Tigercat 602 CARRIER OPERATOR'S MANUAL - PDF DOWNLOAD

602 CARRIER

OPERATOR'S MANUAL SERIAL NUMBER 6020101 TO 6020200 SERIAL NUMBER 6021501 TO 6021600

ISSUE 2.1 AUGUST 2017 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat 602 CARRIER TABLE OF CONTENTS

INTRODUCTION.....................................................................................................................................v MACHINE IDENTIFICATION AND SERIAL NUMBERS.........................................................................vi S.A.E. STANDARDS............................................................................................................................. vii NON-APPROVED FIELD PRODUCT CHANGES................................................................................ viii REGULATORY INFORMATION.............................................................................................................ix SAFETY...................................................................................................................................................1 CONTROLS AND OPERATION..............................................................................................................2 LUBRICATION AND MAINTENANCE.....................................................................................................3

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

602 Available Literature Operator’s Manual (This Manual)..........................................................Part No. 51818AENG Service Manual .....................................................................................Part No. 51819AENG Parts Catalog, 602 Swing Boom Skidder..............................................Part No. 51820A Parts Catalog, 602 Dual Winch Skidder................................................Part No. 53030A Vehicle Moving and Transporting Instructions.......................................Part No. 41604AMUL Engine Operation and Maintenance Manual, N45 Tier 2......................Part No. 45045AMUL Engine Operation and Maintenance Manual, N45 Tier 4f.....................Part No. 42939AMUL iii

iv

Tigercat 602 Carrier INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 602 Carrier.

Serial numbers:602 602

Swing Boom Skidder Dual Winch Skidder

6020101 to 6020200 6021501 to 6021600

The 602 Swing Boom Skidder and Dual Winch Skidder are designed for skidding trees in selective felling and clear felling applications in plantations and natural stands.

The operator's manual will assist the operator with the techniques of proper and safe operation of the 602 Carrier. The service manual contains safety and servicing procedures and a preventive maintenance schedule to assist in repair and to ensure optimum machine performance. For manual part numbers, see the title page in each manual.

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

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

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

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

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

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

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

All product or company names that may be mentioned in this publication are trade names, trademarks or registered trademarks of their respective owners.

Tigercat Industries Inc.

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Introduction

Tigercat 602 Carrier

MACHINE IDENTIFICATION AND SERIAL NUMBERS Please record all serial numbers related to this machine below and have ready before calling for assistance.

The machine serial number plate is located inside the cab above the right door.

The machine serial number is also stamped on the front chassis and rear chassis near the centre joint on the right side of the machine.

Machine Model Number:_____________________ Machine Serial Number:_____________________

Cab machine serial number plate location.

Model Year:_______________________________

Front chassis and rear chassis serial number stamp locations.

The engine identification label is located on top of the engine beside the oil fill cap.

The engine serial number is also stamped on the side of the engine, below the exhaust manifold.

Engine Serial Number:______________________ Engine Date of Manufacture:__________________ Engine identification label location.

Engine serial number stamp location. vi

Tigercat 602 Carrier S.A.E. STANDARDS ROLL-OVER PROTECTION STRUCTURES (ROPS) FALLING OBJECTS PROTECTION STRUCTURES (FOPS) OPERATOR PROTECTION STRUCTURES (OPS)

Introduction

* MODIFICATIONS AND REPAIRS:

The integrity of the ROPS, FOPS, OPS structure and its continued ability to provide the level of protection it was designed for could be seriously affected by any modifications to the structure, its mounting or to the chassis to which it is attached.

Tigercat emphasizes that the certification of approval of the ROPS, FOPS, OPS structure will become void if any such modifications take place.

Tigercat may officially grant approval for modifications only by: i)

Written approval of repairs or modifications signed by the Tigercat Engineering Manager; or

ii) Approved modifications officially released by Tigercat.

Both of the above are provided that the work is carried out in the factory approved manner.

Unauthorized modifications and/or repairs made or contributed to by a customer or a Tigercat distributor may result in creating a dangerous situation and therefore the customer or Tigercat distributor will be considered to have assumed the risk involved or be negligent in creating this situation.

Tigercat will not be held responsible for situations arising from having created unauthorized modifications/ changes to the structure.

Operator's cabs are designed to ROPS, FOPS, OPS standards so that they will withstand force and absorb energy during a roll-over (ROPS), when resisting the impact of a falling object (FOPS) and minimize the possibility of operator injury from penetrating objects (OPS). When a permanent deflection of the structure occurs, the structure can no longer provide the original designed level of protection and should be replaced. Attempts to straighten the structure, particularly by the application of heat, can reduce still further the structures remaining capability to protect.

The mounting and the frame or chassis to which the cab is attached is considered an integral part of the ROPS, FOPS, OPS and is included in the design, test and certification of the product.

Contact the Tigercat Service department before attempting any modifications or repair to roll-over protective structures.

PROTECTIVE STRUCTURES CERTIFICATION

Tigercat Industries Inc.

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

• Any alterations must be approved by manufacturer.

MANUFACTURED BY

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

vii

Introduction

Tigercat 602 Carrier

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.

viii

Tigercat 602 Carrier

Introduction

REGULATORY INFORMATION The operator's cab is equipped with standard or optional equipment that is capable of emitting radio frequency fields.

Bluetooth and Wi-Fi exposure limits are significantly less than the maximum permitted for public use.

IMPORTANT! The RemoteLog™ telematics satellite antenna is externally mounted to the operator cab. When transmitting, the external antenna should always be separated from personnel by a minimum distance of 20 cm (8 in). Transmissions can be silenced by placing the telematics system in repair mode.

FEDERAL COMMUNICATIONS COMMISSION NOTIFICATIONS TO USER INTERNAL (OPERATOR'S CAB): Telematics Module (Wi-Fi)

Contains FCC ID: NCMOCG2101

IQAN-G11 (Bluetooth)

Contains FCC ID: VPYLBZY

Radio (Bluetooth)

Contains FCC ID: OPDJHD36A

Radio (Bluetooth)

Contains FCC ID: OPDJHD1635BT

Radio (Bluetooth)

Contains FCC ID: OPDJHD3630BT

EXTERNAL: Inmarsat Modem (Satellite)

Contains FCC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains FCC ID: Q639603N

These devices comply with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and meets the FCC radio frequency (RF) Exposure Guidelines. This equipment has very low levels of RF energy that is deemed to comply without maximum permissive exposure evaluation (MPE).

INDUSTRY CANADA NOTIFICATIONS TO USER INTERNAL (OPERATOR'S CAB): Telematics Module (Wi-Fi)

Contains IC ID: NCMOCG2101

IQAN-G11 (Bluetooth)

Contains IC ID: VPYLBZY

EXTERNAL: Inmarsat Modem (Satellite)

Contains IC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains IC ID: Q639603N

These devices comply with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

This equipment complies with IC radiation exposure limits set forth for an uncontrolled environment and meets RSS-102 of the IC radio frequency (RF) Exposure rules. This equipment has very low levels of RF energy that is deemed to comply without maximum permissive exposure evaluation (MPE).

ix

Introduction

Tigercat 602 Carrier

x

Tigercat 602 Carrier SECTION 1 - SAFETY Read and understand this Safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1

ISSUE 2.1 AUGUST 2017

ARTICULATION LOCK............................................................................................................................. 1.17 AVOID INJURY FROM BACKOVER ACCIDENTS..................................................................................... 1.8 BATTERY DISCONNECT SWITCH......................................................................................................... 1.11 BATTERY SAFETY.................................................................................................................................... 1.8 CAB EXITS.................................................................................................................................................1.9 CAB SAFETY CABLE.............................................................................................................................. 1.17 CAB SUPPORT BRACE.......................................................................................................................... 1.17 COOLING SYSTEM................................................................................................................................. 1.16 DIESEL EXHAUST FLUID (DEF)............................................................................................................... 1.9 EMERGENCY CAB EXITS......................................................................................................................... 1.9 EXHAUST FUMES................................................................................................................................... 1.19 FIRE PREVENTION................................................................................................................................. 1.25 DRY CHEMICAL CLEANUP PROCEDURES....................................................................................... 1.29 FIRE PREVENTION GUIDELINES....................................................................................................... 1.25 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED............................................................... 1.28 WHAT TO DO TO PREPARE FOR A MACHINE FIRE......................................................................... 1.26 WHAT TO DO WHEN A MACHINE FIRE OCCURS............................................................................. 1.27 FIRST AID..................................................................................................................................................1.6 FLUID INJECTION INJURY..................................................................................................................... 1.20 FLUID LEAKS..........................................................................................................................................1.16 GREASE INJECTION INJURY................................................................................................................. 1.21 HYDRAULIC PRESSURE HAZARD........................................................................................................ 1.16 LIGHTNING SAFETY AWARENESS....................................................................................................... 1.22 LOOSE CLOTHING HAZARD.................................................................................................................. 1.16 NOISE LEVEL INSIDE CAB....................................................................................................................... 1.3 PARKING THE MACHINE........................................................................................................................ 1.10 PROTECTIVE CLOTHING......................................................................................................................... 1.4 REMOTE CONTROL SAFETY................................................................................................................. 1.13 SAFETY LABELS..................................................................................................................................... 1.30 SAFETY PRECAUTIONS, GENERAL....................................................................................................... 1.4 SAFETY PRECAUTIONS, OPERATING.................................................................................................... 1.9 SAFETY PRECAUTIONS, SERVICING................................................................................................... 1.14 SAFETY SYMBOLS................................................................................................................................... 1.4 SIGNAL WORDS........................................................................................................................................ 1.4 VIBRATION LEVELS INSIDE CAB............................................................................................................ 1.3 WELDING, PRIOR TO............................................................................................................................. 1.14 WORKING WITH OIL................................................................................................................................. 1.6

Safety

Tigercat 602 Carrier

1.2

Tigercat 602 Carrier

Safety

VIBRATION AND NOISE LEVEL INSIDE CAB VIBRATION AND NOISE LEVEL INFORMATION TO FOLLOW, NOT AVAILABLE AT TIME OF PRINTING.

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

Prolonged exposure to loud noise can cause permanent hearing loss. This machine exceeds 70dB(A) in the cab and exceeds 85dB(A) when servicing machine engine.

Check with your local Safety Commission to determine if hearing protection is required at these levels.

1.3

Safety

Tigercat 602 Carrier

SAFETY SYMBOLS

GENERAL SAFETY PRECAUTIONS Remember that safety is a prime responsibility of all.

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

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

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

The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

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

Understanding Signal Words

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

Follow all instructions from safety inspector and supervisors.

WARNING

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

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

Do not let an untrained person operate the machine.

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

NOTICE NOTICE indicates a potentially damaging situation which, if not avoided, may result in property damage and is not related to personal injury.

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

1.4

Tigercat 602 Carrier

Safety

These safety rules highlight both general and specific measures the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition. Repair or replace damaged labels.

WARNING

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

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

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

Prolonged exposure to loud noise can cause permanent hearing loss.

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

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

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

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

Do not jump off the machine at any time.

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

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

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

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

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

1.5

Safety

Tigercat 602 Carrier

To reduce the risk of fire, machines should be completely cleaned of debris at least daily, particularly around the engine exhaust components. Hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) should be eliminated immediately, always turn the engine off before cleaning machine.

Check all fluid levels.

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

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

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

Machine should be washed completely at every major service.

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

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.

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

Check window and door guards for damage.

Working with oil

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

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

Some advice which should be observed:

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

• • •

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

•

• • • • • •

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

Avoid contact with oil, particularly heated oil.

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

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

Don't put oily rags in your pockets.

Oil soiled clothing should be changes as soon as possible.

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

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

Avoid breathing in oil fumes.

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

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

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

1.6

Tigercat 602 Carrier

Safety

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

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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

If the machine must be transported, make sure that it is adequately secured to the transporting vehicle. Refer to TRANSPORTING INSTRUCTIONS in SECTION 2.

Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components.

Reduce engine speed to LOW IDLE and let run for approximately 5 minutes to allow gradual dissipation of heat and also to reduce turbo speed.

This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

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

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

Install articulation lock whenever the machine is to be transported.

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

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

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

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

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

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.

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

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

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

WARNING Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

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

1.7

Safety

Tigercat 602 Carrier

Avoid Injury from Backover Accidents

WARNING

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

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

Wash hands after handling.

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

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

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

To avoid backover accidents:

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

•

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

•

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

• •

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

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

• •

1.8

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

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

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

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

Keep windows, mirrors and lights in good condition.

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

Tigercat 602 Carrier

Safety FOR TIER 4F MACHINES ONLY:

OPERATING SAFETY PRECAUTIONS

Diesel Exhaust Fluid (DEF) may irritate eyes or skin. Do not get in eyes. Do not get on skin.

First Aid treatment: DEF Contains Urea. If swallowed call a Poison Control Centre or doctor immediately. Do not induce vomiting. If in eyes rinse with water for 15 minutes. If on skin rinse well with water. If irritation persists seek medical treatment.

D

WARNING

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

Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

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

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

Sound the machine horn before starting the machine.

CAB EXITS

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

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

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

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

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

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

Start the engine by following the instructions in this manual. Refer to OPERATING MACHINE in SECTION 2.

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

WARNING

IMPORTANT !

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

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

For additional information, refer to EMERGENCY EXITS in SECTION 3.

36782BENG R0

Never use a liquid staring aid to start an engine.

Secure loose items in cab.

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

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

1.9

Safety

Tigercat 602 Carrier When parking the machine:

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.

•

Park on level ground ONLY and engage parking brake

•

Do not park on a hillside or incline.

•

Before leaving the operator's cab, lower the dozer blade and grapple or shield to the ground and engage the parking brake.• Stop the engine.

•

Release pilot system pressure by performing the following steps:

WARNING

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

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

Never operate the winch from the ground. Control it only from the operator’s seat, with the exception of operation of winch functions by approved remote control (if equipped). Refer to REMOTE CONTROL SAFETY in THIS SECTION.

1. Fully apply brake foot pedal repeatedly until there is no pedal resistance. This may take a minimum of 150 applications.

2. Release pressure from the rear pilot accumulator as follows: a. Turn the ignition key to the RUN position. b. Using the computer from the main menu navigate to INFORMATION MENU (F3) – More...(F3) – Accumulator (F1)

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

Refer to COMPUTER – INFORMATION MODE MENU in SECTION 2 of the OPERATOR'S or SERVICE MANUAL.

c. Check that all personnel are clear of the machine.

Keep the parking brake properly adjusted at all times.

Keep service brakes properly adjusted and check for proper operation of the service brake. Refer to SERVICE BRAKE – CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3.

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

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

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

d. Press and hold the F1 button (test functions) and operate the dozer, arch or boom DOWN functions a minimum of 150 times to release pressure from the rear pilot accumulator.

Do not leave the operator's cab while the winch cable is under tension when operating winch from the operator's seat.

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

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

1.10

Tigercat 602 Carrier

Safety •

OSCILLATION LOCK MANIFOLD

Prior to performing any service work or maintenance on the machine, stop the engine, remove the ignition key and store it in a safe place.

MANUAL OVERRIDE CONTROL

602-061 602-037

OSCILLATION LOCK MANIFOLD

3. For machines equipped with an oscillating centre joint and oscillation lock function pressure must be relieved from the oscillation lock circuit.

602-002

•

a. Turn the ignition key to the OFF position. b. Remove the ignition key.

Turn the battery disconnect switch OFF if the vehicle is to be parked for an extended period of time (Example - overnight) and prior to performing any service work or maintenance on the machine.

b. Turn OFF the battery disconnect switch d. Use the manual override on the oscillation lock manifold to turn the oscillation lock feature OFF mechanically.

WARNING

The manual override is in its normal position pushed in and turned clockwise.

To override, turn counterclockwise and allow stem to extend.

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

e. In addition, trapped pressure in the oscillation lock circuit must to be relieved by adjusting pressure relief 'RV1' to its lowest setting.

Loosen locknut and turn 'RV1' screw OUT (counterclockwise) all the way to minimum setting. Count and record the number of turns so that 'RV1' can be returned to its normal position when work is completed.

NOTE: Normal 'RV1' setting is 65 bar (950 psi).

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use, the risk zone is 60 m (200 feet).

WARNING

4. Pressure may remain in the system after completing all of the above steps. Use caution when loosening hydraulic connections.

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

When reeling in winch cable, make sure all ground personnel are at a safe distance, at least 1 1/2 times the working length of the cable, in case of rolling logs or whipping cables.

Ground personnel should maintain a safe distance, at least 1 1/2 times the working length of the cable, from a winch cable under tension.

1.11

Safety

Tigercat 602 Carrier

When operating the winch with ground personnel, keep the personnel in view at all times and ensure ground personnel are never allowed to be in line with the load.

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

Use only prearranged and approved signalling practices.

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.

Obey flagger's signal and signs Operate the machine only from a seated position in the operator’s seat, with the exception of operation of winch functions by approved remote control (if equipped). Refer to REMOTE CONTROL SAFETY in THIS SECTION. Do not carry passengers either in the cab or anywhere else on the machine.

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

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

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

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

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

Keep load low and close to skidder for best stability.

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

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

Never approach an unstable log from the downhill side.

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

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

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

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

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

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

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

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.

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

1.12

Tigercat 602 Carrier

Safety

REMOTE CONTROL SAFETY If equippped with an approved remote control refer to manufacturer's instructions for information regarding safety and operation of the remote control.

Use remote control only when necessary.

Whenever possible operate winch functions from the operator's seat.

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use.

No occupants should be in the cab while the remote control is in use.

When using the remote control always operate the machine from a safe position at a safe distance from the machine and have an escape route.

Never position yourself downhill from the machine.

Never allow yourself to be in line with the load.

When reeling in winch cable, make sure all ground personnel are at a safe distance, at least 1 1/2 times the working length of the cable, in case of rolling logs or whipping cables.

Ground personnel should maintain a safe distance, at least 1 1/2 times the working length of the cable, from a winch cable under tension.

When operating the winch with ground personnel, keep the personnel in view at all times and ensure ground personnel are never allowed to be in line with the load.

Use only prearranged and approved signalling practices.

Always ensure the remote control switch is in the OFF position before servicing the machine.

1.13

Safety

Tigercat 602 Carrier This machine may be equipped with an optional variable pitch cooling fan, fan blade pitch is hydraulically varied to control the flow and direction of air through the cooler package.

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

SERVICING SAFETY PRECAUTIONS

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

IMPORTANT

24 VOLT

Conduct maintenance inspections at least as frequently as recommended in section 3 this manual.

ELECTRICAL SYSTEM

When servicing or repairing equipment, turn the engine OFF and turn OFF the battery disconnect switch. Some wiring on the machine is live even when the battery disconnect switch is off.

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.

When servicing the electrical system, turn OFF the battery disconnect switch, remove the battery cables from the batteries disconnecting the negative (-) cables first. Perform the service work, then attach the battery cables reconnecting the positive (+) cables first and turn the battery disconnect switch ON.

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

Turn OFF the battery disconnect switch.

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

Disconnect the battery cables from the batteries, negative (-) cables first.

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

DISCONNECT THE TWO MULTI-PIN PLUGS FROM THE ENGINE ECU

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

Always ensure the remote control switch is in the OFF position before servicing the machine. Refer also to REMOTE CONTROL SAFETY in THIS SECTION. The radiator and the engine cooling system should be cleaned and serviced daily to maintain moderate engine temperatures.

602-027

ENGINE ECU DISCONNECT - LEFT SIDE

Disconnect the engine ECU (electronic control unit) by unplugging the two connectors from the left side of the engine.

1.14

Tigercat 602 Carrier

Safety WARNING

FUSE AND RELAY PANEL Remove the MD3 module fuse from the fuse and relay panel 620E-007

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

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

•

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

•

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

LOCATED IN CAB BEHIND LEFT KICK PANEL

CONNECTOR

620E-043

XS2-A0 MODULE - CAB

MOUNTED ON BACK OF OPERATOR SEAT - REMOVE COVER TO ACCESS XA2-A0 FRONT CHASSIS

CONNECTORS

CONNECTOR

LOCATED UNDER CAB, RIGHT REAR - REMOVE COVER TO ACCESS MODULES 602-010

632E-016

Disconnect the other IQAN control module harness connectors. One module is located in the cab. One module is mounted on the back of the operator's seat. Two modules are located under the cab.

XA2 -A0 MODULE

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

When welding is completed reconnect all connectors, ground and fuse then attach the battery cables reconnecting the positive (+) cables first and turn the battery disconnect switch ON.

MC43 MODULE

CONNECTORS

602-009

XC21 MODULE

MC43 MODULE

1.15

Safety

Tigercat 602 Carrier 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 hands to check for fluid leaks.

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

Turn the engine off. Only remove fill cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

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.

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

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

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

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.

WARNING

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

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

1.16

Tigercat 602 Carrier

Safety CAUTION

SAFETY CABLE

620E-033

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.

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE 602-036

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

SUPPORT BRACE

602-063

620E-009

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

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

TILTED CAB SUPPORTED

BY SUPPORT BRACE

Before working under cab, machine must be parked on level ground. Cab must be fully tilted with safety cable completely tight or cab support brace must be installed between frame and cab to prevent injury. Refer to TILTING THE CAB in SECTION 3 for complete instructions.

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

WARNING

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

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

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

1.17

Safety

Tigercat 602 Carrier BOLT ON ACCESS PANELS

All handles should be hand tight only at all times.

This is particularly important for easy access to the pressurized water system in the event of a fire or other emergency. Refer also to FIRE PREVENTION in THIS SECTION. MAINTENANCE ACCESS DOORS BOLT ON ACCESS PANELS 602-053

ACCESS PANELS RIGHT SIDE

CAUTION

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

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

MAINTENANCE ACCESS DOORS

DOOR PROP

602-051

ACCESS PANELS LEFT SIDE

602-062

1.18

MAINTENANCE ACCESS DOOR (LEFT SIDE SHOWN)

Tigercat 602 Carrier

Safety

If the engine is running inside a building, ensure that sufficient ventilation is available to prevent a build-up of toxic exhaust fumes. Run the engine only when it is necessary for testing or adjustments.

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

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

Dispose of fluids properly.

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

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

1.19

Safety

Tigercat 602 Carrier

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

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

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

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

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

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

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

• Seek professional medical attention immediately.

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

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

Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

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

•

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

Time becomes critical as tissue damage • Place the end of a long piece of wood in the progresses rapidly. The longer you delay getting suspected path of any fluid stream. Never use professional medical attention, the more damage any part of your body. can occur.

• Recognize that the source of the leak and the Although fluid injection accidents are rare, the fluid streaming from it may be very small and resulting injury has on occasion required the not easily visible. You may only be able to see amputation of a finger, a hand or in some cases the fluid that accumulates as a result of the the entire limb. The longer the delay in getting fluid stream. professional medical aid, the further up the limb When performing any service work the tissue damage can spread. An injury of this • Stop the engine and relieve all diesel fuel or type can become very serious or even fatal if not hydraulic pressure before disconnecting any dealt with promptly and properly. lines or otherwise working on the system.

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

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

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

1.20

Tigercat 602 Carrier

Safety

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

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

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

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

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

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

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

•

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

•

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

•

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

•

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

•

Remove dirt and grease from grease fittings prior to greasing.

•

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

•

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

1.21

Safety

Tigercat 602 Carrier LIGHTNING SAFETY

LIGHTNING SAFETY AWARENESS

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

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

1. Designate a member of your crew to

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

•

Monitor daily weather forecasts

•

Observe local weather conditions

•

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

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

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

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

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

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

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

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

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

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

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

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

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

1.22

Tigercat 602 Carrier

Safety WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER. If you can, get inside.

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

2. If inside a building:

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

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

•

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

•

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

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

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

This is called the skin effect.

