. 94
PWM OUT (PULSE WIDTH MODULATION) …………….. 94
COMPUTER…………………………………………… 61
CONTROL SYSTEM………………………………….. 61
EARLIER MACHINES (6401601 TO 6401620) ………… 63
LATER MACHINES (6401621 AND UP) ……………… 75
IQAN CONTROL SYSTEM COMPONENTS……………………. 61
EARLIER MACHINES (6401601 TO 6401620) ………… 63
LATER MACHINES (6401621 AND UP) ……………… 75
COMPUTER SYSTEM OVERVIEW…………………………….. 61
EARLIER MACHINES (6401601 TO 6401620) ……………. 63
LATER MACHINES (6401621 AND UP) …………………. 75
CURRENT OUT – TROUBLESHOOTING FOR OPEN CIRCUITS ………. 94
DOWNLOADING APPLICATIONS FROM DEALER WEBSITE ………….112
ELECTRICAL KIT – SERVICE AND DIAGNOSTICS ……………..110
ELECTRICAL SYSTEM SCHEMATIC DIAGRAMS …………………130
ERROR MESSAGES AND ALARMS……………………………. 61
FAULT CODES : ERROR MESSAGES …………………….108
MAIN SYSTEM ERRORS ……………………………..101
SYSTEM WARNING MESSAGES ………………………… 98
FAULT CODES : ERROR MESSAGES ………………………..108
ERROR :INPUT HIGH ………………………………108
ERROR: INPUT LOW ……………………………….108
ERROR: OUTPUT HIGH ……………………………..108
ERROR: OUTPUT LOW ………………………………108
ERROR: X-AXIS OR ERROR: Y-AXIS ………………….108
INTERPRETING ERROR MESSAGES ……………………..108
FAULT CODES, READING ACTIVE ENGINE CODES …………….. 86
FUSE AND RELAY PANELS ………………………………124
GAUGES AND ALARMS ………………………………….127
GET APPLICATION ……………………………………118
GET ERROR/EVENT LOG ………………………………..122
ID-TAG …………………………………………… 84
INFORMATION CENTER -IQAN MDM COMPUTER DISPLAY ………… 85
SYSTEM DIAGNOSTICS MENUS ……………………….. 87
DIAGNOSTICS MENU DESCRIPTIONS ……………….. 88
DIAGNOSTICS MENU OPERATION ………………….. 89
SYSTEM WARNING MESSAGES ………………………… 98
AXLE FILTER IN BYPASS WARNING ………………..100
CHARGE FILTER IN BYPASS WARNING ………………100
ENGINE TEMPERATURE WARNING ………………….. 99
HYDRAULIC OIL LEVEL LOW WARNING ……………… 98
HYDRAULIC OIL TEMPERATURE WARNING ……………. 98
LOW COOLANT LEVEL WARNING …………………… 99
MODULE IS OFFLINE SYSTEM WARNING ……………..101
OIL PRESSURE WARNING ……………………….. 98
VOLTAGE WARNING ……………………………. 99
IQAN MODULES……………………………………….. 62
EARLIER MACHINES (6401601 TO 6401620)……………… 62
CONTROL SYSTEM OVERVIEW …………………….. 63
IQAN CONTROL SYSTEM COMPONENTS ………………. 63
LX-A0 JOYSTICK MODULE ………………………. 68
MDM DISPLAY MODULE …………………………. 65
XP2-A0 REAR CHASSIS MODULE ………………….. 72
XS-A0 CAB MODULE …………………………… 66
XT2-A0 FRONT CHASSIS MODULE …………………. 70
LATER MACHINES (6401621 AND UP)…………………… 62
CONTROL SYSTEM OVERVIEW …………………….. 75
IQAN CONTROL SYSTEM COMPONENTS ………………. 75
MDM DISPLAY MODULE …………………………. 77
XP2-A0 REAR CHASSIS MODULE ………………….. 82
XS-A0 CAB MODULE …………………………… 78
XT2-A0 FRONT CHASSIS MODULE …………………. 80
IQAN SOFTWARE ……………………………………..112
DOWNLOADING APPLICATIONS FROM DEALER WEBSITE ………112
GET APPLICATION (DOWNLOAD FROM MDM)……………….. 62
USING A PC/LAPTOP …………………………..119
USING A PDA ………………………………..118
GET ERROR/EVENT LOG……………………………… 62
USING A PC/LAPTOP …………………………..123
USING A PDA ………………………………..122