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

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

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

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

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

1.23

•

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

•

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

•

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

•

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

•

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

Safety

Tigercat 602 Carrier What to do if you feel your skin tingling, your hair stands on end, light metal objects vibrate or you hear a crackling sound.

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

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

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

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

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

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

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

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

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

2. Call your local emergency response telephone number immediately.

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

3. If the victim has no pulse, their heart has stopped or they have stopped breathing, start cardiopulmonary resuscitation (CPR) or mouth –to-mouth resuscitation immediately. Use a portable defibrillator if one is available.

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

6. Avoid entering any small enclosures or shelters.

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

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

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

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

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

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

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

11. Do not use the telephone except for emergencies.

1.24

Tigercat 602 Carrier

Safety 4. Clean out all accumulated forest debris (twigs, pine needles, branches, bark, leaves, saw dust, small wood chips) and any other combustible materials from inside the machine belly pans or lower machine structures as well as from areas in proximity to the engine, fuel and hydraulic oil systems no less frequently than at the completion of each work shift.

FIRE PREVENTION

5. Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage.

Check for worn or eroded fuel or hydraulic lines before starting up any equipment.

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

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

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

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

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. 2. Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 3.

3. Blow off all forest debris and fine organic material accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently when working in logging conditions where large amounts of combustible forest debris are present.

Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If dislodged this smoldering debris can fall into other areas of the machine and thereby spread a fire.

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

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

9. Inspect the exhaust system daily for any signs of leakage. Check for worn, cracked, broken or damaged pipes or muffler. Also check for missing or damaged bolts or clamps.

Should any exhaust leaks or defective parts be found, repairs must be made immediately.

Engine exhaust leaks can cause fires. Do not operate the machine until the exhaust leak is repaired.

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

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

12. Never leave the machine parked with boom, arch or blade suspended off the ground. Should their supporting hydraulic hoses burn through during a fire, pressurized hydraulic oil may be injected into the fire and the boom, arch or blade will fall rapidly to the ground.

1.25

Safety

Tigercat 602 Carrier

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

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

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

WHAT TO DO TO PREPARE FOR A MACHINE FIRE

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

•

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

•

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

•

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

•

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

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

Ensure that your fire detection system* is in working order. Refer to FIRE DETECTION SYSTEM in SECTION 2.

Ensure that your fire suppression system** is charged and in working order. Refer to FIRE SUPPRESSION SYSTEM in SECTION 2.

Ensure that you are familiar with the recommended procedures for fire contained in the emergency action plan of your company.

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

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

•

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

•

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

•

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

•

1.26

Tigercat 602 Carrier •

•

•

Safety WHAT TO DO WHEN A MACHINE FIRE OCCURS

Ensure that you follow all national, state / provincial and local regulations dealing with fire fighting in effect in your specific geographic region. Regulations will vary from region to region but most will usually require that: 1. Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

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

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

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

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

•

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

2. Turn the engine OFF. 3. Activate the fire suppression system**.

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

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

6. At all times ensure your own personal safety and the safety of anyone that may be in the area. Approach any fire with extreme caution. All fires can be very dangerous and life threatening.

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

•

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

suppression system** on your machine.

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

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

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

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

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

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

6. If possible a dry chemical fire extinguisher or fire suppression system** should be used first to fight a machine fire.

Then immediately afterwards use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by any debris or hot machine components in the area.

The water will cool the area, reducing the chances of re-ignition.

1.27

Safety •

Tigercat 602 Carrier

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

•

•

•

•

WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED

Pull the pin at the top of the extinguisher that keeps the handle from being pressed.

Break the plastic seal as the pin is pulled.

•

Before returning the machine to work.

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

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

Release the hose before taking aim.

2. Ensure that the fire detection system*

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

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

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

•

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

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

*NOTE: Fire detection systems are offered by

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

**NOTE: Dry chemical fire suppression systems

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

20229A

• • •

• •

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

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

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

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

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

Remain with the machine until help arrives.

1.28

Tigercat 602 Carrier

Safety

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

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

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

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

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

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

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

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

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

Rinse thoroughly with water. Blow-dry to remove all residual water.

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

1.29

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

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

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

Safety

Tigercat 602 Carrier

SAFETY LABELS

NO RIDERS

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

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

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

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

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

1.30

Tigercat 602 Carrier

Safety

USE SEAT BELT

READ OPERATOR'S MANUAL

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

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

Pay close attention to WARNINGS and HAZARD identifications.

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

1.31

Safety OPERATOR'S MANUAL LOCATION

Tigercat 602 Carrier REMOVE IGNITION KEY BEFORE SERVICING THE MACHINE!

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

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

1.32

Tigercat 602 Carrier

Safety

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

ARTICULATION LOCK

REAR CHASSIS

RETAINING PINS

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

602-039

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

602-036

ARTICULATION LOCK STORED POSITION

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

Refer to ARTICULATION LOCK in SECTION 3 for complete instructions.

602-063

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

43304BUNI R0

1.33

Safety

Tigercat 602 Carrier

CRUSH HAZARD

ENTANGLEMENT HAZARD

This label warns of the crush zone by a down force when the cab is in the partial tilt position. DO NOT WORK IN THIS AREA UNTIL THE CAB TILT SUPPORT LOCK IS IN PLACE! Before working under the cab when the cab is in the partial tilt position, be sure the CAB TILT SUPPORT LOCK is in place.

36779BUNI R0

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

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

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

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

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

1.34

Tigercat 602 Carrier

Safety

KEEP CLEAR

DO NOT USE WINCH FOR HOISTING

43424BUNI R0

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

43225BUNI R0

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

Always keep clear of an operating machine.

DO NOT use winch for hoisting.

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

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

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use, the risk zone is 60 m (200 feet).

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

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

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

1.35

Refer to OPERATING MACHINE – OPERATING WINCH and SKIDDING – CABLE SKIDDING in SECTION 2 for instructions regarding the safe use and proper operation of the winch.

Safety

Tigercat 602 Carrier

DO NOT LOOSEN CAP UNTIL COOL

STORED ENERGY HAZARD

33952AUNI R0

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

Turn the engine off. Only remove coolant fill cap when cool enough to touch with bare hands.

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

This label warns of a STORED ENERGY HAZARD. These labels are located on the right side of the front chassis below the cab and in the rear chassis valve compartment.

The machine is equipped with a brake accumulator and rear pilot accumulator. The accumulators have stored hydraulic pressure.

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

DO NOT SERVICE BRAKE ACCUMULATOR BEFORE RELEASING PRESSURE by applying brakes repeatedly with the engine OFF until there is no pedal resistance. This may take a minimum of 150 applications. For the procedure to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION DO NOT SERVICE REAR PILOT ACCUMULATOR BEFORE RELEASING PRESSURE by using the computer display Accumulator Test Function. For the procedure to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION. Refer also to COMPUTER – INFORMATION MODE MENU – ACCUMULATOR INFORMATION in SECTION 2.

1.36

Tigercat 602 Carrier

Safety

FLUID SPRAY HAZARD

EXPLOSION HAZARD

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

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

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

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

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

Contact with fluid under pressure may cause injury.

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

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

Refer also to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3.

1.37

Safety CRUSH HAZARD

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

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

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

In a case where operator controls cannot be used to lower suspended machine elements due to an engine stall or other machine malfunction, suspended elements can be lowered manually.

Refer to DEPRESSURIZING SUSPENDED MACHINE ELEMENTS in SECTION 3.

Tigercat 602 Carrier HAND TIGHT ONLY - ALL HANDLES

This indicates that all handles should be hand tight only at all times.

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

1.38

Tigercat 602 Carrier

Safety

FIRE PREVENTION!

PRESSURIZED WATER SYSTEM INSIDE HAND TIGHTEN ONLY

READ UNDERSTAND AND FOLLOW THE FIRE PREVENTION GUIDELINES IN THIS MANUAL. These guidelines provide all the necessary action required to preventing fires on this machine. DO NOT OPERATE THIS MACHINE until you have read these instructions and have performed any necessary maintenance required that will prevent the potential of a fire from starting on this machine.

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

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

1.39

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

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

All handles should be hand tight only at all times.

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

Safety

Tigercat 602 Carrier

FIRE EXTINGUISHER ACCESS HOLE

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

Refer also to FIRE PREVENTION in THIS SECTION.

1.40

Tigercat 602 Carrier SECTION 2 - CONTROLS & OPERATION 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

ISSUE 2.1 AUGUST 2017

ACCESS PANELS AND DOORS........................................................................................................... 2.107 ARTICULATION LOCK........................................................................................................................... 2.130 BATTERY BOOSTING........................................................................................................................... 2.110 BATTERY BOOSTER CABLE WITH CLAMPS.................................................................................. 2.110 BATTERY DISCONNECT SWITCH........................................................................................................2.111 CAB CONTROLS..................................................................................................................................... 2.12 BRAKE PEDAL ROTATING SEAT & JOYSTICK STEERING..................................................................................... 2.12 COMPUTER DISPLAY......................................................................................................................... 2.32 CONTROL PANEL A/C HEATER CONTROLS - AIR CONDITIONER............................................................................. 2.29 A/C HEATER CONTROLS - AIR SOURCE....................................................................................... 2.29 A/C HEATER CONTROLS - FAN CONTROL................................................................................... 2.29 A/C HEATER CONTROLS - TEMPERATURE.................................................................................. 2.29 AUX (OPTIONAL)............................................................................................................................. 2.24 DIFFERENTIAL LOCK SELECTOR SWITCH SWING BOOM SKIDDER.............................................................................................................. 2.26 FAN CONTROL SWITCH, COOLING............................................................................................... 2.30 HORN, SAFETY ALERT - SWITCH.................................................................................................. 2.26 IGNITION SWITCH........................................................................................................................... 2.24 LIGHTS - SWITCH............................................................................................................................ 2.24 PARKING BRAKE SWITCH.............................................................................................................. 2.24 WINCH CONTROL LEVER SWING BOOM SKIDDER.............................................................................................................. 2.28 WINCH SELECT SWITCH SWING BOOM SKIDDER.............................................................................................................. 2.27 DIFFERENTIAL LOCK SELECTOR SWITCH SWING BOOM SKIDDER................................................................................................................. 2.26 DIFFERENTIAL LOCK(S) ON/OFF SWITCH SWING BOOM SKIDDER................................................................................................................. 2.22 DIRECTION SELECTION SWITCH ROTATING SEAT & JOYSTICK STEERING..................................................................................... 2.14 DOZER BLADE CONTROL LEVER DUAL WINCH SKIDDER................................................................................................................... 2.19 SWING BOOM SKIDDER................................................................................................................. 2.21 DOZER GRAPPLE CONTROL LEVER DUAL WINCH SKIDDER................................................................................................................... 2.18 SWING BOOM SKIDDER................................................................................................................. 2.21 ENGINE SPEED CONTROL, RIGHT JOYSTICK TRIGGER SWING BOOM SKIDDER................................................................................................................. 2.23 ENGINE SPEED/TRAVEL PEDALS ROTATING SEAT & JOYSTICK STEERING..................................................................................... 2.12 FOOT PEDALS, FORWARD FACING AND REAR FACING ROTATING SEAT & JOYSTICK STEERING..................................................................................... 2.12 BRAKE PEDAL.............................................................................................................................. 2.12 TRAVEL/ENGINE SPEED PEDAL................................................................................................ 2.12

Controls and Operation

Tigercat 602 Carrier

HORN, SAFETY ALERT - SWITCH...................................................................................................... 2.26 IGNITION SWITCH............................................................................................................................... 2.24 INSTRUMENT PANEL.......................................................................................................................... 2.32 ALARM LIGHT.................................................................................................................................. 2.32 AUXILIARY POWER OUTLET.......................................................................................................... 2.32 COMPUTER DISPLAY...................................................................................................................... 2.32 COMPUTER USB PLUG................................................................................................................... 2.33 ENGINE DIAGNOSTICS CONNECTION.......................................................................................... 2.33 LIGHTER...........................................................................................................................................2.32 MASTER ALARM.............................................................................................................................. 2.32 STORAGE COMPARTMENT............................................................................................................ 2.33 LEFT JOYSTICK (ROTATING SEAT & JOYSTICK STEERING) DIRECTION SELECTION SWITCH.................................................................................................. 2.14 MAXIMUM SPEED CONTROL......................................................................................................... 2.15 OSCILLATION LOCK SWITCH......................................................................................................... 2.16 STEERING........................................................................................................................................2.14 TRAVEL/ENGINE SPEED TRIGGER............................................................................................... 2.15 MAXIMUM SPEED CONTROL ROTATING SEAT & JOYSTICK STEERING..................................................................................... 2.15 MESSAGES.................................................................................................................... SEE COMPUTER OSCILLATION LOCK SWITCH............................................................................................................ 2.16 REMOTE CONTROL SWITCH............................................................................................................. 2.34 RIGHT ARM REST CONTROL PANEL DUAL WINCH SKIDDER................................................................................................................... 2.18 DIFFERENTIAL LOCK - (FRONT) - SWITCH............................................................................... 2.19 DIFFERENTIAL LOCK - (REAR) -SWITCH.................................................................................. 2.19 DOZER BLADE CONTROL LEVER.............................................................................................. 2.19 DOZER GRAPPLE CONTROL LEVER......................................................................................... 2.18 FAIRLEAD UP/DOWN SWITCH.................................................................................................... 2.19 SHIELD CONTROL LEVER.......................................................................................................... 2.18 WINCH CONTROL LEVER (WINCH 1 & 2).................................................................................. 2.20 WINCH FREESPOOL SWITCH (WINCH 1 & 2)........................................................................... 2.19 RIGHT JOYSTICK SWING BOOM SKIDDER ARCH AND BOOM CONTROLS................................................................................................... 2.22 BOOM AND ARCH CONTROLS................................................................................................... 2.22 DIFFERENTIAL LOCK(S) ON/OFF SWITCH................................................................................ 2.22 GRAPPLE CONSTANT PRESSURE SWITCH............................................................................. 2.22 GRAPPLE OPEN/CLOSE............................................................................................................. 2.23 GRAPPLE ROTATE CONTROLS.................................................................................................. 2.22 TRIGGER SWITCH, ENGINE SPEED CONTROL........................................................................ 2.23 ROTATING SEAT KICK LEVER............................................................................................................ 2.35 SEAT - GRAMMER............................................................................................................................... 2.36 SEAT, ROTATING SEAT KICK LEVER................................................................................................. 2.35 STEERING JOYSTICK......................................................................................................................................... 2.14 TRAVEL/ENGINE SPEED PEDALS ROTATING SEAT & JOYSTICK STEERING..................................................................................... 2.12 TRAVEL/ENGINE SPEED TRIGGER ROTATING SEAT & JOYSTICK STEERING..................................................................................... 2.15 WINCH CONTROLS DUAL WINCH SKIDDER WINCH CONTROL LEVER (WINCH 1 & 2).................................................................................. 2.20 WINCH FREESPOOL SWITCH (WINCH 1 & 2)........................................................................... 2.19 SWING BOOM SKIDDER WINCH CONTROL LEVER........................................................................................................... 2.28 WINCH SELECT SWITCH............................................................................................................ 2.27 2.2

Tigercat 602 Carrier

Controls and Operation

CAB VENTILATION AIR VENTS.........................................................................................................................................2.105 FILTER, FRESH AIR........................................................................................................................... 2.105 FILTER, RECIRCULATING AIR, A/C UNIT......................................................................................... 2.105 CARE OF THE MACHINE...................................................................................................................... 2.129 CENTRE JOINT.....................................................................................................................................2.125 COMPUTER.............................................................................................................................................2.39 ADJUSTMENT MENU EXAMPLE - ADJUSTMENT MENU NAVIGATION............................................................................ 2.51 ADJUSTMENT MENU - ENGINE SETTINGS...................................................................................... 2.46 AUTO RPM.......................................................................................................................................2.46 ENGINE HIGH IDLE ADJUST........................................................................................................... 2.46 WARM UP SPEED............................................................................................................................ 2.46 ADJUSTMENT MENU - FAN SETTINGS (IF EQUIPPED)................................................................... 2.47 CLEAN DURATION........................................................................................................................... 2.47 CLEAN FREQUENCY....................................................................................................................... 2.47 FAN AUTO CLEAN............................................................................................................................ 2.47 ADJUSTMENT MENU - SERVICE SETTINGS.................................................................................... 2.48 AUTO OSCILLATION LOCK............................................................................................................. 2.50 CONSTANT PRESSURE TRIGGER................................................................................................. 2.50 DRIVE TRIGGER (TRAVEL/ENGINE SPEED TRIGGER)................................................................ 2.50 FRONT TIRE SIZE............................................................................................................................ 2.48 HYDRAULIC OIL GRADE................................................................................................................. 2.48 LOAD SENSE OVERRIDE............................................................................................................... 2.50 PROGRAM MODE............................................................................................................................ 2.49 STEERING RATE (JOYSTICK STEERING ONLY)........................................................................... 2.49 STEER INVERT (JOYSTICK STEERING ONLY)............................................................................. 2.49 TRAVEL SPEED DIRECTION SYNC................................................................................................ 2.50 TRAVEL SPEED STEP MODE......................................................................................................... 2.50 COMPUTER CONTROL SYSTEM....................................................................................................... 2.40 COMPUTER CONTROL SYSTEM COMPONENTS............................................................................ 2.40 COMPUTER ELECTRONIC CONTROL & DISPLAY........................................................................... 2.39 COMPUTER MAIN MENU.................................................................................................................... 2.41 ENGINE COOLANT TEMPERATURE GAUGE.................................................................................... 2.43 ENGINE MENU - ENGINE FUNCTIONS.............................................................................................. 2.43 BOOST PRESSURE......................................................................................................................... 2.44 CHARGE AIR TEMPERATURE........................................................................................................ 2.43 COOLANT TEMPERATURE............................................................................................................. 2.43 ENGINE HOURS............................................................................................................................... 2.44 ENGINE OIL TEMPERATURE.......................................................................................................... 2.43 ENGINE SPEED (RPM).................................................................................................................... 2.44 ENGINE VOLTAGE........................................................................................................................... 2.44 ENG % TORQUE.............................................................................................................................. 2.44 FUEL RATE....................................................................................................................................... 2.44 FUEL TEMPERATURE..................................................................................................................... 2.44 OIL PRESSURE................................................................................................................................ 2.44 ENGINE TACHOMETER GAUGE........................................................................................................ 2.44 HYDRAULIC OIL TEMPERATURE GAUGE......................................................................................... 2.56 INFORMATION MODE MENU.............................................................................................................. 2.53 ACCUMULATOR INFORMATION..................................................................................................... 2.55 CLUTCH PRESSURE....................................................................................................................... 2.57 DIFFERENTIAL PRESSURE............................................................................................................ 2.57 DRIVE MOTOR SPEED.................................................................................................................... 2.56 DRIVE PRESSURE FORWARD....................................................................................................... 2.56 DRIVE PRESSURE REVERSE........................................................................................................ 2.56 GRAPPLE CONSTANT PRESSURE................................................................................................ 2.57 2.3

Controls and Operation

Tigercat 602 Carrier

HYDRAULIC FILTER PRESSURE.................................................................................................... 2.57 HYDRAULIC OIL TEMPERATURE................................................................................................... 2.56 LOAD SENSE PRESSURE.............................................................................................................. 2.57 MACHINE HOURS............................................................................................................................ 2.56 MAIN PUMP PRESSURE................................................................................................................. 2.57 PARKING BRAKE PRESSURE........................................................................................................ 2.57 PILOT PRESSURE........................................................................................................................... 2.57 SERIAL NUMBER............................................................................................................................. 2.56 SERVICE BRAKE PRESSURE......................................................................................................... 2.57 TELEMATICS INFORMATION.......................................................................................................... 2.55 TOTAL FUEL INFORMATION........................................................................................................... 2.57 TRANSMISSION TEMPERATURE................................................................................................... 2.57 TRAVEL SPEED............................................................................................................................... 2.56 TRIP FUEL INFORMATION.............................................................................................................. 2.57 MAIN MENU.........................................................................................................................................2.41 MAIN MENU PAGE............................................................................................................................... 2.58 MAIN MENU PAGE - ADJUST MENU.................................................................................................. 2.59 CUSTOM ADJUST GROUP.............................................................................................................. 2.61 OPERATOR ADJUST GROUP DUAL WINCH SKIDDER............................................................................................................... 2.60 SWING BOOM ADJUST GROUP SWING BOOM SKIDDER.............................................................................................................. 2.60 MAIN MENU PAGE - INFO MENU....................................................................................................... 2.67 LOGS................................................................................................................................................2.68 MODULES......................................................................................................................................... 2.68 MAIN MENU PAGE - MEASURE MENU.............................................................................................. 2.62 MAIN MENU PAGE - PREFERENCES MENU..................................................................................... 2.63 DATE/TIME ADJUSTMENT.............................................................................................................. 2.65 DISPLAY ADJUSTMENT.................................................................................................................. 2.64 LANGUAGE ADJUSTMENT............................................................................................................. 2.67 MESSAGES..........................................................................................................................................2.69 ALERT MESSAGES (YELLOW)....................................................................................................... 2.87 CRITICAL MESSAGES (RED)......................................................................................................... 2.70 ERROR MESSAGES (RED)............................................................................................................. 2.83 INFORMATION MESSAGES (BLUE)............................................................................................. 2.102 MESSAGES - ALERT CONTROL SYSTEM - REMOTE CONTROLS ACTIVATED............................................................. 2.91 DIESEL EXHAUST FLUID < 5%....................................................................................................... 2.96 DIESEL EXHAUST FLUID LEVEL <10%.......................................................................................... 2.96 DIESEL EXHAUST FLUID LEVEL EMPTY....................................................................................... 2.96 DIESEL EXHAUST FLUID QUALITY................................................................................................ 2.97 DRIVE CHARGE FILTER BYPASSED.............................................................................................. 2.89 DRIVE CHARGE SYSTEM PRESSURE LOW................................................................................. 2.90 DRIVE TRIGGER INTERLOCK........................................................................................................ 2.91 ENGINE AIR INTAKE FILTER RESTRICTED................................................................................... 2.88 ENGINE COOLANT TEMPERATURE HIGH.................................................................................... 2.95 ENGINE FAULT CODE MESSAGES - ALERT.................................................................................. 2.98 ENGINE TORQUE DERATE ACTIVE............................................................................................... 2.97 ENGINE VOLTAGE HIGH................................................................................................................. 2.95 ENGINE VOLTAGE LOW.................................................................................................................. 2.95 FUEL LEVEL LOW............................................................................................................................ 2.88 FUEL - WATER IN FUEL................................................................................................................... 2.95 HARDWARE FAILURE - COUT........................................................................................................ 2.94 HARDWARE FAILURE - DIN............................................................................................................ 2.94 HARDWARE FAILURE - DOUT........................................................................................................ 2.94 HARDWARE FAILURE - VIN............................................................................................................ 2.94 2.4

Tigercat 602 Carrier

Controls and Operation

HARDWARE FAULT - MC43............................................................................................................. 2.92 HARDWARE FAULT - MD3............................................................................................................... 2.92 HARDWARE FAULT - XA2................................................................................................................ 2.93 HARDWARE FAULT - XC21............................................................................................................. 2.92 HARDWARE FAULT - XS2................................................................................................................ 2.92 JOYSTICK BUTTON INTERLOCK.................................................................................................. 2.91 JOYSTICK & PEDAL INTERLOCK................................................................................................... 2.91 MACHINE VOLTAGE HIGH.............................................................................................................. 2.90 MACHINE VOLTAGE LOW............................................................................................................... 2.90 MAIN FUEL FILTER CLOGGED....................................................................................................... 2.89 MODULE HIGH SUPPLY VOLTAGE - ALERT................................................................................ 2.100 MODULE HIGH TEMPERATURE - ALERT....................................................................................... 2.99 MODULE LOW SUPPLY VOLTAGE - ALERT................................................................................. 2.101 PILOT MANIFOLD PRESSURE HIGH.............................................................................................. 2.89 SERVICE BRAKE PRESSURE LOW............................................................................................... 2.90 TRANSMISSION FILTER BYPASSED.............................................................................................. 2.89 MESSAGES - CRITICAL AFTERTREATMENT SYSTEM ENGINE IDLE TOO LONG............................................................. 2.79 AFTERTREATMENT SYSTEM TECHNICAL FAILURE.................................................................... 2.78 DRIVE MOTOR CLUTCH PRESSURE HIGH................................................................................... 2.73 DRIVE MOTOR CLUTCH PRESSURE LOW................................................................................... 2.71 DRIVE MOTOR CLUTCH SLOW RESPONSE................................................................................. 2.73 DRIVE MOTOR OVERSPEED.......................................................................................................... 2.71 ENGINE COOLANT LEVEL LOW..................................................................................................... 2.78 ENGINE COOLANT TEMPERATURE HIGH.................................................................................... 2.77 ENGINE COOLANT TEMPERATURE HIGH - ENGINE DERATE.................................................... 2.77 ENGINE FAULT CODE MESSAGES - CRITICAL............................................................................. 2.82 ENGINE LOCKED OUT.................................................................................................................... 2.79 ENGINE OIL PRESSURE LOW........................................................................................................ 2.80 ENGINE OIL PRESSURE LOW - ENGINE DERATE........................................................................ 2.80 ENGINE OIL TEMPERATURE HIGH................................................................................................ 2.82 ENGINE OVERSPEED..................................................................................................................... 2.81 ENGINE OVERSPEED MAX............................................................................................................ 2.81 ENGINE RESTARTS REMAINING UNTIL ENGINE LOCKOUT....................................................... 2.80 FUNCTIONS ACTIVE........................................................................................................................ 2.74 HARDWARE FAULT - ENGINE......................................................................................................... 2.75 HARDWARE FAULT - MC43............................................................................................................. 2.76 HARDWARE FAULT - MD3............................................................................................................... 2.75 HARDWARE FAULT - XA2................................................................................................................ 2.76 HARDWARE FAULT - XC21............................................................................................................. 2.76 HARDWARE FAULT - XS2................................................................................................................ 2.76 HYDRAULIC OIL FILTER BYPASS................................................................................................... 2.74 HYDRAULIC OIL LEVEL LOW.......................................................................................................... 2.71 HYDRAULIC OIL TEMPERATURE HIGH......................................................................................... 2.72 INTERLOCK SYSTEM...................................................................................................................... 2.72 LH DRIVE MOTOR SPEED SENSOR FAULT.................................................................................. 2.73 MAIN FUEL FILTER CLOGGED ENGINE DERATE......................................................................... 2.75 RH DRIVE MOTOR SPEED SENSOR FAULT OR CLUTCH SLIP.................................................. 2.73 TRANSMISSION OIL TEMPERATURE HIGH.................................................................................. 2.72 MESSAGES - ERROR CURRENT OUTPUT ERROR (COUT)............................................................................................. 2.86 DIGITAL INPUT ERROR (DIN)......................................................................................................... 2.86 DIGITAL OUTPUT ERROR (DOUT)................................................................................................. 2.86 MODULE NO CONTACT ERROR.................................................................................................... 2.84 MODULE VREF ERROR.................................................................................................................. 2.85 VOLTAGE INPUT ERROR (VIN)....................................................................................................... 2.86 2.5

Controls and Operation

Tigercat 602 Carrier

MESSAGES - INFORMATION MACHINE STEERING INVERT DISABLED................................................................................... 2.104 SETUP MODE - DRIVE MOTOR SETUP....................................................................................... 2.103 SETUP MODE - DRIVE PUMP POR SETUP................................................................................. 2.103 SETUP MODE - DRIVE PUMP REGULATION SETUP.................................................................. 2.103 SETUP MODE - ENGINE HP TEST................................................................................................ 2.103 SETUP MODE - FUNCTION SETUP.............................................................................................. 2.103 SETUP MODE - MAX CURRENT SETUP MODE.......................................................................... 2.103 DIESEL EXHAUST FLUID (DEF) LEVEL MESSAGES............................................................................ 2.96 DIESEL EXHAUST FLUID (DEF) QUALITY MESSAGES....................................................................... 2.97 DOORS AND ACCESS PANELS........................................................................................................... 2.107 ENGINE FAULT CODE MESSAGES - ALERT......................................................................................... 2.98 ENGINE FAULT CODE MESSAGES - CRITICAL.................................................................................... 2.82 FIRE EXTINGUISHER, PORTABLE...................................................................................................... 2.106 FIRE PREVENTION FIRE EXTINGUISHER, PORTABLE................................................................................................... 2.106 PRESSURIZED WATER SYSTEM..................................................................................................... 2.112 GRAPPLE, OPERATING........................................................................................................................ 2.125 MACHINE WARM UP OPERATION....................................................................................................... 2.119 MACHINE WARM UP SPEED ADJUSTMENT....................................................................................... 2.120 MESSAGES....................................................................................................................... SEE COMPUTER MOVING INSTRUCTIONS................................................................................. SEE SEPARATE BOOKLET OPERATING MACHINE......................................................................................................................... 2.113 CENTRE JOINT.................................................................................................................................. 2.125 MACHINE WARM UP OPERATION................................................................................................... 2.119 MACHINE WARM UP SPEED ADJUSTMENT................................................................................... 2.120 OPERATING GRAPPLE..................................................................................................................... 2.125 OPERATING WINCH.......................................................................................................................... 2.126 PRE-START CHECKS........................................................................................................................ 2.113 RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL............................................................. 2.123 STARTING ENGINE........................................................................................................................... 2.117 STARTING IN COLD WEATHER........................................................................................................ 2.118 STOPPING ENGINE........................................................................................................................... 2.123 SYSTEM TEST AND WARM UP........................................................................................................ 2.122 TRAVELLING WITHOUT A LOAD...................................................................................................... 2.124 OSCILLATION LOCK MANUAL OVERRIDE........................................................................................... 2.17 PARKING BRAKE SWITCH..................................................................................................................... 2.24 PICTOGRAM DESCRIPTIONS.................................................................................................................. 2.8 PRE-START CHECKS........................................................................................................................... 2.113 RADIO, AM/FM CD................................................................................................................................. 2.106 RADIO, CB (IF EQUIPPED)................................................................................................................... 2.106 RETRIEVAL POINTS............................................................................................................................. 2.131 ROTATING SEAT KICK LEVER............................................................................................................... 2.35 SKIDDING CABLE SKIDDING.............................................................................................................................. 2.128 GRAPPLE SKIDDING........................................................................................................................ 2.128 SAFETY..............................................................................................................................................2.127 SKIDDING TECHNIQUE.................................................................................................................... 2.127 STARTING ENGINE............................................................................................................................... 2.117 STEERING JOYSTICK STEERING......................................................................................................................... 2.14 2.6

Tigercat 602 Carrier

Controls and Operation

STEP COMPARTMENTS....................................................................................................................... 2.109 STEREO, AM/FM CD............................................................................................................................. 2.106 STOPPING ENGINE.............................................................................................................................. 2.123 SYSTEM MESSAGES....................................................................................................... SEE COMPUTER SYSTEM TEST AND WARM UP............................................................................................................ 2.122 TELEMATICS INFORMATION................................................................................................................. 2.55 TILT CAB..............................................................................................................................SEE SECTION 3 TOWING INSTRUCTIONS - EHS TRANSMISSION.............................................................................. 2.135 TOWING INSTRUCTIONS - SINGLE SPEED MECHANICAL TRANSMISSION.................................. 2.134 TRANSMISSION DIPSTICK....................................................................................................................2.111 TRANSMISSION OIL FILL LOCATION...................................................................................................2.111 TRANSPORTING INSTRUCTIONS....................................................................................................... 2.132 LIFTING POINTS................................................................................................................................ 2.133 TIE DOWN POINTS............................................................................................................................ 2.133 WINCH, OPERATING............................................................................................................................ 2.126

2.7

Controls and Operation

Tigercat 602 Carrier

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

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

or FAST =

and the rabbit

that are often used to describe

.

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

= Accumulator (Information Icon)

= Boom UP = Adjustment Menu Icon

OR

= Brake

= Air Conditioner ON

=Cigarette Lighter, 24 Volt

= Air Conditioner OFF

= Clutch Pressure (EHS Transmission only)

= Air Source, Fresh Air

= Control lever, multidirectional

= Air Source, Recirculate

= Control lever, dual direction

= Alert Message Symbol

= Critical Message Symbol

= Arch IN

= Diesel Exhaust Fluid (DEF, AUS32, AdBlue)

= Arch OUT

= Differential Locks (ON/OFF)

= Auxiliary Power Outlet 12 V

= Differential Lock, Front

= Battery CONNECT / Voltage = Differential Locks, Front and Rear = Battery DISCONNECT

2.8

Tigercat 602 Carrier

Controls and Operation

= Differential Lock, Rear

= Engine Oil Pressure

= Differential Pressure (between Main Pump and Load Sense pressures)

= Engine Oil Temperature

= Engine Run = Dozer Blade DOWN = Engine Start = Dozer Blade UP = Engine Stop = Dozer Grapple Close = Engine Speed Control = Dozer Grapple Open = Engine Speed/travel = Drive Motor Speed = Engine Speed = Drive Pressure Forward = Engine Torque % = Drive Pressure Reverse

= Engine Wait to start

= Engine Boost Pressure

= Error Message Symbol

= Engine Charge Air Temperature

= Fairlead down

= Engine Coolant Temperature

= Fairlead up

= Engine Fan, Variable Pitch, Full On

= Foot Pedal Control = Fuel Information, Total Usage

= Engine Fan, Variable Pitch, Auto

= Fuel

= Engine Fan, Variable Pitch, Clean

= Fuel Diesel

= Engine Hours

= Fuel Reset / Trip Fuel Information = Engine Menu Icon 2.9

Controls and Operation

Tigercat 602 Carrier = Main Pump Pressure

= Grapple CLOSE

= Grapple Constant Pressure

= Maximum speed control

= Grapple OPEN

= OFF

= Grapple Rotate Clockwise

= ON

= Grapple Rotate Counter Clockwise

= Oscillation Lock

= Hand tighten only

P

= Horn

= Parking Brake = Pilot Pressure (Multifunction Manifold)

= Hydraulic Filter Bypass

= Shield DOWN = Hydraulic oil level = Shield UP = Hydraulic Oil Temperature = Serial Number = Imperial/Metric Toggle Symbol

= Speed FAST or HIGH = Speed SLOW or LOW

= Information Menu Icon = Steer Left = Information Message Symbol = Steer Left (Seat Forward Facing)

= Lights, Work = Load Sense Pressure

= Steer Left (Seat Rear Facing)

= Machine Hours

= Steer Right

= Machine Warm Up

2.10

Tigercat 602 Carrier

Controls and Operation

= Steer Right (Seat Forward Facing)

= Travel FORWARD (Seat Rear Facing)

= Steer Right (Seat Rear Facing)

= Travel REVERSE

= Telematics = Travel REVERSE (Seat Forward Facing) = Telematics, Connectivity = Travel REVERSE (Seat Rear Facing) = Telematics, Messages sent/recorded = Travel Speed = Telematics, Latitude = Ventilation Blower Fan = Telematics, Longitude

= Volume, FULL

= Volume, EMPTY

= Temperature

= Voltage / Battery CONNECT

= Transmission Temperature (EHS)

= Winch = Travel Direction = Winch Brake (Dynamic) = Travel Direction (Seat Forward Facing)

= Winch Freespool

= Winch IN

= Travel Direction (Seat Rear Facing)

= Travel FORWARD

= Travel FORWARD (Seat Forward Facing)

2.11

Controls and Operation

Tigercat 602 Carrier

IMPORTANT !

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

CAB CONTROLS B

A

B

A

620E-014

Rear Facing Foot Pedals (Seat Facing Rear Of Machine)

632E-025

Forward Facing Foot Pedals (Seat Facing Front Of Machine)

A Travel/Engine Speed Pedal B Brake Pedal

A Travel/Engine Speed Pedal B Brake Pedal

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

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

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

Refer to LEFT JOYSTICK – DIRECTION SELECTION SWITCH in THIS SECTION. This function can also be performed with the travel/engine speed trigger. Refer also to CAB CONTROLS – LEFT JOYSTICK (ROTATING SEAT & JOYSTICK STEERING) – TRAVEL/ ENGINE SPEED TRIGGER in THIS SECTION.

BRAKE PEDAL (ROTATING SEAT & JOYSTICK STEERING) Press the foot pedal to apply the hydraulic brakes in the front axle. This will also apply braking to the rear axle since they are mechanically locked together by the drive shafts and transmission.

NOTE: As a safety precaution before working on or around the machine; After the engine has been turned off, depress this pedal repeatedly until there is no pedal resistance to relieve any pressure that may be stored in the hydraulic system. This may take a minimum of 150 applications.

Check service brake for proper operation daily.

Refer to SERVICE BRAKE – CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3.

FORWARD FACING PEDALS AND REAR FACING PEDALS (ROTATING SEAT & JOYSTICK STEERING) The rotating seat cab is equipped with two sets of pedals one set forward facing and the other set rear facing.

Note that control of machine travel is automatically transferred by the computer control system from the forward facing travel/engine speed pedal to the rear facing travel/engine speed pedal based on the 2.12

Tigercat 602 Carrier

Controls and Operation

position of the operator's seat. Both brake pedals operate regardless of seat position.

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

2.13

Controls and Operation LEFT JOYSTICK

Tigercat 602 Carrier

(ROTATING SEAT & JOYSTICK STEERING) D

A

B

C

FORWARD FACING SEAT

632E-026

A B C D

Left Joystick

Direction Selection Switch Maximum Speed Control Travel/Engine Speed Trigger Oscillation Lock Switch

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

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

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

Refer to COMPUTER – MESSAGES INFORMATION – MACHINE STEERING INVERT DISABLED and COMPUTER – ADJUSTMENT MENU - SERVICE SETTINGS – STEER INVERT (JOYSTICK STEERING ONLY) in THIS SECTION.

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

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

For safe operation of all controls the operator's seat must be locked in either the forward facing or rear facing position. Refer also to ROTATING SEAT KICK LEVER in THIS SECTION. DIRECTION SELECTION SWITCH (ROTATING SEAT & JOYSTICK STEERING) This switch selects the direction of travel for the travel/engine speed pedal in use (either forward facing or rear facing).

This is a three position switch.

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

Place switch in the centre position for neutral.

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

*NOTE: Control of machine travel is automatically transferred by the computer control system from the forward facing travel/engine speed pedal to the rear facing travel/engine speed pedal based This machine is equipped with variable ratio load on the position of the operator's seat. Therefore sensing steering. The speed that the vehicle FORWARD and REVERSE as described above responds to the steering control input will vary, are considered to be forward and reverse as depending on the speed at which the steering viewed by the operator either from the forward control is moved.

2.14

Tigercat 602 Carrier

Controls and Operation

facing seat position or the rear facing seat position.

Refer also to FOOT PEDALS, FORWARD FACING AND REAR FACING – TRAVEL/ENGINE SPEED PEDAL and ROTATING SEAT KICK LEVER in THIS SECTION. MAXIMUM SPEED CONTROL (ROTATING SEAT & JOYSTICK STEERING) The maximum speed control allows the operator to set the maximum travel speed of the machine to maintain a given travel speed without having to feather the drive pedal.

Push and hold control forward to increase the maximum travel speed. Control spring returns to centre when released.

Pull and hold control back to decrease the maximum travel speed of the machine. Control returns to centre when released.

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

Small movements of this control change setting slowly. Larger movements of this control change settings faster.

NOTE: Maximum speed control settings for forward and reverse travel can be adjusted to the same setting (factory default) or independently.

Refer to COMPUTER – ADJUSTMENT MENU -SERVICE SETTINGS – TRAVEL SPEED DIRECTION SYNC in THIS SECTION. NOTE: Maximum speed control settings can be adjusted in increments of 1% (factory default) or in steps (0%,5%,10%,15%,20%,30%,40%,5 0%,60%,80%,100%). Refer to COMPUTER – ADJUSTMENT MENU -SERVICE SETTINGS – TRAVEL SPEED STEP MODE in THIS SECTION. TRAVEL/ENGINE SPEED TRIGGER (ROTATING SEAT & JOYSTICK STEERING) The drive trigger (travel/engine speed trigger) service setting must be set to ON to enable this control to function. Refer to COMPUTER – ADJUSTMENT MENU - SERVICE SETTINGS – Drive Trigger (Travel/Engine Speed Trigger) in THIS SECTION. Pull trigger to drive in the direction selected on the direction selection switch on the left joystick.

When adjusting maximum speed control computer display will show setting (Turtle 0% to 100% Rabbit).

A maximum speed control setting indicator is also shown on the top right side of the main menu of the computer display (Turtle 0% to 100% Rabbit).

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

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

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

Refer to LEFT JOYSTICK – DIRECTION SELECTION SWITCH in THIS SECTION. This function can also be performed with the travel/engine speed pedal. Refer also to CAB CONTROLS – TRAVEL/ENGINE SPEED PEDAL (ROTATING SEAT & JOYSTICK STEERING) in THIS SECTION.

2.15

Controls and Operation D

A

Tigercat 602 Carrier B

C

HYDRAULIC CYLINDERS

632E-026

A B C D

Left Joystick

Direction Selection Switch Maximum Speed Control Travel/Engine Speed Trigger Oscillation Lock Switch

FRONT CHASSIS 602-043

The oscillation lock switch can be operated in Automatic or Manual mode. For more information refer to COMPUTER – ADJUSTMENT MENU SERVICE SETTINGS – Auto Oscillation Lock in THIS SECTION.

OSCILLATION LOCK

MANUAL MODE When operated in Manual mode oscillation lock is manually controlled by the operator.

AUTOMATIC MODE When operated in Automatic mode the oscillation lock is automatically locked whenever the machine is not travelling and automatically unlocked when travel is resumed. The oscillation lock icon on the main menu of the computer display will be illuminated when the oscillation locks are on (when the machine is stopped).

Press this switch to turn ON the oscillation lock override feature. The oscillation lock is locked at all times.

REAR CHASSIS

The a small lock symbol at the bottom right of oscillation lock icon on the main menu of the computer display will be illuminated when the oscillation lock override feature is ON.

OSCILLATION LOCK SWITCH

The oscillation lock switch acts as an oscillation lock override in automatic mode (with Auto Oscillation Lock set to ON). Refer to COMPUTER – ADJUSTMENT MENU - SERVICE SETTINGS – Auto Oscillation Lock in THIS SECTION.

OSCILLATION JOINT

The oscillation lock switch acts as an on/off switch in Manual mode (with Auto Oscillation Lock set to OFF). Refer to COMPUTER – ADJUSTMENT MENU - SERVICE SETTINGS – Auto Oscillation Lock in THIS SECTION. Press this switch to turn ON the oscillation lock function. When this function is ON the oscillation lock, between the front chassis and rear chassis, is locked at all times.

Press the switch again to turn OFF the oscillation lock function allowing free oscillation between the front chassis and rear chassis at all times.

The oscillation lock icon on the main menu of the computer display will be illuminated when the oscillation lock switch is ON.

Press the switch again to turn OFF the oscillation lock override feature. The oscillation lock is automatically locked whenever the machine is not travelling and automatically unlocked when travel is resumed 2.16

Tigercat 602 Carrier

Controls and Operation

OSCILLATION LOCK MANIFOLD

MANUAL OVERRIDE CONTROL

RV1

602-061

OSCILLATION LOCK MANIFOLD The centre joint oscillation lock system consists of two hydraulic cylinders mounted on the rear chassis, the oscillation lock manifold located in the rear valve compartment and the oscillation lock switch.

602-037

NOTE: There is a manual override on the control valve, that can be used to turn the oscillation lock feature OFF mechanically. The manual override is in its normal position pushed in and turned clockwise. To override, turn counterclockwise and allow stem to extend.

In addition to the manual override trapped pressure in the oscillation lock circuit must to be relieved by adjusting pressure relief 'RV1' to its lowest setting before performing work on components, or disconnecting any hoses. Refer to PARKING THE MACHINE in SECTION 1 for complete instructions.

WARNING The machine is equipped with a brake accumulator and rear pilot accumulator. The accumulators have stored hydraulic pressure.

Servicing the accumulators or any hydraulic components before releasing pressure could result in death or serious injury. For the procedure to RELIEVE PRESSURE, refer to PARKING THE MACHINE in SECTION 1.

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower grapple and dozer blade to the ground and relieve trapped pressure from the brake accumulator, rear pilot accumulator and oscillation lock system (if equipped) before performing work on components, or disconnecting any hoses. For the procedure to RELIEVE PRESSURE, refer to PARKING THE MACHINE in SECTION 1.

Pressure may remain in the system after completing all the steps in the parking the machine procedure. Use caution when loosening hydraulic connections.

2.17

Controls and Operation

Tigercat 602 Carrier A

B

D

C

E

F G

H

G

H

DW602-001

A B C D

Right Arm Rest Control Panel (Dual Winch Skidder)

Shield Dozer Grapple Control Lever (if equipped) Dozer Blade Control Lever Differential Lock Front Switch

E F G H

Differential Lock Rear Switch Fawirlead Up/Down Switch Winch Freespool Switch (Winch 1 & 2) Winch Control Lever (Winch 1 & 2)

RIGHT ARM REST CONTROL PANEL DUAL WINCH SKIDDER

A. SHIELD CONTROL LEVER Pull the lever BACK to RAISE the shield.

Push the lever FORWARD to LOWER the shield.

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

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

WARNING

B. DOZER GRAPPLE CONTROL LEVER Pull the lever BACK to OPEN grapple.

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

the dozer

Push the lever FORWARD to CLOSE dozer grapple.

the

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

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

2.18

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

Tigercat 602 Carrier

Controls and Operation

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

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

the dozer

Push the lever FORWARD to LOWER dozer blade.

the

Press the bottom of the switch to turn the rear differential lock OFF.

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

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

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

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

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

F.

D. DIFFERENTIAL LOCK - (FRONT) - SWITCH

FAIRLEAD UP/DOWN SWITCH This is a three position momentary switch used to operate the adjustable fairlead up/ down function.

This is a two position switch used to turn the front axle differential lock ON or OFF. Press the top of the switch to turn the front differential lock ON. This will lock up the front axle differential and provide drive torque to both front wheels.

Press and hold the top of the switch to move the adjustable fairlead UP.

The front differential locks can be engaged or disengaged while the machine is in motion.

This switch returns to the neutral position when released.

Press and hold the bottom of the switch to move the adjustable fairlead DOWN.

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

G. WINCH FREESPOOL SWITCH (WINCH 1 & 2) This is a two position switch used to turn the winch freespool function ON or OFF.

Press the bottom of the switch to turn the front differential lock OFF. Note: This machine is equipped with a 10 minute AUTO-OFF feature which automatically deactivates the differential locks after 10 minutes have passed.

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

When the winch freespool switch is in the ON position it disengages the winch brake.

This permits the cable to unwind freely. The cable can then be pulled from the drum by the operator.

The winch freespool icon on the main menu of the computer display will be illuminated when the winch freespool switch is in the ON position.

Refer also to CAB CONTROLS – RIGHT ARM REST CONTROL PANEL – WINCH CONTROL LEVER in THIS SECTION.

E. DIFFERENTIAL LOCK - (REAR) -SWITCH This is a two position switch used to turn the rear axle differential lock ON or OFF. Press the top of the switch to turn the rear differential lock ON. This will lock up the rear axle differential and provide drive torque to both rear wheels.