GRAPHING AND MEASUREMENT OF CHANNELS………………. 62
USING A PC/LAPTOP …………………………..121
USING A PDA ………………………………..120
PDA REGISTRATION ……………………………….112
UPDATING THE IQAN APPLICATION…………………….. 62
FROM A PC/LAPTOP ………………………….116
FROM A PDA …………………………………114
MAIN SYSTEM ERRORS …………………………………101
ENGINE RELATED J1939 CONNECTION ERRORS ……………106
LX-A0 MODULE OFFLINE ERROR ……………………..103
MDM MODULE BLANK SCREEN …………………………101
MODULE IS OFFLINE ………………………………101
XP2-A0 MODULE OFFLINE ERRORS …………………….105
XS-A0 MODULE OFFLINE ERROR ……………………..102
XT2-A0 MODULE OFFLINE ERROR …………………….104
MODULE IS OFFLINE ………………………………….101
PDA REGISTRATION …………………………………..112
READING ENGINE FAULT CODES …………………………. 86
SWITCH AND SENSOR LOCATIONS………………………….. 62
EARLIER MACHINES (6401601 TO 6401620) …………….128
LATER MACHINES (6401621 AND UP) ………………….129
UPDATE APPLICATION …………………………………114
WIRE COLOUR CODE CHART ……………………………..130
SECTION 7 – ENGINE START AND STOP…………………………151
MAIN PUMP UNLOADING VALVE ………………………….153
START CIRCUIT DESCRIPTION…………………………….151
EARLIER MACHINES (6401601 TO 6401620) ……………152
LATER MACHINES (6401621 AND UP) …………………156
START CIRCUIT DIAGRAM………………………………..151
EARLIER MACHINES (6401601 TO 6401620) ……………154
LATER MACHINES (6401621 AND UP) …………………158
SECTION 8 – DRIVE……………………………………….161
CHARGE PUMP ………………………………………..165
CIRCUIT DESCRIPTION …………………………………162
DRIVE CIRCUIT DIAGRAM………………………………..161
6401601 TO 6401620 ………………………………174
6401621 AND UP ………………………………….176
DRIVE CIRCUIT HYDRAULIC SCHEMATIC……………………..161
6401601 TO 6401620 ………………………………175
6401621 AND UP ………………………………….177
DRIVE COUPLING………………………………………161
EARLIER DESIGN…………………………………..161
TORSIONAL DRIVE SHAFT COUPLING BOLT TORQUE ……..183
LATER DESIGN ……………………………………184
DRIVE MOTOR ………………………………………..168
DRIVE MOTOR SPEED VERIFICATION ……………………….179
DRIVE PRESSURE CHECKS AND ADJUSTMENTS …………………180
DRIVE PUMP………………………………………….161
EARLIER DESIGN 6401601 TO 6401620 …………………163
LATER DESIGN 6401621 AND UP ………………………166
DRIVE PUMP PRESSURE CHECKS …………………………..178
HYDRAULIC OIL HEATING PROCEDURE ………………………182
MAXIUMUM SPEED CONTROL DIAL ………………………….173
TRAVEL/ENGINE SPEED PEDALS……………………………161
EARLIER DESIGN 6401601 TO 6401620 …………………170
LATER DESIGN 6401621 AND UP ………………………171
SECTION 9 – BRAKES………………………………………185
ACCUMULATOR…………………………………………185
ACCUMULATOR …………………………………….188
CHARGING AND TESTING DEVICE ………………………188
CHARGING THE ACCUMULATOR …………………………189
CHECKING GAS PRESSURE ……………………………188
BRAKES……………………………………………..185
BRAKE PEDAL VALVE ……………………………….188
FRONT AXLE BRAKE. See SECTION 15…………………..185
PARKING BRAKE …………………………………..196
CHARGING VALVE, ACCUMULATOR ………………………….189
CIRCUIT DESCRIPTION …………………………………190
CIRCUIT DIAGRAM……………………………………..185
6401601 TO 6401620 ………………………………191
6401621 AND UP ………………………………….193
CIRCUIT HYDRAULIC SCHEMATIC…………………………..185