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

2.19

Controls and Operation

Tigercat 602 Carrier A

B

D

C

E

F G

H

DW602-001

A B C D

Right Arm Rest Control Panel (Dual Winch Skidder)

Shield Dozer Grapple Control Lever (if equipped) Dozer Blade Control Lever Differential Lock Front Switch

E F G H

H. WINCH CONTROL LEVER (WINCH 1 & 2) WINCH IN - Pull and hold the lever BACK to wind in the winch cable. The control lever will return to the neutral position (brake on) when released.

BRAKE ON - The neutral position actuates the winch brake and prevents the drum from rotating.

FREESPOOL - Push and hold lever FULLY FORWARD to disengage the brake. This permits the cable to unwind freely. The control lever will return to the neutral position (brake on) when released.

The winch freespool icon on the main menu of the computer display will be illuminated when the winch control lever is held in the freespool position.

Refer also to CAB CONTROLS – RIGHT ARM REST CONTROL PANEL – WINCH FREESPOOL SWITCH in THIS SECTION.

2.20

Differential Lock Rear Switch Fairlead Up/Down Switch Winch Freespool Switch (Winch 1 & 2) Winch Control Lever (Winch 1 & 2)

G

H

Tigercat 602 Carrier

Controls and Operation LOCATED TO THE RIGHT OF THE JOYSTICK ON THE RIGHT ARM REST

A

B

A

610E-001

620E-023

A Dozer Blade Control Lever

DOZER BLADE CONTROL LEVER SWING BOOM SKIDDER

Pull the lever BACK to RAISE

the dozer blade.

Push the lever FORWARD to LOWER dozer blade.

the

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

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

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

A Dozer Blade Control Lever B Dozer Grapple Control Lever

DOZER GRAPPLE CONTROL LEVER (OPTIONAL) SWING BOOM SKIDDER

Pull the lever BACK to OPEN grapple.

the dozer

Push the lever FORWARD to CLOSE dozer blade.

the

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

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

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

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

2.21

Controls and Operation RIGHT JOYSTICK

Tigercat 602 Carrier B

C

A

D

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

E

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

620E-005

A B C D E

Right Joystick

Grapple Rotate Buttons Constant Pressure (grapple) Button Differential Locks ON/OFF Button Grapple OPEN/CLOSE Buttons Engine Speed Control Trigger

Also refer to GRAPPLE, OPERATING in THIS SECTION. Differential Locks ON/OFF - One push button (Top right - RIGHT BUTTON)

SWING BOOM SKIDDER NOTE: Standard dual arch grapple skidder controls are shown. Non-standard machines or machines modified after shipment may use this joystick to control some other functions. Always verify all functions before operating this machine.

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

Boom

Push button a second time to deactivate.

Move the joystick BACK to RAISE

the boom.

Move the joystick FORWARD to LOWER boom.

the

Arch Move the joystick to the RIGHT to tilt arch OUT Move the joystick to the LEFT to tilt arch IN

.

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

Push RIGHT BUTTON to rotate grapple CLOCKWISE .

Press button to activate differential lock(s).

The differential locks can be engaged or disengaged while the machine is in motion. The differential lock icon on the main menu of the computer display will be illuminated when the front, rear or front and rear differential locks are engaged ( , or ).

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

Refer also to CAB CONTROLS – CONTROL PANEL – DIFFERENTIAL LOCK SELECTOR SWITCH in THIS SECTION. IMPORTANT !

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

2.22

Tigercat 602 Carrier

Controls and Operation

Grapple open/close - Two push buttons (Bottom) Push LEFT BUTTON to CLOSE grapple

.

Push RIGHT BUTTON to OPEN grapple

.

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

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

2.23

Controls and Operation 1

2

6 54827BX

CONTROL PANEL

Tigercat 602 Carrier 3

4

7

5

8

12

9

13

14

15

10

11

16

CONTROL PANEL (SWING BOOM SKIDDER)

1. IGNITION SWITCH - 3 POSITION STOP position - All electrical power fed through the ignition switch is turned "OFF"

7. PARKING BRAKE SWITCH P This is a three position switch which operates a driveline brake.

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

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

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

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

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

In an emergency the parking brake can be engaged manually to slow down or stop the machine.

Refer also to STARTING ENGINE in THIS SECTION. 2. LIGHTS FRONT - SWITCH This switch turns on working lights.

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

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

SWITCH

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

ACTUATOR ON DOOR

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

6. MAXIMUM SPEED CONTROL DIAL (STATIONARY SEAT & STEERING WHEEL) Not used for this application.

620E-027

2.24

INTERLOCK SWITCHES ON CAB DOORS

Tigercat 602 Carrier 1

2

6

Controls and Operation 3

4

7

5

8

12

9

13

14

10

15

11

16

CONTROL PANEL (DUAL WINCH SKIDDER) NOTE ALSO: The interlock system prevents WARNING the machine from being driven and function controls from being operated while the parking This machine is equipped with a controls brake is ENGAGED. safety interlock system. This system is

DW610E-003

intended to ensure machine functions are activated only when the operator is in the cab with the doors shut.

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

As part of the interlock system this machine automatically engages the parking brake whenever a cab door is open. This prevents accidental or improper operation of the controls from anywhere but the operator's seat.

Refer also to COMPUTER – MESSAGES CRITICAL – INTERLOCK SYSTEM in THIS SECTION.

As part of the interlock system this machine automatically engages the parking brake whenever a cab door is open. This prevents accidental or improper operation of the controls from anywhere but the operator's seat.

The parking brake must be kept properly adjusted at all times and should be serviced every 500 hours during normal operating conditions. Refer to PARKING BRAKE ADJUSTMENT in SECTION 3.

Do not alter or bypass this safety feature.

Once the doors are shut and the parking brake is DISENGAGED the safety of both the operator and all persons outside the cab becomes the responsibility of the operator.

Do not allow machine controls to be activated without an operator in the cab.

The parking brake, door interlock switches, and IQAN computer system interlock features are safety devices and must not be defeated in any way.

2.25

Controls and Operation 1

2

6

Tigercat 602 Carrier 3

4

7

5

8

12

9

13

14

10

15

11

16

CONTROL PANEL (SWING BOOM SKIDDER) 9. DIFFERENTIAL LOCK SELECTOR SWITCH 8. HORN, SAFETY ALERT - SWITCH Dual Winch Skidder This is a two position "momentary" switch.

Not used on this machine configuration.

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

Refer to RIGHT ARM REST CONTROL 54827BX

PANEL – DIFFERENTIAL LOCK - (FRONT) - SWITCH and DIFFERENTIAL LOCK (REAR) -SWITCH in THIS SECTION.

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

Swing Boom Skidder This is a three position switch,

/

/

.

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

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

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

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

2.26

Tigercat 602 Carrier 1

2

6

Controls and Operation 3

4

7

5

12

8

9

13

14

10

15

11

16

CONTROL PANEL (DUAL WINCH SKIDDER) Refer also to WINCH CONTROL LEVER in 10. WINCH SELECT SWITCH THIS SECTION .

Dual Winch Skidder DW610E-003

Not used on this machine configuration

WARNING

Swing Boom Skidder FOR CARCO WINCH This is a three position switch, O / I /

.

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

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

Place this switch in the (FREESPOOL) position to disconnect the drive motor from the drum in the winch and allow the cable to be freely pulled from the spool by hand. The freespool function is intended for use in pulling the cable by hand only and must not be used when the cable is loaded. Improper use of the freespool function will result in damage to the winch.

Free spool must be turned off to activate a pull with the winch. The winch freespool icon on the main menu of the computer display will be illuminated when the winch selector switch is in the position.

2.27

When operating Carco winches the load MUST be removed from the cable before placing the winch control in the freespool position to avoid damage to the winch which could cause a safety hazard.

Attempting to engage or disengage the freespool function with a load on the cable will cause damage to clutch halves, piston, final planetary gearing and/or output shaft.

Damage to freespool components can cause a sudden loss of load control which could result in death or serious injury.

Controls and Operation 1

2

6

Tigercat 602 Carrier 3

4

7

5

12

8

9

13

14

10

15

11

16

54827BX CONTROL PANEL (SWING BOOM SKIDDER) 11. WINCH CONTROL LEVER operator by hand. The freespool function is intended for use in pulling the cable by hand Dual Winch Skidder only and must not be used when the cable is Not used on this machine configuration. loaded. Improper use of the freespool function will result in damage to the winch.

Refer to RIGHT ARM REST CONTROL PANEL – WINCH CONTROL LEVER (WINCH Refer also to WINCH SELECT SWITCH in 1 & 2) and WINCH CONTROL LEVER THIS SECTION. (WINCH 1 & 2) in THIS SECTION.

Swing Boom Skidder

WARNING

FOR CARCO WINCH Place the winch select switch (to the left of the lever) in the I (ON) position. Push and hold the winch control lever FORWARD to release the dynamic brake for dropping a load on the fly or drive away from a load with slight tension on the cable. The control lever will return to the centre neutral position when released.

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

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

Placing the winch select switch (to the left of the lever) in the (FREESPOOL) position permits the cable to unwind freely. The cable can then be pulled from the drum by the 2.28

When operating Carco winches the load MUST be removed from the cable before placing the winch control in the freespool position to avoid damage to the winch which could cause a safety hazard.

Attempting to engage or disengage the freespool function with a load on the cable will cause damage to clutch halves, piston, final planetary gearing and/or output shaft.

Damage to freespool components can cause a sudden loss of load control which could result in death or serious injury.

Tigercat 602 Carrier 1

2

6

Controls and Operation 3

4

7

5

8

12

9

13

14

10

15

11

16

CONTROL PANEL (DUAL WINCH SKIDDER)

DW610E-003

12. AIR CONDITIONER

ENGINE

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

position the air condition is ON.

In the

position the air conditioner is OFF.

SHUT-OFF VALVE

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

In the cab.

HOSE TO A/C HEATER UNIT

position fresh air is brought into the 602-035

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

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

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

Refer also to CAB VENTILATION in THIS SECTION. 14. TEMPERATURE CONTROL This is a variable, rotary control used to adjust the temperature of air in the cab for heating or air conditioning. The blue area of the scale indicates cooler temperatures the red area indicates warmer temperatures. Temperature is adjusted by regulating the flow of engine coolant into the heater core.

HOT WATER SHUT-OFF VALVE

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

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

2.29

Controls and Operation 1

2

6

Tigercat 602 Carrier 3

4

7

5

8

12

9

13

14

10

15

11

16

CONTROL PANEL (SWING BOOM SKIDDER)

54827BX

16. FAN CONTROL - SWITCH (IF EQUIPPED - VARIABLE PITCH FAN)

flow is reduced, as less cooling is required for efficient operation of the cooler package.

This is a three position switch, labeled / / (FULL ON/ AUTOMATIC/ CLEAN).

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

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

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

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

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

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

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

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

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

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

Automatic control of fan air flow to match your operating conditions can lower fuel consumption and reduce operating costs. In high temperature operating conditions the fan air flow is increased to improve cooling ability and efficient operation of the cooler package and air conditioning systems. In low temperature operating conditions fan air 2.30

Tigercat 602 Carrier 1

2

6 DW610E-003

Controls and Operation 3

4

7

5

8

12

9

13

14

10

CONTROL PANEL (DUAL WINCH SKIDDER)

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

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

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

Refer also to COMPUTER – ADJUSTMENT MENU - FAN SETTINGS in THIS SECTION. It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures.

Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

2.31

15

11

16

Controls and Operation

Tigercat 602 Carrier 3

4

5

2

1

7 73068BUNIX

8

6

INSTRUMENT PANEL (SWING BOOM SKIDDER)

INSTRUMENT PANEL

4. MASTER ALARM This alarm will sound to alert the operator that an alarm condition has been detected and should be dealt with immediately. All messages can be viewed on the computer display on the instrument panel. Refer to the COMPUTER – MESSAGES in THIS SECTION.

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

2. LIGHTER 24V Cigarette lighter is supplied.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

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

3. ALARM LIGHT

Refer to COMPUTER in THIS SECTION for complete operating details.

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

Refer to the COMPUTER – MESSAGES in THIS SECTION.

2.32

Tigercat 602 Carrier

Controls and Operation 3

4

5

2

1

7

8

6

INSTRUMENT PANEL (DUAL WINCH SKIDDER)

81024BUNIX

6. STORAGE COMPARTMENT 7

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

8

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

632E-002

REMOVE COVER TO ACCESS

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

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

2.33

Controls and Operation REMOTE CONTROL ON/OFF SWITCH

DW610E-005

Tigercat 602 Carrier

REMOTE CONTROL ON/OFF SWITCH

This is a two postion switch, ON/OFF. Place this switch in the ON position to activate the remote control joystick. Note that when the remote control is activated the cab controls are disabled.

An alert message is displayed on the computer display when the switch is in this position.

Place this switch in the OFF position to deactivate the remote control joystick. Note that when the remote control is de-activated the cab controls are activated.

Refer COMPUTER ­– MESSAGES - ALERT – CONTROL SYSTEM REMOTE CONTROLS ACTIVATED in THIS SECTION. Refer to manufacturer's instructions for information regarding safety and operation of the remote control.

Refer also to REMOTE CONTROL SAFETY in SECTION 1.

DW610E-004

REMOTE CONTROL (EXAMPLE)

Control System Remote controls activated. Cab controls disabled.

2.34

Tigercat 602 Carrier ROTATING SEAT KICK LEVER

(ROTATING SEAT & JOYSTICK STEERING)

620E-024

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

ROTATING SEAT KICK LEVER

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

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

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

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

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

Refer also to FOOT PEDALS, FORWARD FACING AND REAR FACING – TRAVEL/ ENGINE SPEED PEDAL and LEFT JOYSTICK – DIRECTION SELECTION SWITCH in THIS SECTION. Note that steering control is automatically adjusted by the computer control system based on the position of the operator's seat. Refer also to LEFT JOYSTICK – STEERING in THIS SECTION. It should also be noted that the machine steering invert function can be disabled. Refer to COMPUTER – MESSAGES - INFORMATION – MACHINE STEERING INVERT DISABLED and COMPUTER – ADJUSTMENT MENU - SERVICE SETTINGS – STEER INVERT (JOYSTICK STEERING ONLY) in THIS SECTION. 2.35

Controls and Operation OPERATOR’S SEAT - GRAMMER WARNING The seat belt supplied with this seat must be used at all times when operating this machine.

SHOULDER HARNESS SEAT BELT ADJUSTERS

Tigercat 602 Carrier 3. Pull out on the two lap belt adjusters to allow the belt to slide through and extend the lap belt.

4. Buckle the lap belt.

5. Pull the seat belt ends on each side of the lap belt to tighten the lap belt. Lap belt should be snug to allow proper operation of the seat belt and the seat air suspension system.

6. EARLIER SHOULDER HARNESS Pull the seat belt ends on each side of the shoulder harness to tighten the shoulder straps.

LATER SHOULDER HARNESS Fasten the shoulder harness connector.

7. Shoulder straps should be snug to allow proper operation of the seat belt and the seat air suspension system.

SEAT ADJUSTMENTS

LAP BELT SEAT BELT ADJUSTERS

600E-031

SEAT BELT ADJUSTMENT (EARLIER SHOULDER HARNESS)

SHOULDER HARNESS CONNECTOR

This seat is equipped with a weight adjustment air suspension system for operator comfort and safety.

IMPORTANT! For proper operation of the weight adjustment air suspension system for operator comfort and safety the seat must be individually adjusted for each new operator before operating the machine.

In addtion weight adjustment should be done at the beginning of each operator’s shift to ensure optimal operation of the weight adjustment air suspension system.

NOTE: Joystick pods and armrests can be rotated up out of the way for ease of entry and exit from the cab.

LAP BELT SEAT BELT ADJUSTERS 600E-035

A. WEIGHT ADJUSTMENT Operator must be sitting in the seat with the machine parked on level ground for proper weight adjustment.

SEAT BELT ADJUSTMENT (LATER SHOULDER HARNESS)

SEAT BELT ADJUSTMENT This seat is equipped with a manually adjustable four point seat belt harness.

Before performing the initial weight adjustment, place the shock absorber lever in position 1 (soft). In addition, for more accurate weight adjustment release previous settings by pressing down on the weight adjustment lever until all air has been released and the seat suspension bottoms out.

1. Sit in the seat.

2. EARLIER SHOULDER HARNESS Place the shoulder harness over shoulders and pull out on the shoulder harness belt adjusters to allow the belt to slide through and extend the harness.

Pull up briefly on the weight adjustment lever to begin the weight adjustment. The operator should sit absolutely still during this process.

LATER SHOULDER HARNESS Place the shoulder harness over shoulders.

2.36

Tigercat 602 Carrier

Controls and Operation D

G

C 3 MEDIUM

H

2 4 1 SOFT 5 HARD

SHOCK ABSORBER SETTINGS then be adjusted as needed for operator preference and/or operating conditions.

600E-032

B SHOWN IN

A

POSITION 1 (SOFT)

L

IMPORTANT! When setting weight and height adjustments shock absorber lever should first be placed temporarily in position 1 (soft).

600E-030

I

C. SEAT ANGLE ADJUSTMENT Pull the left handle upward and adjust the angle of the seat by moving the front edge of the seat cushion up or down until it is in the desired position. Release the handle to lock the seat cushion in position.

E K

J

D. SEAT DEPTH ADJUSTMENT Pull the right handle upward and adjust the depth of the seat by moving the seat cushion forward/backward until the seat depth is adjusted to the desired position. Release the handle to lock the seat cushion in position.

SHOWN F WITH COVER ON

600E-029

E. ARMREST ANGLE ADJUSTMENT Turn adjusting knob toward the outside of the seat to raise the angle of the armrest. Turn the adjusting knob toward the inside of the seat to lower the angle of the armrest.

Once weight adjustment is done it is recommended that operators adjust all other seat adjustments before adjusting the height of the seat further as any further height adjustment places limits on the effectiveness of the seat's air suspension system.

F

IMPORTANT! When setting weight adjustment shock absorber lever should first be placed temporarily in position 1 (soft).

IMPORTANT! Weight adjustment should be done at the beginning of each operator’s shift to ensure optimal operation of the weight adjustment air suspension system.

600E-033

F.

SHOWN WITH COVER REMOVED

ARMREST HEIGHT ADJUSTING NUT

ARMREST HEIGHT Armrest height can be adjusted if required.

Carefully remove the snap on cover by pulling out on both sides to access the adjusting nut.

Loosen the hexagon nut (13mm), adjust the armrest to the desired height and retighten the nut. Replace the plastic cover.

B. SHOCK ABSORBER (5 SETTINGS) The shock absorber lever setting can be varied adjusting the cushioning effect to suit operating conditions.

Turn the lever to the desired position and release. Five positions are available from 1 (soft) to 5 (hard). Position 3 (medium) is recommended as an initial setting which can 2.37

Controls and Operation

Tigercat 602 Carrier

D G

I.

C

SEAT HEATER/COOLER This is a three position switch.

H

Seat Heater ON - press top of switch.

OFF - Centre position.

Seat Cooler ON - Press the bottom of switch.

J. LUMBAR SUPPORT

B SHOWN IN

A

POSITION 1 (SOFT)

The two lumbar support switches individually adjust the curvature of the upper and lower areas of the backrest for operator comfort.

L

Increase curvature by pressing "+" or reduce curvature by pressing "-". Upper or lower backrest curvature is individually adjusted by using the upper or lower switches respectively.

When maximum curvature adjustment is reached pressing "+" will no longer cause an adjustment and the switch should be released.

600E-030

I

E J

K

K. BACKREST ANGLE ADJUSTMENT Lean forward and pull up the locking lever to release the backrest catch. Adjust backrest angle to the desired position. Release the lever to lock in place.

IMPORTANT! The locking lever must latch when released to lock the seat in position. It should not be possible to move the seat when it is locked.

SHOWN

F WITH

COVER ON

600E-029

G. SEAT FORWARD/BACK POSITION RELATIVE TO JOYSTICK PODS

L

HEIGHT ADJUSTMENT Once weight adjustment is done it is recommended that operators adjust all other seat adjustments before adjusting the height of the seat further as any further height adjustment places limits on the effectiveness of the seat's air suspension system.

Pull up on locking lever and move seat forward/backward to position the seat comfortably for operation of the joysticks.

Release the locking lever to lock in place.

Height adjustment is possible after the initial weight adjustment process. Pull up on weight/ height lever to raise seat height. Push down on weight/height lever to lower height.

IMPORTANT! The locking lever must latch with an audible click when released to lock the seat in position. It should not be possible to move the seat when it is locked.

End stops (top and bottom) limit height adjustment in order to guarantee minimum spring travel and proper operation of the air suspension. If the seat height is adjusted manually beyond an end stop it will be readjusted to a height with adequate suspension travel.

H. SEAT FORWARD/BACK POSITION Pull up on lever and move seat (and joystick pods) forward/backward to position the seat comfortably for operation of the foot pedals.

Release the lever to lock in place.

IMPORTANT! The lever must latch with an audible click when released to lock the seat in position. It should not be possible to move the seat when it is locked.

IMPORTANT! When setting height adjustment shock absorber lever should first be placed temporarily in position 1 (soft).

2.38

Tigercat 602 Carrier

Controls and Operation

COLOUR DISPLAY

COMPUTER DISPLAY MODULE ARROW (SCROLL) UP OK (ENTER) ARROW (SCROLL) DOWN

F1 632E-301A

F2

F3

F4

ESC (BACK) MENU

COMPUTER, ELECTRONIC CONTROL AND DISPLAY

COMPUTER ELECTRONIC CONTROL & DISPLAY

COMPUTER USB PLUG

ALARM LIGHT

MASTER ALARM

COMPUTER

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

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

• F1 through F4 function buttons.

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

• Up and down arrow buttons.

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

• OK button.

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

INSTRUMENT PANEL • Menu button .

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

• ’Esc’ or BACK button

.

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

2.39

Controls and Operation

Tigercat 602 Carrier

MD3 COMPUTER MODULE

MC43 COMPUTER MODULE

XA2-A0 EXPANSION MODULE FRONT CHASSIS

XS2 EXPANSION MODULE CAB

XC21 EXPANSION MODULE SEAT

ENGINE DIAGNOSTIC CONNECTOR TELEMATICS (IF EQUIPPED) 602-001

REMOTE CONTROL (IF EQUIPPED)

G11 BLUETOOTH DIAGNOSTIC DONGLE (IF EQUIPPED)

ENGINE ELECTRONIC CONTROL UNIT MODULE

COMPUTER CONTROL SYSTEM COMPONENTS

COMPUTER CONTROL SYSTEM

LOCATED IN CAB BEHIND LEFT KICK PANEL

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

MD3 Computer and Display Module MC43 Module XS2 Expansion Module (Cab) XC21 Expansion Module (Seat) XA2-A0 Expansion Module (Front Chassis) Engine Electronic Control Unit Module (Tigercat/FPT NEF 6.7L) Remote Control Base Station Module (if equipped) Telematics (if equipped) G11 Bluetooth Diagnostic Dongle (if equipped) Various controls, switches, sensors and valves not shown.

620E-043

XS2-A0 MODULE - CAB

XA2-A0 FRONT CHASSIS

The computer and display module is the main control unit in the system. The computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

MC43 MODULE

LOCATED UNDER CAB, REMOVE COVERS TO ACCESS MODULES

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

602-066

XA2 MODULE AND MC43 MODULE MOUNTED ON BACK OF OPERATOR SEAT - REMOVE COVER TO ACCESS

NOTE: The computer control system is softwarebased. This software may be updated after the machine is in service as a part of on-going product improvement programs and service newsletters.

The information contained in this manual is accurate at the time of printing. Improvements to the machine and/or software are on-going and may not be covered. In these cases contact your Tigercat dealer for appropriate information.

632E-016

2.40

XC21 MODULE

Tigercat 602 Carrier 1

Controls and Operation

2A 2B

3

4A

4B

5

6

7

18

8

17 16 15 14

9

10

11

12

13

MAIN MENU

602-301

COMPUTER MAIN MENU

12. INFORMATION MENU - Press F3 to select

1. ** PARKING BRAKE - ENGAGED/DISENGAGED 2A. ** REAR DIFFERENTIAL LOCK - ENGAGED/DISENGAGED 2B. ** FRONT DIFFERENTIAL LOCK - ENGAGED/DISENGAGED 3. *GRAPPLE CONSTANT PRESSURE ON/OFF

13. ALARM INDICATORS - Press F4 to select

4A. * WINCH ON/OFF (

)

4B. * WINCH FREE SPOOL (

)

14. HYDRAULIC OIL GRADE INDICATOR 15. HYDRAULIC OIL TEMPERATURE GAUGE*** 16. DEF LEVEL INDICATOR***** 17. FUEL LEVEL GAUGE**** 18. MAXIMUM SPEED CONTROL SETTING INDICATOR (%) * When the icon is illuminated, function is ON.

5. * MACHINE WARM UP ON/OFF

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

6. HYDRAULIC OIL FILTER BYPASS 7. OSCILLATION LOCK

*** Note that gauge symbol colour changes indicate temperature range (blue=low, white=normal, red=high)

8. ENGINE TACHOMETER GAUGE 9. ENGINE MENU - Press F1 to select 10. ADJUSTMENT MENU - Press F2 to select

**** Note yellow fuel symbol indicates fuel level low.

11. ENGINE COOLANT TEMPERATURE GAUGE***

***** DEF level indicator applicable to Tier 4f machines only.

2.41

Controls and Operation

Tigercat 602 Carrier

ENGINE MENU

The engine functions on display are as follows: Charge Air Temperature - °F or °C From the main menu press the F1 button to select the engine display.

Engine Coolant Temperature - °F or °C Engine Oil Temperature - °F or °C

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

Fuel Temperature - °F or °C Engine Speed - rpm Turbocharger Boost Pressure - psi or bar Engine Oil Pressure - psi or bar Engine Torque - % Engine Hours - h Voltage - V Fuel Rate - US gph or L/h (instantaneous)

2.42

Tigercat 602 Carrier

Controls and Operation 1.

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

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

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

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

Refer also to the COMPUTER – MESSAGES in THIS SECTION.

ENGINE FUNCTIONS Press the F1 button to toggle the machine warm up function ON/OFF. Refer to MACHINE WARM UP OPERATION and MACHINE WARM UP SPEED ADJUSTMENT in THIS SECTION.

2.

Engine Coolant Temperature (°F or °C) This display indicates the current engine coolant temperature.

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

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

• Plugged air intake access panel screens • Plugged radiator.

Press the back button to return to the main menu.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

NOTE: Coolant temperature can also be monitored using the engine coolant temperature gauge shown on the main menu.

Note also that gauge symbol colour changes indicate temperature range (blue=low, white=normal, red=high) Refer also to the COMPUTER – MESSAGES in THIS SECTION. 3.

Engine Oil Temperature (°F or °C) This display indicates the current engine oil temperature.

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

• Plugged air intake access panel screens • Plugged radiator.

DO NOT continue to operate machine.

2.43

Controls and Operation Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

Tigercat 602 Carrier 8.

This display indicates the percentage of maximum engine peak torque currently in use.

Refer also to the COMPUTER – MESSAGES in THIS SECTION. 4.

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

Fuel Temperature - °F or °C This display indicates the fuel temperature.

5.

Parking Brake ENGAGED 6-10%

Engine Speed (rpm)

Readings with the parking brake DISENGAGED should be 10-14%.

This display indicates engine speed in rpm.

Maintaining Correct Engine RPM

If the readings are outside this range investigate the cause.

It is important that the engine speeds be correct at all times:

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

FPT N67 Engine: Low Idle 950 RPM (No Load) High Idle 2200 RPM (No Load)* NOTE: The above values are measured with the hydraulic and engine oil at normal operating temperatures and no functions activated.

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

Eng % Torque (%)

9.

Engine Hours - h This display indicates the total number of hours the engine has run.

10.

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

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

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

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

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

* Refer also to COMPUTER – ADJUSTMENT MENU - ENGINE SETTINGS – ENGINE HIGH IDLE ADJUST and AUTO RPM in THIS SECTION. 6.

Boost Pressure (psi or bar) This display indicates air intake manifold boost pressure in psi.

7.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM 11.

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

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

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

Refer to the COMPUTER – MESSAGES in THIS SECTION.

2.44

Tigercat 602 Carrier

Controls and Operation

ADJUSTMENT MENU

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

•

Engine Settings - Shown first by default.

•

Fan Settings - Press F2 to select

•

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

2.45

Controls and Operation

Tigercat 602 Carrier The adjustable engine settings are: Engine High Idle Adjust Range 1800 to 2200* rpm This parameter allows the operator to adjust engine high idle speed limit, this limit will be in effect whenever the grapple constant pressure function is NOT activated. This function is intended to allow the automatic reduction of the engine high idle speed limit when travelling without a load.

Auto RPM Max rpm* Off 2000 rpm

ENGINE SETTINGS

When the Auto RPM function is set to the default setting of Max rpm the engine speed will automatically increase proportionally with operation of all joystick functions to a maximum of 2200 rpm. Note that if the engine high idle adjust setting is lower than the Auto RPM setting engine speed will be limited to the lower speed setting.

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

Press F1 (Adjust) to adjust engine settings.

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

The Auto RPM function can also be set to 2000 rpm.

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

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

Warm Up Speed Range 950 to 1500 rpm (1500* rpm) Refer also to MACHINE WARM UP OPERATION and MACHINE WARM UP SPEED ADJUSTMENT in THIS SECTION. * NOTE: Reset default settings are marked.

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

2.46

Tigercat 602 Carrier

Controls and Operation The adjustable fan settings are: Fan Auto Clean On* or Off Clean Frequency Range 1 to 420 minutes (*30 minutes) Clean Duration Range 5 to 20 seconds (*15 seconds) * NOTE: Reset default settings are marked.

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

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

The fan settings menu will appear.

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

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

2.47

Controls and Operation

Tigercat 602 Carrier The adjustable service settings are: Hydraulic Oil Grade ISO 22* Petro CAN MV 22 ISO 32 Petro CAN MV 36 ISO 46 Esso Univis Ultra 46 Petro CAN MV 60 ISO 68 This information is used by the machine program to adapt hydraulic oil temperature messages for the operating range of each Hydraulic Oil Grade.

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

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

Press F3 (Adjust) to adjust service settings Press the back button to return the Service Settings Menu display.

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

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

Refer also to COMPUTER – MESSAGES - CRITICAL – HYDRAULIC OIL TEMPERATURE HIGH in THIS SECTION for more information about the hydraulic oil temperature message.

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

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

2.48

Tigercat 602 Carrier Program Mode

Controls and Operation Steer Invert (Joystick steering only)

Normal* Engine HP Test Mode Drive Motor Setup Mode Drive Pump POR Setup Mode Drive Pump Regulation Setup Function Setup Mode Max Current Setup Mode

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

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

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

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

IMPORTANT !

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

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

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

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

Attempting to use these controls will reactivate the information message.

Steering Rate (Joystick steering only) 0 25 50* 75 100 This setting adjusts the performance of the joystick steering function. A lower setting will result in a slower response. A higher setting will result in a quicker response.

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

2.49

Controls and Operation

Tigercat 602 Carrier

Constant Pressure Trigger

Drive Trigger (Travel/Engine Speed Trigger) (Joystick steering only)

Range 2700 to 3300 psi (3000* psi)

Off* or On

This setting adjusts the grapple constant pressure trigger setting.

During normal operation when the grapple constant pressure switch is activated on a load sense equipped skidder the pressure supplied to the grapple constant pressure function will fall gradually due to normal leakage or more suddenly due to load shift. Pressure will fall until it reaches the grapple constant pressure trigger setting which triggers the supply of more pressure to reset the grapple constant pressure function to full pressure.

When OFF the travel/engine speed trigger function on the left joystick is disabled.

When ON the travel/engine speed trigger function on the left joystick is enabled.

Refer also to CAB CONTROLS – TRAVEL/ ENGINE SPEED TRIGGER in THIS SECTION for more information about travel/engine speed trigger function.

Load Sense Override Off* or On

Travel Speed Direction Sync

When OFF the main pump output is controlled by a load sense signal from the control valves.

This default setting should be used in normal operating conditions to benefit from load sense functionality.

On* or Off When ON the maximum speed control setting is identical for both forward and reverse travel.

When OFF the maximum control speed settings can be set independently for forward and reverse travel.

When ON the main pump output is controlled by the POR setting. This setting is intended for use by service technicians for setup procedures and trouble shooting. In some cases this setting may also be used to improve performance in extreme cold weather conditions.

For more information about maximum speed control refer to CAB CONTROLS – MAXIMUM SPEED CONTROL – ROTATING SEAT & JOYSTICK STEERING in THIS SECTION. Travel Speed Step Mode

Auto Oscillation Lock

Off* or On

On* or Off

When OFF the maximum speed control setting is adjusted increments of 1%.

When ON the auto oscillation lock switch operates in Automatic mode.

When ON the the maximum speed control setting is adjusted in steps (0%,5%,10%,15%, 20%,30%,40%,50%,60%,80%,100%).

When OFF the auto oscillation lock switch operates in Manual mode.

For more information about maximum speed control refer to CAB CONTROLS – MAXIMUM SPEED CONTROL – ROTATING SEAT & JOYSTICK STEERING in THIS SECTION.

Refer to CAB CONTROLS – OSCILLATION LOCK SWITCH in THIS SECTION for operational details. * NOTE: Reset default settings are marked.

2.50

Tigercat 602 Carrier

Controls and Operation

EXAMPLE – ADJUSTMENT MENU:

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

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

Press the F2 button to reset to default setting.

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

The engine settings menu will appear by default.

Press F1 (Adjust) to adjust engine settings

2.51

Controls and Operation

Tigercat 602 Carrier

OR

OR

Press the OK button to go to the adjustment display.

To reset to default setting press the F2 button.

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

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

Press the OK button to confirm the setting.

Press the back button to return to the adjustment menu.

Press the back main menu.

2.52

button again to return to the

Tigercat 602 Carrier

Controls and Operation

INFORMATION MODE MENU

The information functions on display are as follows: Drive Pressure Forward - psi or bar

Press the F3 button to access the information menu.

Drive Pressure Reverse - psi or bar

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

Travel Speed - mph or km/h Drive Motor Speed - rpm Serial Number Machine Hours - h Hydraulic Oil Temp -°F or °C Transmission Temperature -°F or °C (EHS Transmission only) Total fuel information Trip fuel information Press the F1 button to reset the trip average fuel rate and trip fuel used functions.

Press the F2 button to toggle between imperial and metric units of measure for all information displays.

Press F3 to move to the next information screen.

Press the back button to return to the main

2.53

Controls and Operation

Tigercat 602 Carrier Press the F1 button access accumulator screen.

Press the F2 button access telematics screen (if equipped).

Press the F3 button to return to the first information menu display.

OR Press the back button to return to the previous screen.

Press again to return to the information menu.

Press again to return to the main menu.

When is selected the next screen appears and the information functions on display are as follows: Main Pump Pressure - psi or bar Load Sense Pressure - psi or bar Differential Pressure - psi or bar (Differential between Main Pump and Load Sense pressures) Pilot Pressure - psi or bar (Multifunction Manifold) Grapple Constant Pressure - psi or bar Hydraulic Filter Pressure - psi or bar Service Brake Pressure - psi or bar

P Parking Brake Pressure - psi or bar Clutch Pressure - psi or bar (EHS Transmission only)

2.54

Tigercat 602 Carrier

ACCUMULATOR INFORMATION When accumulator (F1) is selected the accumulator screen appears.

This screen is used to test the functionality of the pilot accumulator. Refer to REAR PILOT ACCUMULATOR – CHECKING FOR PROPER PROPER OPERATION in SECTION 3.

Controls and Operation

TELEMATICS INFORMATION When telematics (F2) is selected the telematics information screen appears and the information on display is as follows: Connectivity - dB-Hz Messages sent/recorded counter

This screen can be used to safely lower the dozer, arch and boom when the engine is OFF. Refer to DEPRESSURIZING SUSPENDED ELEMENTS in SECTION 3 for more information.

Latitude Longitude

This screen is also used in the procedure to relieve pressure from the rear pilot accumulator.

Refer to PARKING THE MACHINE in SECTION 1.

Press the back button to return to the previous screen.

In addition it may be used by service technicians for service procedures.

Press the back button to return to the previous screen.

2.55

Controls and Operation

Tigercat 602 Carrier • • • • • •

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

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

INFORMATION FUNCTIONS 1.

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

Note also that gauge symbol colour changes indicate temperature range (blue=low, white=normal, red=high)

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

2.

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

3.

Travel Speed - mph or km/h

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

This display indicates machine travel speed.

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

4.

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

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

Drive Motor Speed - rpm This display indicates the drive motor speed in rpm.

5

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

Serial Number This display indicates machine serial number.

6.

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

Machine Hours - h

Refer also to COMPUTER – MESSAGES - CRITICAL – HYDRAULIC OIL TEMPERATURE HIGH in THIS SECTION for more information about the hydraulic oil temperature message.

This display indicates the total number of hours the machine has run.

7.

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

If the temperature rises above the recommended operating range for the type of hydraulic oil in use, alarm will sound, check the following: 2.56

Tigercat 602 Carrier 8.

Controls and Operation

Transmission Temperature -°F or °C (EHS transmission only) This display indicates the hydrostatic circuit temperature as read by the temperature sensor located on the drive pump.

9.

Total fuel information This display indicates the total fuel used during the life of the machine.

• • •

10.

Total fuel used US gal or L, Total hours h Total fuel rate US gph or L/h.

Trip fuel information

This display indicates the average fuel consumption rate for the machine since last reset.

• • •

Trip fuel used US gal or L, Trip hours h Trip fuel rate US gph or L/h.

15.

Grapple Constant Pressure - psi or bar This display indicates the grapple constant pressure measured at the pressure sensor mounted on the rear chassis (left side).

16.

Hydraulic Filter Pressure - psi or bar This display indicates hydraulic filter pressure measured at the pressure sensor mounted on the return filter inlet manifold.

FUEL GAUGE

17.

The fuel level gauge is shown on the main menu.

Note that a yellow fuel symbol indicates fuel level low.

11.

Main Pump Pressure - psi or bar

This display indicates service brake pressure measured at the pressure transducer in port ACC on the main pump manifold block.

18.

This display indicates the main pump pressure measured at the pressure sensor in port GP on the pump control/auto brake manifold.

12.

Load Sense Pressure - psi or bar

19.

Clutch Pressure - psi or bar (EHS Transmission only) This display indicates clutch pressure measured at the pressure sensor in port G on the EHS transmission clutch manifold..

Differential Pressure - psi or bar This display indicates the calculated differential between Main Pump and Load Sense pressures.

14.

P Parking Brake Pressure - psi or bar This display indicates parking brake pressure measured at the pressure sensor in port GD on the multifunction manifold.

This display indicates load sense pressure measured at the pressure sensor in the inlet section of the front chassis control valve.

13.

Service Brake Pressure - psi or bar

Pilot Pressure - psi or bar This display indicates pilot pressure measured at the pressure sensor in port GP1 on the pump control/auto brake manifold.

2.57

Controls and Operation

Tigercat 602 Carrier

MAIN MENU PAGE From any menu page.

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

The main menu page displays the following selections: •

Adjust - Press F1 to select

•

Measure - Press F2 to select

•

Preferences - Press F3 to select

•

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

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

2.58

Tigercat 602 Carrier ADJUST MENU

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

Controls and Operation ENGINE ADJUST GROUP*

FAN ADJUST GROUP* (IF EQUIPPED)

The following menu items can be selected:

• • • • • • •

Engine Adjust Group* Fan Adjust Group* (if equipped) Service Adjust Group* Swing Boom Adjust Group (if equipped) Operator Adjust Group (if equipped) Custom Adjust Group (if equipped) Engine Operations (locked)

SERVICE ADJUST GROUP*

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

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

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

2.59

Controls and Operation

Tigercat 602 Carrier

SWING BOOM ADJUST GROUP

OPERATOR ADJUST GROUP

Swing Boom Skidder

Dual Winch Skidder

From the adjust menu use the Arrow Up or Arrow Down to select Operator Adjust Group. Press OK to confirm the selection.

From the adjust menu use the Arrow Up or Arrow Down to select Operator Adjust Group. Press OK to confirm the selection.

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

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

Press the back button to return to the adjust menu.

Press the back button to return to the adjust menu.

Press F1 to return to the main menu page.

Press F1 to return to the main menu page.

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

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

The adjustable clutch adjust group settings are:

The adjustable clutch adjust group settings are:

Swing Min Current Range 280 to 350 mA (*300 mA) Swing Max Speed Range 25 to 100% (*75%) Swing Start Slope Range 50 to 250% (*100%) Swing Stop Slope Range 50 to 250% (*100%) Swing Stationary Time Range *3.00 to 10.00 s

Winch 2 Brake Off Delay *90 ms Winch 2 Clutch Delay Off *90 ms Winch 1 Brake Off Delay *90 ms Winch 1 Clutch Delay Off *90 ms Crane Engine Speed Range 950 rpm to 2200 rpm (*2200 rpm)

Swing Brake Release Delay Range 0 ms to 100 ms (*25 ms)

Winch Motor Override Time

Brake Release To Swing Begin Delay Range 0 ms to 100 ms (*25 ms)

* NOTE: Reset default settings are marked.

Swing Motor Release Delay Range 0 ms to 1000 ms (*300 ms)

Range 0 ms to 20000 ms (*2000 ms) Refer to COMPUTER – ADJUSTMENT MENU – EXAMPLE – ADJUSTMENT MENU NAVIGATION for an example of adjustment menu navigation.

* NOTE: Reset default settings are marked.

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

2.60

Tigercat 602 Carrier

Controls and Operation

CUSTOM ADJUST GROUP From the adjust menu use the Arrow Up or Arrow Down to select Custom Adjust Group. Press OK to confirm the selection.

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

Press the back button to return to the adjust menu.

Press F1 to return to the main menu page.

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

The adjustable clutch adjust group settings are: Minimum Remote Travel Speed Range 2% to 25% (*25 %) Maximum Remote Travel Speed Range 40% to 100% (*100 %) * NOTE: Reset default settings are marked.

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

2.61

Controls and Operation MEASURE MENU

Tigercat 602 Carrier

The following menu items can be selected.

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

• • • • • • • • • • • • • •

Inputs Outputs J1939 Parameter Inputs Drive/HP Test Function Valve Variable Pitch Fan Differential Locks Module Diagnostics Clutch Engage Carco winch control comands Hydrostatic Set-up Engage/Release Time Telematics (if equipped) Remote Inputs

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

This menu is used by Tigercat service technicians.

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

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

2.62

Tigercat 602 Carrier PREFERENCES MENU

Controls and Operation

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

The following menu items can be selected for adjustment.

•

Display - Press F1 to select

•

Date/Time - Press F2 to select

•

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

2.63

Controls and Operation

Tigercat 602 Carrier

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

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

•

Main Menu Page - Press F1 to select

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

•

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

•

SCREEN SAVER OFF

•

•

DIMMED - Timeout - Dimmed light

•

BLACK - Timeout

The following menu items can be selected:

Press the back button to return to the preferences menu.

Backlight Adjustment Press F2 to access the backlight adjustment.

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

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

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

2.64

Tigercat 602 Carrier

Controls and Operation

DATE/TIME ADJUSTMENT

Date Adjustment

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

Press F1 to access the date adjustment.

The following menu items can be selected:

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

•

Date - Press F1 to select

Press the OK button to confirm year selected.

•

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

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

Press the OK button to confirm month selected.

2.65

Controls and Operation

Tigercat 602 Carrier Time Adjustment Press F1 to access the time adjustment.

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

Press the OK button to confirm day selected.

Use the Arrow Up or Arrow Down to select the HOUR. Press the OK button to confirm selection.

The display will return to the Date/Time menu.

Press the back button to return to the preferences menu.

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

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

Press OK button to confirm the selection.

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

Press the back button to return to the preferences menu.

2.66

Tigercat 602 Carrier LANGUAGE ADJUSTMENT

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

Controls and Operation INFO MENU

From the main menu page press the F4 button (Info) and the access the info menu.

The languages available for selection will be shown.

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

Press OK to confirm the selection.

The display will return to the LANGUAGE menu screen.

Press the back button to return to the preferences menu.

The machine ID information will be displayed on the screen.

The following menu items can be selected: •

Modules - Press F1 to select

•

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

2.67

Controls and Operation

Tigercat 602 Carrier

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

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

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

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

These menus provides information on the following machine modules: •

Display (MD3 Module)

• • • • • • •

MC43(1) Cab Module (XS2 Module) Front Chassis Module (XA2 -A0 Module) Engine Seat Module (XC21 Module) Telematics (if equipped) Remote Module

LOGS

•

Torque Control

•

Exhaust Brake (if equipped)

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

Press F3 from the info menu page to select logs.

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

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

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

2.68

Tigercat 602 Carrier MESSAGES ALARM LIGHT

MASTER ALARM

Controls and Operation COMPUTER

INSTRUMENT PANEL The computer displays messages, activates the master alarm and alarm light whenever a system fault occurs. Note that the computer control system will automatically perform a bulb test at engine start-up to ensure that master alarm and alarm light are functioning. Refer to STARTING ENGINE in THIS SECTION. There are different types of Messages and Alarms, they appear on the screen as a block message.

The types of messages are: • • • •

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

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

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

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

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

2.69

Controls and Operation CRITICAL MESSAGES (RED)

Tigercat 602 Carrier

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

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

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

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

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

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

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

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

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

A list of CRITICAL MESSAGES is as follows: Hydraulic Oil Level Low Drive Motor Clutch Pressure Low Drive Motor Overspeed Transmission Oil Temperature High Interlock System Hydraulic Oil Temperature High LH Drive Motor Speed Sensor Fault RH Drive Motor Speed Sensor Fault or Clutch Slip Drive Motor Clutch Slow Response Drive Motor Clutch Pressure High Functions Active Hydraulic Oil Filter Bypass Main Fuel Filter Clogged Engine Derate Hardware Fault - MD3 Hardware Fault - Engine Hardware Fault - MC43 Hardware Fault - XS2 Hardware Fault - XC21 Hardware Fault - XA2 Engine Coolant Temperature High Engine Coolant Temperature High - Engine Derate Engine Coolant Level low Aftertreatment System Technical Failure* Aftertreatment System Engine Idle Too Long* Engine Locked Out* Engine Restarts Remaining Until Engine Lockout* Engine Oil Pressure Low Engine Oil Pressure Low - Engine Derate Engine Overspeed Engine Overspeed Max Engine Oil Temperature High Engine Fault Code Messages - Critical *NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

2.70

Tigercat 602 Carrier CRITICAL MESSAGES

Controls and Operation

Drive Motor Hydraulic Oil

Overspeed. Reduce travel speed.

Level Low.

HYDRAULIC OIL LEVEL LOW

LH Drive Motor

This message will be displayed, alarm light will flash and alarm will sound when the main hydraulic tank oil level is low.

Overspeed. Reduce travel speed.

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

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

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

Drive Motor Clutch Pressure Low.

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

RH Drive Motor Overspeed. Reduce travel speed.