6401601 TO 6401620 ………………………………194
6401621 AND UP ………………………………….195
MAIN PUMP ………………………………………….186
MAIN PUMP UNLOADING VALVE. See SECTION 7……………….185
PARKING BRAKE……………………………………….185
CHECKING FOR PROPER ADJUSTMENT ……………………198
LIMIT SWITCH ……………………………………198
PROXIMITY SENSOR ………………………………..198
PRESSURE SETTINGS, MAIN PUMP …………………………199
PRIORITY VALVE. See SECTION 11………………………..185
SERVICE BRAKE, FRONT AXLE. See SECTION 15………………185
SECTION 10-OIL COOLER/RADIATOR AND CROSS-FLOW FAN…………..201
CIRCUIT DESCRIPTION………………………………….201
FAN ……………………………………………218
OIL COOLER ……………………………………..208
CIRCUIT DIAGRAM……………………………………..201
FAN CIRCUIT……………………………………..201
(EARLIER MACHINES 6401601 TO 6401620) ………….219
(LATER MACHINES 6401621 & UP) …………………221
OIL COOLER CIRCUIT……………………………….201
(EARLIER MACHINES 6401601 TO 6401620) ………….209
(LATER MACHINES 6401621 & UP) …………………211
COOLING PUMP ……………………………………….204
FAN MANIFOLD………………………………………..201
EARLIER DESIGN (6401601 to 6401620) ……………….215
LATER DESIGN (6401621 & UP) ………………………216
FAN MOTOR ………………………………………….217
FAN PUMP …………………………………………..214
FAN SPEED CHECKS ……………………………………224
CHECK FOR NO A/C DURING CLEAN MODE ………………..224
FAN ‘CLEAN’ SPEED ……………………………….224
fan FULL ON speed ……………………………….224
MINIMUM FAN SPEED WITH A/C “ON” …………………..224
FILTER, HYDRAULIC TRIPLE ELEMENT ……………………..205
HYDRAULIC CIRCUIT SCHEMATIC…………………………..201
COOLING CIRCUIT………………………………….201
(EARLIER MACHINES 6401601 TO 6401620) ………….212
(LATER MACHINES 6401621 & UP) …………………213
FAN CIRCUIT……………………………………..201
(EARLIER MACHINES 6401601 TO 6401620) ………….222
(LATER MACHINES 6401621 & UP) …………………223
HYDRAULIC OIL TANK, MAIN …………………………….205
OIL COOLER/ RADIATOR/ cHARGE AIR COOLER ……………….202
SUCTION STRAINER…………………………………….201
EARLIER DESIGN (6401601 TO 6401620) ……………….206
LATER DESIGN (6401621 & UP) ………………………207
SECTION 11 – STEERING AND CENTER JOINT…………………….225
CENTER JOINT………………………………………..234
checking center joint visually for looseness ……….234
checking the center joint preload………………….225
center joint preload adjustment ……………….235
DIAGRAM ………………………………………..235
grease seals – ORIENTATION ……………………….236
lubrication …………………………………….234
maintenance …………………………………….234
PRIORITY VALVE ……………………………………..228
STEER CONTROL VALVE …………………………………226
STEERING……………………………………………225
CIRCUIT DIAGRAM………………………………….225
6401601 TO 6401620 …………………………..231
6401621 AND UP ………………………………233
CIRCUIT HYDRAULIC SCHEMATIC……………………….225
6401601 TO 6401620 …………………………..230
6401621 AND UP ………………………………232
testing the Steering Operation ……………………….236
SECTION 12 – CLAM……………………………………….237
EARLIER MACHINES 6401601 TO 6401620……………………237
CIRCUIT DESCRIPTION ……………………………..246
CIRCUIT DIAGRAM …………………………………247
CONTROL VALVE …………………………………..238
HYDRAULIC SCHEMATIC ……………………………..249
JOYSTICK (IQAN LX-A0 MODULE) See SECTION 6………….237
PRESSURE CHECKS …………………………………254
IQAN MODULES See SECTION 6……………………………237
LATER MACHINES 6401621 AND UP…………………………237
CIRCUIT DESCRIPTION ……………………………..250
CIRCUIT DIAGRAM …………………………………251
CONTROL VALVE …………………………………..241
HYDRAULIC SCHEMATIC ……………………………..253
JOYSTICK (6-BUTTON) ……………………………..245
PRESSURE CHECKS …………………………………256
MAIN PUMP See SECTION 9………………………………237
PRIORITY VALVE See SECTION 11…………………………237
SECTION 14 – DOZER BLADE…………………………………259
CIRCUIT DESCRIPTION………………………………….259
6401601 TO 6401620 ………………………………266
6401621 AND UP ………………………………….270
CIRCUIT DIAGRAM……………………………………..259
6401601 TO 6401620 ………………………………267
6401621 AND UP ………………………………….271
CONTROL VALVE……………………………………….259
6401601 TO 6401620 ………………………………260
6401621 AND UP ………………………………….263
DOZER CONTROL LEVER …………………………………265
HYDRAULIC SCHEMATIC, CIRCUIT………………………….259
6401601 TO 6401620 ………………………………269
6401621 AND UP ………………………………….273
PRESSURE CHECKS……………………………………..259
DOZER UP/DOWN RELIEFS…………………………….259
6401601 TO 6401620 …………………………..274
6401621 AND UP ………………………………276
SECTION 15 – AXLES AND DIFFERENTIAL LOCKS………………….279
AXLE OIL LEVEL CHECK See SECTION 3…………………….279
AXLE OIL LEVEL TOP UP See SECTION 3……………………279
AXLE PUMP ………………………………………….281
AXLES………………………………………………279
capacities ……………………………………..299
DIFFERENTIAL AND DIFFERENTIAL LOCKS ……………….284
OIL capacities ………………………………….299
OSCILLATION SHIM CHECK AND ADJUSTMENT (FRONT AXLE) ….304
Service brakes (front axle only)…………………..279
BRAKE BLEEDING ………………………………286
BRAKE LINING INSPECTION ………………………285
SERVICING BRAKES …………………………….285
BRAKE CIRCUIT See SECTION 9…………………………..279
BRAKE PEDAL See SECTION 9…………………………….279
CIRCUIT DESCRIPTION………………………………….279
6401601 TO 6401620 ………………………………288
6401621 AND UP ………………………………….294
CIRCUIT DIAGRAM……………………………………..279
6401601 TO 6401610 ………………………………289
6401611 TO 6401620 ………………………………291
6401621 AND UP ………………………………….295
FRONT AXLE …………………………………………284
AXLE OIL FILL …………………………………..299
HYDRAULIC SCHEMATIC, CIRCUIT………………………….279
6401601 TO 6401610 ………………………………291
6401611 TO 6401620 ………………………………293
6401621 AND UP ………………………………….297
MANIFOLD DIFFERENTIAL LOCK……………………………279
6401601 TO 6401610 ………………………………282
6401611 AND UP ………………………………….283
pressure settings……………………………………279
axle pilot pressure check and adjustment …………..298
REAR (BOGIE) AXLE …………………………………..287
BOGIE HOUSINGS (2 FILLING POINTS) …………………307
DIFFERENTIAL (1 FILLING POINT) ……………………306
DIFFERENTIAL AND DIFFERENTIAL LOCK ………………..287
DRAINING AND REFILLING BOGIE AXLE …………………306
PLANETARY DRIVES (4 FILLING POINTS) ……………….307
WHEEL INSTALLATION ………………………………….308
TAPERED ASSEMBLY STUD ……………………………308

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TIGERCAT C640C CLAMBUNK SKIDDER SERVICE MANUAL – PDF DOWNLOAD:

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