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

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

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

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

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

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Controls and Operation

Tigercat 602 Carrier

Transmission Oil

Hydraulic Oil

Temperature High

TRANSMISSION OIL TEMPERATURE HIGH (IF EQUIPPED WITH EHS TRANSMISSION)

Temperature High.

HYDRAULIC OIL TEMPERATURE HIGH

This message will be displayed, alarm light will flash and alarm will sound when the transmission oil temperature is high.

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

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

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

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

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

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

INTERLOCK SYSTEM This message will be displayed, alarm light will flash and alarm will sound to a alert the operator that the Interlock System has disabled the machine drive.

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

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

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

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

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

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

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

2.72

Tigercat 602 Carrier

Controls and Operation

LH Drive Motor

Drive Motor Clutch

Speed sensor fault

Slow response.

LH DRIVE MOTOR SPEED SENSOR FAULT (IF EQUIPPED WITH EHS TRANSMISSION)

DRIVE MOTOR CLUTCH SLOW RESPONSE (IF EQUIPPED WITH EHS TRANSMISSION)

This message will be displayed, alarm light will flash and alarm will sound when a speed sensor fault is detected in the left drive motor.

This message will be displayed, alarm light will flash and alarm will sound when there is a delay in clutch response.

Stop the machine immediately when this alarm is activated and check the speed sensor for proper operation.

Stop the machine immediately when this alarm is activated and check the EHS transmission for proper operation. Air may be present in the circuit causing slow clutch response, check to ensure suction line is tight.

Check for proper sensor functionality, wiring, connectors and calibration. Refer to DRIVE MOTOR SPEED SENSOR INSTALLATION in SECTION 8 of the SERVICE MANUAL.

RH Drive Motor

Drive Motor Clutch

Speed sensor fault or clutch slip.

Pressure High.

RH DRIVE MOTOR SPEED SENSOR FAULT OR CLUTCH SLIP (IF EQUIPPED WITH EHS TRANSMISSION)

DRIVE MOTOR CLUTCH PRESSURE HIGH (IF EQUIPPED WITH EHS TRANSMISSION) This message will be displayed, alarm light will flash and alarm will sound when the drive motor clutch pressure is high.

This message will be displayed, alarm light will flash and alarm will sound when a speed sensor fault is detected in the right drive motor or the clutch is slipping.

Stop the machine immediately when this alarm is activated. Check for proper sensor functionality, wiring, connectors and calibration first. Refer to DRIVE MOTOR SPEED SENSOR INSTALLATION in SECTION 8 of the SERVICE MANUAL. Check EHS transmission for clutch slip and proper operation only if speed sensor is found to be ok.

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

2.73

Controls and Operation

Tigercat 602 Carrier

Functions Active

Hydraulic Oil

Dozer, arch & boom can be lowered rapidly.

Filter Bypass

Ensure all personnel are clear of machine before lowering.

FUNCTIONS ACTIVE

HYDRAULIC OIL FILTER BYPASS

This message will be displayed, alarm light will flash and alarm will sound when the engine is stalled during operation. This message is intended to alert the operator to immediately ensure all personnel are clear of the machine and when it is safe to do so lower the dozer, arch and boom to the ground. This should be done promptly while rear accumulator pressure is available and function controls are still operational.

This message is displayed, alarm light flashes and alarm sounds to inform the operator that the hydraulic oil is bypassing the return filters.

In the event that this is not possible refer to DEPRESSURIZING SUSPENDED ELEMENTS in SECTION 3 of THIS MANUAL for more information about safely lowering suspended elements in the event of an engine stall or other machine malfunction.

When this happens the filter requires immediate service.

If alarm sounds during cold start-ups, the engine speed should be reduced and the warm up procedure continued. Note that the bypass message will only be displayed when hydraulic oil temperature is above 80°F (27°C) and the filter is in bypass mode.

NOTE: The hydraulic oil filter bypass icon will be illuminated yellow when the filter restriction pressure reading approaches the bypass level. The hydraulic oil filter bypass icon will be illuminated red in addition to the above warning when the filter restriction pressure reading reaches bypass level indicating that hydraulic oil is bypassing the return filters.

HYDRAULIC FILTER BYPASS (YELLOW)

HYDRAULIC FILTER BYPASS (RED)

2.74

Tigercat 602 Carrier

Main Fuel Filter

Hardware Fault - MD3

Clogged - Engine Derate

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

MAIN FUEL FILTER CLOGGED ENGINE DERATE This message will be displayed, alarm light will flash and alarm will sound when an engine derate is triggered due to a clogged main fuel filter. This message may be accompanied by Engine Fault Code Messages.

When a main fuel filter clog is detected a message is displayed to alert the operator.

This message results in the following derate sequence: •

Controls and Operation

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

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

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

When a fuel filter clog continues for more than 5 minutes this message will be shown and the engine will immediately begin to derate at 50 rpm/s to a set creep speed allowing the operator to safely stop the machine (creep speed setting is programmed to suit each machine type/model).

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

Change engine filter as soon as possible to correct. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine fuel filter replacement instructions. If the problem continues contact dealer for service.

•

When a fuel filter clog condition is no longer detected for more than 5 seconds this message will be turned off and the engine will automatically ramp up engine speed at 50 rpm/s to full operating speed.

NOTE: An Engine Torque Derate Active message will also be triggered as the engine begins to derate. Refer to COMPUTER – MESSAGES CRITICAL – ENGINE TORQUE DERATE ACTIVE in THIS SECTION.

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

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

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

2.75

Controls and Operation

Tigercat 602 Carrier

Hardware Fault - MC43

Hardware Fault - XC21

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

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

HARDWARE FAULT - MC43

HARDWARE FAULT - XC21

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the MC43 Module has been hidden.

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the XC21 Module has been hidden.

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

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

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

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

Hardware Fault - XS2

Hardware Fault - XA2

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

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

HARDWARE FAULT - XS2

HARDWARE FAULT - XA2

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the XS2 Cab Module has been hidden.

This message will be displayed, alarm light will flash and alarm will sound when a critical active hardware fault related to the XA2 Front Chassis Module has been hidden.

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

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

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

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

2.76

Tigercat 602 Carrier

Controls and Operation

Engine Coolant

Engine Coolant

Temperature high.

Temperature High - Engine Derate

ENGINE COOLANT TEMPERATURE HIGH ENGINE DERATE

SPN: 63011 1 of 1 Engine coolant temperature high.

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

This message will be displayed, alarm light will flash and alarm will sound when an engine derate is triggered due to high engine coolant temperature. This message may be accompanied

by Engine Fault Code Messages related to coolant temperature.

This message results in the following derate sequence: •

symbol •

When this alarm is activated check for:

• •

When coolant temperature rises to 225°F (107°C) for more than 5 seconds the critical

Plugged air intake access panel screens Plugged radiator.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

will flash.

When coolant temperature rises to 230°F (110°C) for more than 5 seconds this message will be shown and the engine will immediately begin to derate at 50 rpm/s to a set creep speed allowing the operator to safely stop the machine (creep speed setting is programmed to suit each machine type/model). DO NOT continue to operate machine.

Safely stop the machine, idle the engine and turn the A/C off. If the engine coolant temperature reading does not return to normal operating levels turn the engine OFF and perform further cooling system checks. Refer also to MESSAGES - CRITICAL – ENGINE TEMPERATURE HIGH in THIS SECTION for recommended corrective action. If engine coolant temperature does not return to normal operating levels contact dealer for service.

•

When coolant temperatures fall below 223°F (106°C) for more than 5 seconds this message will be turned off and the engine will automatically ramp up engine speed at 50 rpm/s to full operating speed.

NOTE: An Engine Torque Derate Active message will also be triggered as the engine begins to derate. Refer to COMPUTER – MESSAGES CRITICAL – ENGINE TORQUE DERATE ACTIVE in THIS SECTION.

2.77

Controls and Operation

Tigercat 602 Carrier

Engine Coolant

Aftertreatment System

Level Low.

Technical failure severe. Engine lockout may occur after full torque derate and 3 engine restarts.

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

If this light comes on when the engine is running, stop the engine immediately and correct the fault.

With engine running, top up radiator using correct solution of coolant antifreeze.

Refer to SERVICE AND LUBRICATION POINTS CHART in SECTION 3.

WARNING

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

Turn then engine OFF. Only remove engine radiator fill cap when cool enough to touch with bare hands.

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

AFTERTREATMENT SYSTEM TECHNICAL FAILURE NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

This message will be displayed, alarm light will flash and alarm will sound when an aftertreatment techical fault is detected. Action to correct the problem should be taken immediately to avoid affecting engine performance and damage to the diesel oxidation catalyst /selective catalytic reduction (DOC/SCR) aftertreatment system components.

This message results in the following derate sequence if no action is taken to correct the problem: • Beginning immediately after an aftertreatment system technical message there will be a ramp down of Torque by 25% over 25 minutes.

• After 1 hour at reduced torque there will be a ramp down of Engine Speed by 60% and Torque by 65% over 40 minutes.

• After 50 minutes at derated engine speed and torque the engine is derated to idle within 30 minutes.

• Some less severe technical faults can be fixed at any time, even after then engine has been fully derated to idle speed.

• More severe technical faults will result in an engine lockout when the engine has derated to idle and there have been 3 restarts (redetects). Once locked out the engine will only operate at idle. Action to correct the original cause(s) of the lockout must be taken before the engine can be reset. Contact dealer to reset engine lockout for normal operation.

Refer to COMPUTER – MESSAGES CRITICAL – ENGINE LOCKED OUT and ENGINE RESTARTS REMAINING UNTIL ENGINE LOCKOUT in THIS SECTION. Identify the cause of the technical failure and take action to correct the problem.

Refer also to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

2.78

Tigercat 602 Carrier

Controls and Operation

Aftertreatment System

Engine

Engine idle too long. Shutdown engine to prevent damage to emission control system.

Engine locked out. Engine derate to 0% Torque and 850 rpm. Contact Dealer

ENGINE LOCKED OUT

AFTERTREATMENT SYSTEM ENGINE IDLE TOO LONG

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

This message will be displayed, alarm light will flash and alarm will sound when an engine is locked out by the computer system to prevent further damage to the engine and aftertreatment system.

This message will be displayed, alarm light will flash and alarm will sound when this engine has idled for more than 9 consecutive hours.

Shutdown engine to prevent damage to the emission control system.

IMPORTANT !

Engine should not idle longer than 9 consecutive hours. Damage to the emission control system will result. When this machine idles for an extended period excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon at full load immediately after a long idle period will generate excess heat which will cause damage to emission control system components.

Note that an engine is locked out after several other critical aftertreatment system messages regarding the cause of the problem and additional messages regarding the number of restarts until engine lockout.

Once locked out the engine will only operate at idle. Action to correct the original cause(s) of the lockout must be taken before the engine can be reset. Contact dealer to reset engine lockout for normal operation.

Refer to Engine Manuals for code information.

Refer also to COMPUTER – MESSAGES - CRITICAL – ENGINE RESTARTS REMAINING UNTIL ENGINE LOCKOUT in THIS SECTION.

2.79

Controls and Operation

Tigercat 602 Carrier

Engine

Engine Oil Pressure

3 restarts remaining until engine lockout.

Oil Pressure Low - Engine Derate

ENGINE RESTARTS REMAINING UNTIL ENGINE LOCKOUT

ENGINE OIL PRESSURE LOW ENGINE DERATE

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

This message will be displayed, alarm light will flash and alarm will sound when an engine derate is triggered due to low engine oil pressure. This message may be accompanied by Engine Fault Code Messages related to engine oil pressure.

This message will be displayed, alarm light will flash and alarm will sound to inform the operator of the number of restarts available before the engine is locked out.

Note that an engine is locked out after several other critical aftertreatment system messages regarding the cause of the problem and this message regarding the number of restarts until engine lockout.

This message results in the following derate sequence: •

Refer also to COMPUTER – MESSAGES CRITICAL – ENGINE LOCKED OUT in THIS SECTION.

SPN: 9939 1 of 1 Engine Oil Pressure Low.

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

When engine oil pressure readings fall below 17 psi (1.2 bar) for more than 5 seconds this message will be shown and the engine will immediately begin to derate at 50 rpm/s to a set creep speed allowing the operator to safely stop the machine (creep speed setting is programmed to suit each machine type/ model). DO NOT continue to operate machine.

Safely stop the machine and turn the engine OFF. Refer also to MESSAGES - CRITICAL – ENGINE OIL PRESSURE LOW in THIS SECTION for recommended corrective action.

If the problem continues contact dealer for service.

•

When engine oil pressure readings rise above 20 psi (1.4 bar) for more than 5 seconds this message will be turned off and the engine will automatically ramp up engine speed at 50 rpm/s to full operating speed.

NOTE: An Engine Torque Derate Active message will also be triggered as the engine begins to derate. Refer to COMPUTER – MESSAGES CRITICAL – ENGINE TORQUE DERATE ACTIVE in THIS SECTION.

Stop the engine when this alarm is activated.

Check engine oil levels.

Refer to STARTING ENGINE in THIS SECTION for more information.

2.80

Tigercat 602 Carrier

Controls and Operation

Engine Overspeed

Engine Overspeed Max

Apply service brakes to reduce travel speed.

3750 rpm. Reduce speed when skidding.

ENGINE OVERSPEED

ENGINE OVERSPEED MAX

This message will be displayed, alarm light will flash and alarm will sound when engine speed exceeds the recommended engine overspeed limit.

This message will be displayed, alarm light will flash and alarm will sound after an engine overspeed message has been triggered to indicate to the operator the maximum engine speed level which triggered the engine overspeed message.

Apply service brakes to reduce travel speed and avoid engine overspeed.

It is important to keep engine speed within the recommended operating range to avoid costly damage to the engine itself and to other machine components affected by engine overspeed.

Operating at engine speeds outside the recommended operating range will result in costly damage and reduce the expected life of the engine and other machine components affected by engine overspeed.

Whenever this message is displayed a second message follows once engine speed has been reduced to a level within normal limits. The second message indicates to the operator the maximum engine speed level which triggered the engine overspeed message. Refer also to COMPUTER – MESSAGES - CRITICAL – ENGINE OVERSPEED MAX in THIS SECTION.

This message is intended to remind operators to reduce speed when skidding to suit operating conditions and avoid engine overspeed.

It is important to keep engine speed within the recommended operating range to avoid costly damage to the engine itself and to other machine components affected by engine overspeed.

Operating at engine speeds outside the recommended operating range will result in costly damage and reduce the expected life of the engine and other machine components affected by engine overspeed.

Refer also to COMPUTER – MESSAGES CRITICAL – ENGINE OVERSPEED in THIS SECTION.

2.81

Controls and Operation

Tigercat 602 Carrier

SPN: 7123 1 of 1

SPN: 4645 1 of 1

Engine oil temperature high.

Contact dealer.

ENGINE OIL TEMPERATURE HIGH

ENGINE FAULT CODE MESSAGES - CRITICAL

This message will be displayed, alarm light will flash and alarm will sound when engine oil temperature exceeds recommended engine temperature.

Critical engine fault message(s) will be displayed, alarm light will flash and alarm will sound when a critical engine fault message is received from the engine electronic control module.

Check the cooler package and fan for proper operation and run a clean cycle if the machine is equipped with a variable pitch fan. It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures. Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

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

Refer to Engine manuals for more information.

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

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

Note that some less common engine fault codes will appear without a message describing the fault.

Make a note of the SPN code and contact service for more information.

Refer to engine manual for specific information regarding the engine and aftertreatment system.

NOTE: Contact your Tigercat dealer to obtain an Engine Fault Codes chart. An up to date copy should be kept in the Manual’s Box (in the cab). The chart is updated regularly by the engine manufacturer, so it is important to check periodically with the Tigercat dealer to ensure that you have a current copy of the Engine Fault Codes chart.

2.82

Tigercat 602 Carrier ERROR MESSAGES (RED)

Controls and Operation

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

Error messages are computer system generated and are generally triggered by computer system error and fault related conditions.

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

Error messages are activated whenever a fault such as an electrical connection is broken/ disconnected. Most error messages are due to computer system hardware or connection faults.

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

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

A list of some types of ERROR MESSAGES is as follows: Module No Contact Error Module VREF Error Voltage Input Error (VIN) Digital Input Error (DIN) Digital Output Error (DOUT) Current Output Error (COUT) * Note that not all error messages are shown.

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

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

Messages are acknowledged by pressing the F2 button (OK). To recall active messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

Error messages flash the critical symbol

or the

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

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

2.83

Controls and Operation ERROR MESSAGES

Tigercat 602 Carrier XS2[0]@MC43[1]:D

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

Cab Module No contact

When a module loses contact all machine functions controlled by that module cease and all messages associated with that module are triggered. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

XC21[3]@MC43[1]:D

Note that if the display module has a loss of power or other malfunction the screen may go blank and all machine functions controlled by the computer system will be affected..

Seat Module No contact

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES - CRITICAL – HARDWARE FAULT in THIS SECTION.

XA2[0]@MC43[1]:D

Front Chassis Module No contact

J1939-E0

Tigercat/ FPT NEF 6.7L No contact

Telematics No contact

Disable

2.84

Tigercat 602 Carrier

Controls and Operation

MODULE VREF ERROR

MD3

The module VREF message will be displayed to indicate a problem related to the 5V reference signal coming from the module.

Display VREF error

The module is identified on the display screen.

This message indicates a problem with a sensor, connecting wires or the 5V reference signal itself.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES - CRITICAL – HARDWARE FAULT in THIS SECTION.

XC21[3]@MC43[1]:D

Seat Module VREF error

XS2[0]@MC43[1]:D

Cab Module VREF error

XA2[0]@MC43[1]:D

Front Chassis Module VREF error

MC43[1]

MC43[1] VREF error

2.85

Controls and Operation

Tigercat 602 Carrier Cab Module Pin C1:25

Travel Direction Select VIN High error

CURRENT OUTPUT ERROR (COUT) Current output error messages will be displayed to indicate a problem with a current output signal from a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal destination and the text indicates the type of error.

VOLTAGE INPUT ERROR (VIN) Voltage input error messages will be displayed to indicate a problem with a voltage input signal to a computer system module.

The module and pin number are identified on the display screen.

The display is similar to the voltage input error message shown above.

Once acknowledged these message will be replaced with a hardware failure message for the corresponding module when active faults recalled to the screen. Refer to COMPUTER – MESSAGES - ALERT – HARDWARE FAILURE in THIS SECTION.

The heading identifies the signal source and the text indicates the type of error.

An example of a voltage input error message is shown above.

DIGITAL INPUT ERROR (DIN) Digital input error messages will be displayed to indicate a problem with a digital input signal to a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal source and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

DIGITAL OUTPUT ERROR (DOUT) Digital output error messages will be displayed to indicate a problem with a digital output signal from a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal destination and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

2.86

Tigercat 602 Carrier ALERT MESSAGES (YELLOW)

Controls and Operation

Alert messages advise the operator that machine operation will be compromised.

Alert messages have the third level of priority and are used to indicate to the operator that action is required to prevent future damage to the machine.

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

Action should be taken to service the machine to correct the problem at the earliest opportunity to prevent future damage to the machine.

Alert messages flash the alert symbol above the F4 button when active messages are hidden.

There are two types of alert messages: Alert programmed messages generally triggered by machine function related conditions.

When an alert message is displayed, the master alarm and light will sound and flash three times to alert the operator of the message. The message remains on the screen until the operator hides it.

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

Active messages that have been hidden can be reviewed by pressing the F4 button. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Note that if both a critical level fault and an alert level fault are present the critical symbol will take priority until the critical fault becomes inactive.

Alert computer system generated messages are generally triggered by computer system error and fault related conditions.

When a system generated alert message is displayed he master alarm and light will sound and flash three times to alert the operator of the message.

The message remains on the screen until the operator hides it.

Note that active hardware fault alert messages are acknowledged by pressing the F2 button (OK).

To recall these messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

2.87

Controls and Operation A list of ALERT MESSAGES is as follows:

Tigercat 602 Carrier ALERT MESSAGES

Fuel Level low.

Engine Air Intake Filter Restricted Drive Charge Filter Bypassed

Fuel

Transmission Filter Bypassed

Level low.

Main Fuel Filter Clogged Pilot Manifold Pressure High Machine Voltage Low. Machine Voltage High Service Brake Pressure Low Drive Charge System Pressure Low Drive Trigger Interlock Joystick & Pedal Interlock Joystick Button Interlock Control System Remote Controls Activated - Alert Hardware Fault - MD3 Hardware Fault - MC43

FUEL LEVEL LOW This message will be displayed when the fuel level falls below 5% of full.

Note that the fuel gauge symbol changes from its normal white to yellow when fuel level is low.

Refer to FUEL TANK in SECTION 3 for tank capacities.

Hardware Fault - XS2 Hardware Fault - XC21 Hardware Fault - XA2 Hardware Failure - VIN Hardware Failure - DIN Hardware Failure -DOUT Hardware Failure -COUT Engine Voltage Low

Engine Air Intake Filter

Engine Voltage High

Restricted. Service Machine to correct.

Fuel Water In Fuel Engine Coolant Temperature High Diesel Exhaust Fluid Level <10%* Diesel Exhaust Fluid Level <5%* Diesel Exhaust Fluid Level Empty*

ENGINE AIR INTAKE FILTER RESTRICTED

Diesel Exhaust Fluid Quality*

This message will be displayed when a signal is received from the restriction indicator switch on the engine air cleaner.

Engine Torque Derate Active Engine Fault Code Messages - Alert Some types of computer system generated alert messages are listed below: Module High Temperature - Alert Module High Supply Voltage - Alert

When this happens the engine air cleaner requires immediate service.

Refer to AIR CLEANER MAINTENANCE in SECTION 3.

Module Low Supply Voltage - Alert *NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

NOTE: Not all system generated alert messages are shown.

2.88

Tigercat 602 Carrier

Controls and Operation

Drive Charge Filter

Main Fuel Filter

Bypassed. Service machine to correct.

Clogged. Replace filter to prevent engine derate.

DRIVE CHARGE FILTER BYPASSED

MAIN FUEL FILTER CLOGGED

This message will be displayed when an oil flow restriction in excess of 50 psi (3.5 bar) is encountered at the hydrostatic oil charge filter.

This pressure build up also opens the filter bypass valve in the filter head allowing oil to bypass the filter element.

This message will be displayed when a main fuel filter clog is detected.

Replace engine fuel filter to prevent engine derate. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine fuel filter replacement instructions

When this happens the filter requires immediate service.

When a fuel filter clog continues for more than 5 minutes a critical message will be shown and the engine will immediately begin to derate. Refer to COMPUTER – MESSAGES - CRITICAL – MAIN FUEL FILTER CLOGGED- ENGINE DERATE in THIS SECTION.

If alarm sounds during cold start-ups, the engine speed should be reduced and the warm up procedure continued. Note that the bypass message will only be displayed when hydraulic oil temperature is above 85°F (29°C) and the filter is in bypass mode.

Transmission Filter

Pilot Manifold

Bypassed. Service machine to correct.

Pressure High. Service Machine to correct.

TRANSMISSION FILTER BYPASSED

PILOT MANIFOLD PRESSURE HIGH

This message will be displayed when an oil flow restriction in excess of 50 psi (3.5 bar) is encountered at the transmission filter. This pressure build up also opens the filter bypass valve in the filter head allowing oil to bypass the filter element.

This message will be displayed when high pressure is detected in the multifunction manifold (pilot manifold).

Check multifunction manifold pressure reducing valve and relief valve for proper opertion. Refer to MULTIFUNCTION MANIFOLD in SECTION 9.

When this happens the filter requires immediate service.

If alarm sounds during cold start-ups, the engine speed should be reduced and the warm up procedure continued. Note that the bypass message will only be displayed when transmission oil temperature is above 40°F (4°C) and the filter is in bypass mode.

2.89

Controls and Operation

Tigercat 602 Carrier

Machine Voltage

Service Brake

Low. Service machine to correct.

Pressure Low. Service machine to correct.

MACHINE VOLTAGE LOW

SERVICE BRAKE PRESSURE LOW

This message will be displayed when machine voltage readings of less than 20 volts are detected.

This message will be displayed when service brake pressure falls below 800 psi (55 bar).

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

When this message is activated check first for leaks in the brake circuit. If no leaks are found check for proper operation of the brake pedal valve, accumulator, check valve and brake pressure sensor.

For more information about the service brake circuit refer to SECTION 9 of THE SERVICE MANUAL.

Machine Voltage

Drive Charge System

High. Service machine to correct.

Pressure Low. Service machine to correct.

MACHINE VOLTAGE HIGH

DRIVE CHARGE SYSTEM PRESSURE LOW

This message will be displayed when machine voltage readings of greater than 30 volts are detected.

This message will be displayed when drive charge pressure falls below 250 psi (17 bar). The charge pressure is monitored at the forward and reverse pressure sensors on the drive pump.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

When this message is activated check the charge filter for proper operation then, if necessary, check the charge pressure using a gauge.

Refer to DRIVE PUMP PRESSURE CHECKS in SECTION 8 of THE SERVICE MANUAL. Refer also to COMPUTER – MESSAGES ALERT – DRIVE CHARGE FILTER BYPASSED message in THIS SECTION.

2.90

Tigercat 602 Carrier

Controls and Operation

Drive Trigger Interlock

Joystick Button Interlock

Release drive trigger and press OK

Release depressed joystick button.

OK DRIVE TRIGGER INTERLOCK

JOYSTICK BUTTON INTERLOCK

This message will be shown when the drive trigger is activated before the parking brake is disengaged. Function operation is prevented until the control is released and the operator presses OK (F2) on the computer display.

This message will be shown when a joystick button function control is activated before the parking brake is disengaged. Function operation is prevented until the control is released.

This interlock prevents unintended operation of the travel/engine speed trigger.

This interlock prevents unintended operation of machine functions.

Refer to CAB CONTROLS – TRAVEL/ENGINE SPEED TRIGGER (ROTATING SEAT & JOYSTICK STEERING) in THIS SECTION.

Joystick & Pedal Interlock

Control System

Release active joystick or pedal

Remote controls activated. Cab controls disabled.

JOYSTICK & PEDAL INTERLOCK This message will be shown when joystick or pedal function control is activated before the parking brake is disengaged. Function operation is prevented until the control is released.

This interlock prevents unintended operation of machine functions.

CONTROL SYSTEM REMOTE CONTROLS ACTIVATED - ALERT This warning will be displayed when the remote control switch is in the in the ON position.

Note that when the remote control is activated the cab controls are disabled.

Refer to CAB CONTROLS – ­ REMOTE CONTROL SWITCH in THIS SECTION. Refer to manufacturer's instructions for information regarding safety and operation of the remote control.

2.91

Controls and Operation

Tigercat 602 Carrier

Hardware Fault - MD3

Hardware Fault - XS2

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

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

HARDWARE FAULT - MD3

HARDWARE FAULT - XS2

This message will be displayed when an alert level active hardware fault related to the MD3 Display Module has been hidden.

This message will be displayed when an alert level active hardware fault related to the XS2 Cab Module has been hidden.

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

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

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

Hardware Fault - MC43

Hardware Fault - XC21

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

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

HARDWARE FAULT - MC43

HARDWARE FAULT - XC21

This message will be displayed when an alert level active hardware fault related to the MC43 Module has been hidden.

This message will be displayed when an alert level active hardware fault related to the XC21 Module has been hidden.

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

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

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

2.92

Tigercat 602 Carrier

Controls and Operation

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

HARDWARE FAULT - XA2 This message will be displayed when an alert level active hardware fault related to the XA2 Front Chassis Module has been hidden.

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

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

2.93

Controls and Operation

Tigercat 602 Carrier

Hardware Failure - VIN

Hardware Failure - DOUT

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

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

HARDWARE FAILURE - VIN

HARDWARE FAILURE - DOUT

This message will be displayed when a voltage input error message has been hidden.

This message will be displayed when a digital output error message has been hidden.

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

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

Hardware Failure - DIN

Hardware Failure - COUT

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

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

HARDWARE FAILURE - DIN

HARDWARE FAILURE - COUT

This message will be displayed when a digital input error message has been hidden.

This message will be displayed when a current output error message has been hidden.

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

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

2.94

Tigercat 602 Carrier

Controls and Operation

SPN: 62755 1 of 1

SPN: 8801 1 of 1

Engine coolant temperature high.

Engine voltage low.

ENGINE VOLTAGE LOW

ENGINE COOLANT TEMPERATURE HIGH

This message will be displayed when engine voltage readings of less than 20 volts are detected.

This message will be displayed, alarm light will flash and alarm will sound when engine temperature exceeds recommended engine temperature.

When this alarm is activated investigate the cause immediately.

Investigate cause as soon as possible.

When this alarm is activated check for:

• •

Plugged air intake access panel screens Plugged radiator.

Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

Refer to COMPUTER – MESSAGES - CRITICAL – ENGINE COOLANT TEMPERATURE HIGH.

SPN: 4449 1 of 1

SPN: 17429 1 of 1

Engine voltage high.

Water in Fuel.

ENGINE VOLTAGE HIGH

FUEL - WATER IN FUEL

This message will be displayed when engine voltage readings of greater than 30 volts are detected.

This message will be displayed when water is detected in the fuel by the engine computer system.

When this alarm is activated investigate the cause immediately.

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

2.95

Controls and Operation DIESEL EXHAUST FLUID LEVEL MESSAGES NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

Tigercat 602 Carrier Fill DEF tank and restart engine to clear the message.

There are three levels of diesel exhaust fluid level messages generated by the Engine ECU.

SPN: 64191 1 of 1 DEF tank empty.

SPN: 61839 1 of 1 DEF Level below 10%.

DIESEL EXHAUST FLUID LEVEL <10% This message will be displayed, alarm light will flash and alarm will sound when a diesel exhaust fluid level below 10% is detected.

Action to correct DEF levels should be taken immediately to avoid affecting engine performance and damage to the diesel oxidation catalyst / selective catalytic reduction (DOC/SCR) aftertreatment system components.

Fill DEF tank and restart engine to clear the message.

Refer to DIESEL EXHAUST FLUID TANK in SECTION 3.

DIESEL EXHAUST FLUID LEVEL EMPTY This message will be displayed, alarm light will flash and alarm will sound when diesel exhaust fluid level empty is detected. Action to correct DEF levels should be taken immediately to avoid affecting engine performance and damage to the diesel oxidation catalyst /selective catalytic reduction (DOC/SCR) aftertreatment system components.

•

Beginning immediately after a DEF level empty message, the engine is derated to idle within 30 minutes.

Fill DEF tank and restart engine to clear the message.

Note that an Engine Torque Derate Active message will also be triggered as the engine begins to derate. Refer to COMPUTER – MESSAGES - CRITICAL – ENGINE TORQUE DERATE ACTIVE in THIS SECTION.

SPN: 62095 1 of 1 DEF Level below 5%.

DIESEL EXHAUST FLUID LEVEL <5% This message will be displayed, alarm light will flash and alarm will sound when a diesel exhaust fluid level below 5% is detected. Action to correct DEF levels should be taken immediately to avoid affecting engine performance and damage to the diesel oxidation catalyst /selective catalytic reduction (DOC/SCR) aftertreatment system components.

• Beginning immediately after a DEF level <5% message, there will be a ramp down of Engine Speed by 60% and Torque by 65% over 40 minutes.

2.96

Tigercat 602 Carrier

Controls and Operation WARNING Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

SPN: 19402 1 of 2 DEF quality low.

SPN: 19658 2 of 2 DEF quality low.

DIESEL EXHAUST FLUID QUALITY NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

This message will be displayed, alarm light will flash and alarm will sound when a diesel fluid quality problem is detected. Action to correct the problem should be taken immediately to avoid affecting engine performance and damage to aftertreatment system components.

This message results in the following derate and engine lockout sequence if no action is taken to correct the problem: • Beginning 1 hour after a DEF quality message there will be a ramp down of Engine Speed by 60% and Torque by 65% over 40 minutes.

• After 2 hours at derated engine speed and torque the engine is derated to idle within 30 minutes.

To correct the DEF quality problem clean the area around the DEF tank then drain and refill the tank with clean DEF which meets ISO 22241 specifications.

Note that an Engine Torque Derate Active message will also be triggered as the engine begins to derate. Refer to COMPUTER – MESSAGES - CRITICAL – ENGINE TORQUE DERATE ACTIVE in THIS SECTION.

SPN: 64911 1 of 1 Engine torque derate active.

ENGINE TORQUE DERATE ACTIVE NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

This message will be displayed, alarm light will flash and alarm will sound when the Engine ECU has derated the engine. The code for a Torque Derate due to too high NOx emissions is shown above as an example.

Refer to Engine Manuals for code information to identify the cause(s) of engine derating and more information regarding failure cause and repair.

Refer to DIESEL EXHAUST FLUID TANK in SECTION 3.

Refer also to AFTERTREATMENT SYSTEM in SECTION 3 for more information regarding the use of DEF and its function in the DOC/SCR aftertreatment system.

2.97

Controls and Operation

Tigercat 602 Carrier

SPN: ###### 1 of 1 Contact dealer.

ENGINE FAULT CODE MESSAGES - ALERT Alert engine fault message(s) will be displayed, alarm light will flash and alarm will sound when an alert engine fault message is received from the engine electronic control module.

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

Alert engine fault codes are lower priority messages than critical level engine fault code messages. Alert messages can be hidden but action (service engine) is required to resolve the cause of the fault.

An example of an alert engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault.

Make a note of the SPN code and contact service for more information.

Refer to engine manual for specific information regarding the engine and aftertreatment system.

NOTE: Contact your Tigercat dealer to obtain an Engine Fault Codes chart. An up to date copy should be kept in the Manual’s Box (in the cab). The chart is updated regularly by the engine manufacturer, so it is important to check periodically with the Tigercat dealer to ensure that you have a current copy of the Engine Fault Codes chart.

2.98

Tigercat 602 Carrier

Controls and Operation

MODULE HIGH TEMPERATURE - ALERT

MD3

Module high temperature alert message will be displayed to indicate that the computer control system has detected high temperature readings in a system module.

Display High temperature Value 73°C

The module is identified on the display screen.

The temperature reading value is also displayed.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES - ALERT – HARDWARE FAULT in THIS SECTION.

XS2[0]@MC43[1]:D

Cab Module High temperature Value 94°C

XA2[0]@MC43[1]:D

Front Chassis Module High temperature Value 87°C

MC43[1]

MC43[1] High temperature Value 136°C

2.99

Controls and Operation

Tigercat 602 Carrier

MODULE HIGH SUPPLY VOLTAGE - ALERT

MD3[0]

Module high supply voltage alert message will be displayed to indicate that the computer control system has detected high supply voltage readings in a system module.

Display High supply voltage Value 37.63 V

The module is identified on the display screen.

The voltage reading value is also displayed.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES - ALERT – HARDWARE FAULT in THIS SECTION.

XS2[0]@MC43[1]:D

Cab Module High supply voltage Value 37.63 V

XA2[0]@MC43[1]:D

Front Chassis Module High supply voltage Value 37.63 V

MC43[1]

MC43[1] High supply voltage Value 37.63 V

2.100

Tigercat 602 Carrier

Controls and Operation

MODULE LOW SUPPLY VOLTAGE - ALERT

MD3

Module low supply voltage alert message will be displayed to indicate that the computer control system has detected low supply voltage readings in a system module.

Display Low supply voltage

The module is identified on the display screen.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER – MESSAGES - ALERT – HARDWARE FAULT in THIS SECTION.

XS2[0]@MC43[1]:D

Cab Module Low supply voltage

XA2[0]@MC43[1]:D

Front Chassis Module Low supply voltage

MC43[1]

MC43[1] Low supply voltage

2.101

Controls and Operation INFORMATION MESSAGES (BLUE)

Tigercat 602 Carrier

Information messages give the operator information regarding an event or problem condition while the event or problem exists.

Information messages have lowest priority and are used to give the operator information that is useful to the operator, but requires no action to prevent immediate or future damage to the machine When an information message is displayed on the screen the message will either automatically disappear when the condition no longer exists or stay on the screen until the operator acknowledges the message.

Information messages can be acknowledged by pressing the F2 button (OK). Acknowledged information messages are removed from the screen.

A list of the INFORMATION MESSAGES is as follows: Setup Mode - Engine HP Test Setup Mode - Drive Motor Setup Setup Mode - Drive Pump POR Setup Setup Mode - Drive Pump Regulation Setup Setup Mode - Function Setup Setup Mode - Max Current Setup Machine Steering Invert Disabled

Information messages do not have an indicator after they have been acknowledged.

Most information messages that have been acknowledged cannot be reviewed.

Recurrence of an event or problem condition related to an information message may cause the message to be shown again.

Restarting the machine may also cause the message to be shown again.

2.102

Tigercat 602 Carrier INFORMATION MESSAGES

Controls and Operation IMPORTANT !

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

SETUP MODE One of these messages will be displayed until the message is acknowledged when the machine is placed in a service program mode:

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

• Engine HP Test Mode • Drive Motor Setup Mode • Drive Pump POR Setup Mode • Drive Pump Regulation Setup • Function Setup Mode • Max Current Setup Mode Setup Program Modes are intended for setup and testing and should only be used by qualified Tigercat service technicians or on specific instructions from a service technician.

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

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

Attempting to use these controls will reactivate the information message.

NOTE ALSO: •

In Engine HP Test, Drive Motor Setup, Drive Pump POR Setup, Drive Pump Regulation and Max Current Setup Modes the arch and boom are deactivated. Attempting to use these controls will reactivate the information message.

•

In Function Setup Mode the drive pedals and steering are deactivated. Attempting to use these controls will reactivate the information message.

Setup Mode Engine HP Test Mode for service use only.

Return to Normal Mode to operate machine.

Setup Mode Drive Motor Setup Mode for service use only.

Return to Normal Mode to operate machine.

For more information on the setup mode settings refer to COMPUTER – ADJUSTMENT MENU SERVICE SETTINGS – PROGRAM MODE in THIS SECTION.

Setup Mode Drive Pump POR Setup Mode for service use only. Return to Normal Mode to operate machine.

2.103

Controls and Operation

Tigercat 602 Carrier

Machine Steering

Setup Mode

Steering invert disabled. Steer joystick direction does not change when operator is facing rearward.

Drive Pump Regulation Setup for service use only. Return to Normal Mode to operate machine.

Setup Mode Function Setup Mode for service use only.

Return to Normal Mode to operate machine.

Setup Mode Max Current Setup Mode for service use only.

Return to Normal Mode to operate machine.

MACHINE STEERING INVERT DISABLED This message will be displayed each time the machine is started when the joystick steering invert function is disabled.

When the joystick steering invert function is disabled. Steer joystick direction does not change when operator is facing rearward. Therefore LEFT articulation and RIGHT articulation are considered to be left and right as viewed by the operator from the forward facing seat position regardless of the position of the operator's seat.

For more information regarding the steer invert function setting refer to COMPUTER – ADJUSTMENT MENU - SERVICE SETTINGS – STEER INVERT (JOYSTICK STEERING ONLY) in THIS SECTION. Refer also to LEFT JOYSTICK – STEERING, ROTATING SEAT KICK LEVER and COMPUTER – MESSAGES - INFORMATION – MACHINE STEERING INVERT DISABLED in THIS SECTION.

2.104

Tigercat 602 Carrier CAB VENTILATION

Controls and Operation 1

1. AIR VENTS The Air Conditioner/Heater package has 8 air outlets in the cab.

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

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

• 2 on the rear dash, below the window.

• 1 behind seat on the lower right.

• 1 behind seat on the lower left.

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

620E-026

RIGHT DOOR POST VENTS - 2

2. 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 on a regular basis.

This is done by removing two thumb screws in the filter box cover.

3. FILTER - FRESH AIR When the air source switch is in the ON position , outside air is drawn into the cab air conditioning unit through this filter and mixed with interior air from the cab. To reduce dust in the cab area, use the FRESH AIR option with the A/C on. This pressurizes the cab, forcing dust out and reducing dust coming in. The FRESH AIR filter is accessible from outside of the cab, at the back between the lights. The filter should be inspected on a regular basis and cleaned/replaced when severely plugged or wet. This is done by removing 6 bolts (3/8”) and removing the air inlet cover. Next remove two nuts (1/4”) and remove the filter box cover. This will allow access to the filter.

1

REAR DASH VENTS - 2

620E-021

1

620E-020

2

VENTS BEHIND SEAT - 2 3

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

620E-019

2.105

FRESH AIR FILTER

Controls and Operation

Tigercat 602 Carrier LOCATED IN OPERATOR'S CAB

CHARGE GAUGE

620E-018

AM/FM STEREO CD With two front mounted speakers. Consult the manufacturer's instruction manual for additional information.

620E-006

FIRE EXTINGUISHER, PORTABLE

FIRE EXTINGUISHER, PORTABLE A portable fire extinguisher is located in the operator's cab. The extinguisher should be checked daily to ensure that it is charged. The pointer on the charge gauge should point to the green region. If the indicator falls out of this green area, the extinguisher should be serviced immediately. Refer also to FIRE PREVENTION in SECTION 1.

620E-028

RADIO - CB (IF EQUIPPED) Consult the manufacturer's instruction manual for additional information.

2.106

Tigercat 602 Carrier

Controls and Operation

CHASSIS

BOLT ON ACCESS PANELS

MAINTENANCE ACCESS DOORS

BOLTS

602-051

ACCESS PANELS LEFT SIDE

BOLT ON ACCESS PANELS

602-054

FRONT DOOR

DOORS AND ACCESS PANELS TO OPEN: 1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

MAINTENANCE ACCESS DOORS

6. Turn OFF the battery disconnect switch.

7. Block wheels.

8. Install the articulation lock bar.

602-053

9. Remove the two bolts from the left side of the door and swing open.

ACCESS PANELS RIGHT SIDE

CAUTION

10. When the maintenance is complete, close the door and reinstall bolts.

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

Park on level ground to prevent unexpected door closing.

IMPORTANT !

DO NOT operate dozer with door open.

2.107

Controls and Operation ACCESS PANELS

Tigercat 602 Carrier

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

DOOR PROP

602-062

MAINTENANCE ACCESS DOOR (LEFT SIDE SHOWN)

Some panels are equipped with a maintenance access door to provide quick access for routine daily maintenance. Maintenance access doors are equipped with a door prop to hold them open while in use as shown above.

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

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

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

2.108

Tigercat 602 Carrier STEP COMPARTMENTS

Controls and Operation

602-071

LEFT STEP COMPARTMENT

602-071

RIGHT STEP COMPARTMENT

602-071

LEFT STEP COMPARTMENT

602-071

RIGHT STEP COMPARTMENT

2.109

Controls and Operation BATTERY BOOSTING

Tigercat 602 Carrier 7. Connect the other clamp of the red jumper cable to the positive (+) terminal of the good battery.

NOTICE

8. Connect the clamp of the black jumper cable to the negative (–) terminal of the good battery.

This machine has a 24 volt starting system.

Only use the same voltage when boosting with an auxiliary battery. Using a higher or lower voltage will cause serious damage to the electrical system. Only a compatible (same) voltage is permissible.

9. Connect the other clamp of the black jumper cable to the negative (–) terminal of the dead battery.

10. Start the engine with the good battery.

11. Start the engine with the dead battery.

The batteries are located in the step compartment below the left cab door.

12. Disconnect the clamp of the black jumper cable from the negative (–) terminal of the dead battery.

Refer also to BATTERY CARE in SECTION 3.

BATTERY BOOSTER CABLE WITH CLAMPS

13. Disconnect the clamp of the black jumper cable from the negative (-) terminal of the good battery.

1. Bring the machines as close as possible, make sure the machines do not touch.

14. Disconnect the clamp of the red jumper cable from the positive (+) terminal of the good battery.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

15. Disconnect the clamp of the red jumper cable from the positive (+) terminal of the dead battery.

2. Make sure the machine with the good battery uses a 24 volt system.

3. Turn OFF the ignition of both machines.

4. Access the batteries.

16. Install the battery box cover and mounting hardware.

5. Find the red positive (+) and black negative (–) battery terminals.

If the batteries need charging, refer to BATTERY CARE in SECTION 3.

B

A 602-003

A Positive Battery Terminal (Red) B Negative Battery Terminal (Black)

6. Connect the clamp of the red jumper cable to the positive (+) terminal of the dead battery.

2.110

Tigercat 602 Carrier BATTERY DISCONNECT SWITCH

Controls and Operation BELOW RIGHT CAB DOOR

BATTERY DISCONNECT SWITCH

TRANSMISSION OIL FILL LOCATION

TRANSMISSION DIPSTICK

610E-006

TRANSMISSION DIPSTICK AND FILL LOCATION

TRANSMISSION DIPSTICK 602-003

The transmission dipstick is located below the right cab door.

BATTERY DISCONNECT SWITCH LEFT SIDE ENGINE COMPARTMENT

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

TRANSMISSION OIL FILL LOCATION The transmission oil fill is located below the right cab door.

When in the OFF position it completely disconnects all the machine's electrical circuits from the battery and isolates the engine electronic control unit (ECU) power fuses.

NOTE: This machine is equipped with an After Run Disconnect Relay which delays the power disconnect to engine related fuses and relays by 90 seconds.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

On Tier 4f machines only, whenever the engine is stopped all DEF solution is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds. Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

2.111

Controls and Operation PRESSURIZED WATER SYSTEM (IF EQUIPPED) WATER WATER TANK CONTROL VALVE

SHUT-OFF VALVE IN CLOSED POSITION 620E-004

Tigercat 602 Carrier

DOZER BLADE

HOSE STORAGE COMPARTMENT

PRESSURIZED WATER SYSTEM

A water tank is incorporated into the dozer blade and is pressurized to 60 psi (4 bar). A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade.

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

The pressure gauge on the valve should read 60 psi (4 bar) check system pressure daily.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3.

All handles should be hand tight only at all times.

This is particularly important for easy access to the pressurized water system in the event of a fire or other emergency.

Refer also to FIRE PREVENTION in SECTION 1.

2.112

Tigercat 602 Carrier

Controls and Operation

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

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

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

3. Check fuel gauge and DEF level indicator (if applicable). Refer to FUEL TANK and DIESEL EXHAUST FLUID (DEF) TANK in SECTION 3 for standard tank capacity information.

NOTE: DEF level indicator and its related components are applicable to TIER 4f machines only.

Read and understand the entire manual before operating the machine.

PRE-START CHECKS:

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

5. Remove the ignition key.

1.

Place the ignition switch in the RUN position (engine NOT running) to provide power to the computer system. Check for any alarms noted on the computer display and investigate the cause. Refer to COMPUTER in THIS SECTION. ICON ILLUMINATED (RED) WHEN PARKING BRAKE IS ENGAGED

SIGHT GAUGE

602-032

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

MAIN HYDRAULIC OIL SIGHT GAUGE

6. Check hydraulic tank oil level with the dozer blade and grapple or shield on the ground. In this position the oil level should reach the full mark. Note that the oil level will drop 2 to 3 in (5 to 7.5 cm) when all cylinders are extended.

2.113

Controls and Operation FILL LOCATION

Tigercat 602 Carrier LOCATED ON LEFT SIDE

LEFT SIDE OF ENGINE HAND PRIMER

DIPSTICK

FUEL FILTER/ WATER SEPARATOR

ENGINE OIL LEVEL 7. Check the engine oil level. The level of the oil must be between the ADD and the FULL marks on the dipstick.

602-027

BELOW RIGHT CAB DOOR

TRANSMISSION OIL FILL LOCATION

TRANSMISSION DIPSTICK

610E-006

FUEL WATER SEPARATOR 602-012 9. Drain water from fuel line water separator.

Refer to FILTERS, FUEL/WATER SEPARATOR in SECTION 3.

TRANSMISSION DIPSTICK AND FILL LOCATION

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

2.114

Tigercat 602 Carrier

Controls and Operation

FILL CAP

33952AUNI R0

ENGINE COOLANT LEVEL 10. Check the engine coolant level. Fill if required.

620E-025

602-033 INLET HOOD 12. Check inlet hood (if equipped) for foreign material build-up in air intake area.

ENGINE AIR PRECLEANER A/C COMPRESSOR BELT

SERPENTINE BELT 630E-308

ENGINE AIR PRECLEANER

13. Check air intake precleaner (if equipped) for foreign material build-up in air intake area or discharge louver area.

AIR CLEANER 602-013

CHECK CONDITION OF ENGINE BELTS

11. Check tension and condition of all engine belts. Refer to SERPENTINE BELT INSPECTION/REPLACEMENT in SECTION 3

AIR CLEANER UNLOADER VALVE

ENGINE AIR CLEANER 14. Check air cleaner unloader valve (if equipped) 602-017

2.115

Controls and Operation

Tigercat 602 Carrier WATER WATER TANK CONTROL VALVE

FILTER RESTRICTION SWITCH

DOZER BLADE

FILTER RESTRICTION INDICATOR AIR CLEANER

SHUT-OFF VALVE IN CLOSED POSITION 620E-004

ENGINE AIR CLEANER 15. Check engine air cleaner restriction indicator.

602-016

HOSE STORAGE COMPARTMENT

PRESSURIZED WATER SYSTEM

17. 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.

18. Perform SCHEDULED MAINTENANCE as shown in SECTION 3.

19. Inspect machine for leaks , damaged or loose components and any other abnormal conditions.

20. Check tire pressures.

21. Check wheel bolts for tightness.

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

23. Unlock all cab doors.

IMPORTANT !

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

602-015

CLEAN RADIATOR, OIL COOLER, CAC AND A/C CONDENSER

16. Clean radiator, oil cooler, CAC (charge air cooler) and A/C condenser. Remove debris from front door and screened access panels on both sides of the machine.

Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

2.116

Tigercat 602 Carrier STARTING ENGINE

Controls and Operation IMPORTANT !

After engine has started, keep engine speed low until engine oil pressure registers on computer display. If engine oil pressure does not register within 10 seconds, stop engine and investigate cause.

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

2. Parking brake ENGAGED. NOTE: The engine will not turn over unless the parking brake is ENGAGED.

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

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

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

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

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

8. Before applying any load to the engine proceed with SYSTEM TEST AND WARM UP. IMPORTANT !

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

4. Wait for WAIT TO START message on computer display to turn off.

NOTE: For cold weather conditions refer to MACHINE WARM UP OPERATION on the following pages.

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

6. Turn ignition key switch to the START position to crank the engine. When engine is started place key switch in RUN position and observe computer display.

Note that the computer control system will automatically perform a bulb test when the keyswitch is released to the RUN position.

The alarm light will flash and the master alarm will sound briefly to test for proper operation.

7. Engine idle speed setting will automatically default to LOW IDLE. Keep engine speed low until engine oil pressure registers on computer display ( ENGINE MENU - ENGINE FUNCTIONS). Low engine oil pressure will trigger an alarm.

IMPORTANT !

Engine should not idle longer than 9 consecutive hours. Damage to the emission control system will result. When this machine idles for an extended period excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon at full load immediately after a long idle period will generate excess heat which will cause damage to emission control system components.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

Refer to COMPUTER – MESSAGES CRITICAL – ENGINE OIL PRESSURE LOW in THIS SECTION.

2.117

Controls and Operation STARTING IN COLD WEATHER

Tigercat 602 Carrier

NOTICE

Cold temperatures may require the use of the engine block heater and the engine oil pan heater.

The engine is equipped with an intake air heater with a grid element.

WARNING: Using starting fluid (or ether start aids) on an engine equipped with a grid heater element can cause an explosion. NEVER USE STARTING FLUIDS on an engine equipped with a grid heater element.

WARNING • EXPLOSION HAZARD.

• DO NOT IDLE THIS ENGINE FOR MORE THAN 9 HOURS. • DAMAGE TO EMISSION CONTROL SYSTEM WILL RESULT.

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

63281BENG R0

36782BENG R0

The grid element preheats engine intake air during cold starts. The wait to start message is shown on the computer display for the duration of the preheating phase of engine startup. To minimize cranking time during cold weather startups, ALWAYS wait for the wait to start message on the computer display to turn off before cranking the engine. Before applying any load to the engine proceed with SYSTEM TEST AND WARM UP. IMPORTANT !

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

Wait 2 minutes between each attempt to start the engine. If engine fails to start, refer to engine manufacturers operator's manual.

IMPORTANT !

Engine should not idle longer than 9 consecutive hours. Damage to the emission control system will result. When this machine idles for an extended period excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon at full load immediately after a long idle period will generate excess heat which will cause damage to emission control system components.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

NOTE: This engine is equipped with a STARTER LOCKOUT feature that prevents the starter motor from being engaged before the engine ECU is online, before the WAIT TO START message on the computer display is OFF and when the engine is already running.

IMPORTANT !

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

NOTE: For cold weather conditions refer to MACHINE WARM UP OPERATION on the following pages.

2.118

Tigercat 602 Carrier MACHINE WARM UP OPERATION

Controls and Operation

The MACHINE WARM UP function is provided to increase engine idle speed to assist in warming the engine and cab temperature in cold weather conditions.

NOTE: To set the MACHINE WARM UP function ON the engine must be running and the parking brake must be ENGAGED. Disengaging the parking brake will turn the MACHINE WARM UP function OFF.

TO TURN MACHINE WARM UP FUNCTION OFF: When engine and cab have warmed to the desired temperature, the machine warm up function can be turned off by pressing the F1 ( ) button again (at the engine display screen) or by disengaging the parking brake.

TO TURN MACHINE WARM UP FUNCTION ON:

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

Press the F1 button to toggle the machine warm up function ON/OFF. The machine warm up icon at the top of the screen is illuminate when the machine warm up function is ON. Refer to MACHINE WARM UP SPEED ADJUSTMENT in THIS SECTION to adjust machine warm up speed setting if required.

2.119

Controls and Operation MACHINE WARM UP SPEED ADJUSTMENT

Tigercat 602 Carrier

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

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

Press the F2 button to reset to default setting.

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

The engine settings menu will appear by default.

Press F1 (Adjust) to adjust engine settings

2.120

Tigercat 602 Carrier

Controls and Operation

OR

OR

Press the OK button to go to the adjustment display.

To reset to default setting press the F2 button.

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

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

Press the back button to return to the adjustment menu.

Press the OK button to confirm the setting.

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

Press the back main menu.

2.121

button again to return to the

Controls and Operation SYSTEM TEST AND WARM UP

Tigercat 602 Carrier 8. Observe all operations.

9. If any operations are not functioning as they should, take the necessary steps to correct the problem.

Before commencing skidding operations, follow the steps below to accomplish the following: • Warm up the hydraulic system.

10. After completion of the warm up and system testing, lower the dozer blade and grapple or shield to the ground.

• Test all systems for proper operation.

• Inspect for hydraulic oil leaks.

11. Check service brake for proper operation.

Refer to SERVICE BRAKE – CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION in SECTION 3.

Ensure that the machine was parked on level ground at last shutdown: 1. Start engine.

2. Ensure that computer displays are indicating normal operating conditions.

12. Engage the parking brake.

13. Decrease engine idle speed to LOW IDLE.

3. Check that all personnel are clear of the machine.

CAUTION

4. Disengage the parking brake.

5. Swing Boom Skidder Slowly raise and lower the boom, check for proper operation.

With the grapple and dozer raised slightly off the ground:

Never use your bare hand to check for fluid leaks.

•

Operate the grapple arms and check for proper operation.

•

Rotate grapple in each direction for several revolutions and check that it is operating correctly.

•

Rotate the swing boom in each direction and check that it is operating correctly.

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.

•

Raise and lower dozer blade

•

Steer the machine to the left and right.

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

Dual Winch Skidder Slowly raise and lower the dozer, check for proper operation.

•

Raise and lower dozer blade

•

Steer the machine to the left and right.

6. When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating the steps outlined in in the previous step several times. As the hydraulic system warms up, engine speed can be increased gradually to HIGH IDLE. 7. When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps outlined in in the previous step several times. As the hydraulic system warms up, engine speed can be increased gradually to HIGH IDLE. 2.122

Tigercat 602 Carrier STOPPING ENGINE:

Controls and Operation RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL

CAUTION

If the engine runs out of fuel, the fuel line is self priming.

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

1.

1. Refill fuel tank completely.

2. Turn ignition key to RUN position and observe computer display.

3. Wait for WAIT TO START message on computer display to turn off.

Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3.

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

4.

Do not race engine before shut-off.

5.

Parking brake ENGAGED.

6.

Stop engine by turning ignition switch to the OFF position.

7.

Remove the ignition key.

8.

Turn OFF the battery disconnect switch.

4. Turn ignition switch to the START position to crank engine.

If it fails to start after 20 seconds, stop and wait for 2 minutes before trying again.

5. When engine starts, release ignition key to RUN position and observe the computer display.

IMPORTANT !

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

Wait 2 minutes between each attempt to start the engine.

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

WARNING

Note that this machine is equipped with an After Run Disconnect Relay which delays by 90 seconds the power disconnect to engine related fuses and relays.

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

On Tier 4f machines only, whenever the engine is stopped all DEF solution is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds. Refer to AFTERTREATMENT SYSTEM in SECTION 3 for more information.

Before leaving the machine, park it in a safe position on level ground. Lower the dozer blade and grapple or shield to the ground and engage parking brake.

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

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

WARNING When leaving the cab, always lower the dozer blade and grapple or shield to the ground, engage the parking brake and turn the ignition switch OFF. If leaving the machine unattended, also remove the ignition key and switch the battery disconnect switch to OFF

2.123

.

Controls and Operation TRAVELLING WITHOUT A LOAD:

Tigercat 602 Carrier 5. Use differential locks sparingly and ONLY when additional traction is required.

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

Raise the dozer blade and grapple or shield to the UP position.

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

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

2. Check the position of the maximum speed control to ensure that it is set to the desired position.

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

NOTE: The high idle adjust function is available.

This function is intended to allow the automatic reduction of the engine high idle speed limit when travelling without a load. Refer also to COMPUTER – ADJUSTMENT MENU - ENGINE SETTINGS – ENGINE HIGH IDLE ADJUST in THIS SECTION.

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

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

3. Use the direction selection switch on the left joystick to choose forward or reverse and press the travel foot pedal to move the machine in that direction.

4. Be aware of the type of steering control (and steer valve option - if applicable) the machine is equipped with. Steering control operation varies with the type of controls in use.

Generally, this machine is equipped with Load Sensing Steering. The speed that the vehicle responds to steering control input will vary, depending on the speed that the steering control is moved.

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

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

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

2.124

Tigercat 602 Carrier OPERATING GRAPPLE:

Controls and Operation CENTRE JOINT

DAILY INSPECTION/SERVICE Check the Operator’s Manual for your Grapple Lubricate all grease fittings Check all hydraulic fittings

FRONT CHASSIS

Check hoses for wear. Replace as required.

REAR CHASSIS

Check for excessive wear at pin points.

CENTRE JOINT

Inspect for trash accumulation and clean out.

CHECK FOR MOVEMENT IN THIS JOINT AREA

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

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

602-043

The controls will return to neutral automatically when released.

The Constant Pressure button on the joystick will provide a constant closing pressure to the tongs to take up the slack as the logs are lifted and settle together. This pressure is released when the grapple is opened.

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

CENTRE JOINT

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

Refer to CENTRE JOINT – ARTICULATION JOINT MAINTENANCE in SECTION 3 for visual checking procedures.

For further information regarding adjustment and maintenance of the centre joint refer to CENTRE JOINT in SECTION 11 of the SERVICE MANUAL.

2.125

Controls and Operation OPERATING WINCH:

Tigercat 602 Carrier WARNING

SWING BOOM SKIDDER

When operating Carco winches the load MUST be removed from the cable before placing the winch control in the freespool position to avoid damage to the winch which could cause a safety hazard.

Attempting to engage or disengage the freespool function with a load on the cable will cause damage to clutch halves, piston, final planetary gearing and/or output shaft.

Damage to freespool components can cause a sudden loss of load control which could result in death or serious injury.

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

Lower the grapple and dozer blade to the ground to anchor the machine.

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

This will allow the cable to unwind freely from the drum and also disconnects the drive motor from the drum in the winch and allow the cable to be freely pulled from the spool by hand. The freespool function is intended for use in pulling the cable by hand only and must not be used when the cable is loaded. Improper use of the freespool function will result in damage to the winch.

DUAL WINCH SKIDDER Place the skidder in a safe, stable location, in line with the load.

Lower the shield and dozer blade to the ground to anchor the machine.

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

Place the winch freespool switch in the ON position.

Avoid winching at an angle to the skidder.

Refer also to CAB CONTROLS – RIGHT ARM REST CONTROL PANEL – WINCH FREESPOOL SWITCH in THIS SECTION.

Pull the cable from the drum and attach to object.

Safety gloves should be worn.

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

To retrieve the cable: Close cab door and disengage parking brake.

Place the winch select switch (to the left of the lever) in the I (ON) position. Pull and hold the lever BACK to wind in the winch cable. For safety reasons this lever returns to the neutral (centre) position when released.

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

Avoid winching at an angle to the skidder.

Pull the cable from the drum and attach to object.

Safety gloves should be worn.

Avoid pulling the hook over the drum and through the throat of the winch.

To retrieve the cable:

To use the driveaway function: Place the winch select switch (to the left of the lever) in the I (ON) position. Push and hold the winch control lever FORWARD to release the dynamic brake for dropping a load on the fly or drive away from a load with slight tension on the cable. The control lever will return to the centre neutral position when released.

Refer also to CAB CONTROLS – WINCH SELECT SWITCH and CAB CONTROLS – WINCH CONTROL LEVER in THIS SECTION.

Deactivate winch FREESPOOL. Place the winch freespool switch in the OFF position.

Pull and hold the lever BACK to wind in the winch cable. For safety reasons this lever returns to the neutral position (brake on) when released and actuates the brake, which locks the drum.

Refer also to CAB CONTROLS – RIGHT ARM REST CONTROL PANEL – WINCH CONTROL LEVER in THIS SECTION. Read, understand and follow all general safety precautions specified by winch manufacturer and in this manual.

2.126

Tigercat 602 Carrier SKIDDING

Controls and Operation SKIDDING TECHNIQUE

WARNING

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

•

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

SAFETY:

•

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

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

•

Never travel across a STEEP slope or side hill.

•

Never make an uphill turn on a slope

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

•

Never approach an unstable log from the downhill side.

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

•

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

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

•

Wear heavy gloves when handing the cables.

•

Use the PARKING BRAKE where appropriate.

•

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

•

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

•

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

•

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.

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

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

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

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

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

10. Be aware of what is happening around you.

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

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

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

2.127

Controls and Operation

Tigercat 602 Carrier

GRAPPLE SKIDDING

CABLE SKIDDING:

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

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

2. Lower the dozer and grapple to the ground to anchor the machine.

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

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

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

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

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

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

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

5. Winch in a straight line to prevent tip over problems. Note that cab doors must be closed and parking brake disengaged to operate the winch in function.

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

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

7. Raise the grapple or shield to a safe height and raise the dozer to its full height.

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

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

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

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

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

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

When running empty, always keep grapple tongs closed to prevent striking the tires or the machine.

2.128

Tigercat 602 Carrier

Controls and Operation

CARE OF THE MACHINE 1. Ensure that all fluid levels are always at the proper level. Use the preventative maintenance schedule in SECTION 3 .

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

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

4. Do not apply load to a cold engine.

5. Close and secure all doors and access covers.

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

Clean frequently but at least once daily.

Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

7. Be sure that the grapple and dozer blade are resting on the ground before servicing or parking the machine.

IMPORTANT !

When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the aftertreatment system and the engine.

2.129

Controls and Operation ARTICULATION LOCK ~ STRAIGHT LOCKED POSITION

Tigercat 602 Carrier ARTICULATION LOCK ~ ARTICULATED LOCKED POSITION

1.

1.

Park the machine on level ground and steer machine into a straight ahead position.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3.

Engage the parking brake.

4.

Turn OFF the engine.

5.

Remove the ignition key.

6.

Turn OFF the battery disconnect switch

REAR CHASSIS

Park the machine on level ground and steer machine into a fully articulated position to the right.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3.

Engage the parking brake.

4.

Turn OFF the engine.

5.

Remove the ignition key.

6.

Turn OFF the battery disconnect switch

ARTICULATION LOCK REAR CHASSIS

ARTICULATION LOCK

RETAINING PINS 602-039

ARTICULATION LOCK STORED POSITION

RETAINING PINS

7.

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.

8.

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

602-036

602-039

ARTICULATION LOCK STORED POSITION

7.

Remove both retaining pins from the articulation lock. Relocate articulation lock between front and rear chassis. Line up holes on the articulation lock with holes in chassis’ as shown and secure in place with both retaining pins.

8.

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

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

602-063

2.130

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

Tigercat 602 Carrier RETRIEVAL POINTS

Controls and Operation These points are designed to accept a lifting chain shackle. Warning: Use shackles and chains that are appropriately sized for the load to be retrieved.

Retrieval of the machine may be required, in the event that a machine becomes immobile due to terrain conditions that do not permit it to escape under its own power.

3. REAR RETRIEVAL POINTS If the machine becomes immobile with its rear oriented towards the aiding machine, there are retrieval points located at the rear chassis on each end of the rear axle. These points are labeled 'I' and 'J' on the machine lifting/tiedown label.

Refer also to TOWING INSTRUCTIONS in THIS SECTION, in the event that the engine or drive system are not functioning well enough to allow the machine to move in tandem with the aiding machine.

1. There are retrieval points located on both the front and rear of the machine to aid in its retrieval.

These points must be used together in a retrieval situation.

These points are designed to accept a lifting chain/hook in either a basket or choker hitch configuration. Warning: Use chains that are appropriately sized for the load to be retrieved.

These points must be used together in a retrieval situation.

2. FRONT RETRIEVAL POINTS If the machine becomes immobile with its front oriented towards the aiding machine, there are two retrieval points located at the front of the front chassis in front of the heat exchanger.

These points are labeled 'G' and 'H' on the machine lifting/tie-down label.

4. Once the immobile machine has been connected to the aiding machine, both machines can move in tandem to free the immobile machine.

These points must be used together in a retrieval situation.

B

AE

I

H

F G

A B C D E

C

D E I,J

F,G

F G H

B,C

A,D E

I 58334BUNI R0

2.131

Controls and Operation TRANSPORTING INSTRUCTIONS

Tigercat 602 Carrier CAUTION

The machine may be transported with the wheels on or off.

As a fire prevention measure, AFTER transporting (trucking) a machine from one job sight to the next, open all doors and access panels and blow off any debris that could have re-positioned itself onto the engine and exhaust parts due to wind turbulance caused by the journey. Refer also to FIRE PREVENTION in SECTION 1.

With wheels on:•

DO NOT remove air from tires, this will result in damage to the tires!

With wheels off:•

If the wheels are removed the machine must be blocked so that the centre joint is one inch or more above the truck bed.

With the wheels on or off:•

The dozer blade must be down on the truck bed.

•

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

602-036

The articulation lock bar must be installed so that the machine is oriented in the straight locked position.

•

The machine must be cross chained (side to side) at both the front and rear axle area.

B

Chains must be attached to the grapple to prevent movement.

•

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

IMPORTANT !

When transporting the machine, chains must be used to prevent forward, reverse and side to side movement of the machine.

Do not secure the machine to the truck ANYWHERE near the centre joint area as this can seriously damage the centre joint.

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

•

•

Use only transport regulation chains for this purpose, example; 5/16" grade 7 with a tensile strength of 43500 kg (96,000lb)/chain. Using inferior or damaged chains could cause the load to shift.

AE

I

H

F G

A B C D E

C

D E I,J

F,G

F G H

B,C

A,D E

I 58334BUNI R0

2.132

Tigercat 602 Carrier

Controls and Operation

TIE DOWN POINTS

6. The dozer blade is to be stored in a position with its blade tip supported by the flat bed platform. The dozer blade tie-down points are labelled 'F' on the machine lifting/tie-down label.

1. When a machine is to be transported on a flat bed the articulation lock bar must be installed so that the machine is oriented in the straight locked position.

A strap or chain is to be tightened across the top of the dozer blade arms to prevent movement.

2. Chains must be used to prevent forward, reverse and side to side movement of the machine. Tie-down locations are provided on the machine for this purpose. All tie-down points must be used to ensure no movement of the machine, or it’s associated parts, occur during transport.

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

WARNING

3. The front axle of the machine must be cross chained from side to side. The front axle tie-down points are labeled 'A' and 'D' on the machine lifting/tie-down label.

Use shackles and chains that are appropriately sized for the load to be lifted.

The chain should be wrapped around each end of the axle housing, without overlapping, and chained at a 45° angle in the forward, reverse and side to side directions.

1. The articulation lock bar must be installed so that the machine is oriented in the straight locked position.

4. In the case of a 4 wheeled machine, the rear axle of the machine must be cross chained from side to side of the flat bed. The rear axle tie-down points are labeled 'B' and 'C' on the machine lifting/tie-down label.

The chain should be wrapped around each end of the axle housing, without overlapping, and chained at 45° angle in the forward, reverse and side to side directions.

5. The grapple is to be stored in a position with grapple tongs closed and supported by the flat bed platform. The grapple tie-down points are labelled 'E' on the machine lifting/tie-down label.

A strap or chain is to be tightened across the top of the grapple box to prevent grapple movement.

2. There are two lifting points located at the front of the front chassis in front of the heat exchanger. These points are labeled 'G' and 'H' on the machine lifting/tie-down label.

These points are designed to accept a lifting chain shackle.

3. Additionally there are lifting points located at the rear chassis on each end of the rear axle.

These points are labeled 'I' and 'J' on the machine lifting/tie-down label.

These points are designed to accept a lifting chain/hook in either a basket or choker hitch configuration.

4. All lifting points must be used during a lifting operation.

5. Position the hoist above the centre of gravity to ensure machine stability & levelling.

2.133

Controls and Operation TOWING INSTRUCTIONS

Tigercat 602 Carrier CAUTION

(IF EQUIPPED WITH SINGLE SPEED MECHANICAL TRANSMISSION)

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

Never tow the machine at over 2 mph.

This will cause significant damage to the transmission.

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

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, below the cab. A short bar is placed through the hole in the lever and pulled upwards to put the transmission into neutral.

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

STEERING CYLINDERS

STEERING CYLINDERS

DISCONNECT LEVER

SM47

NORMAL HOSE CONNECTIONS

HOSES ON ONE CYLINDER CROSS CONNECTED FOR TOWING

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

620E-016

TRANSMISSION DISCONNECT LEVER SHOWN IN NEUTRAL

2. If equipped with an oscillation lock, use manual override to turn the oscillation lock feature OFF mechanically. Refer to OSCILLATION LOCK MANUAL OVERRIDE in THIS SECTION. 3. Remove parking brake supply hose from the manifold and connect to a remote power source. Pressurize circuit to 600 psi to disengage parking brake.

4. Raise the dozer blade and grapple or shield off the ground and turn off the engine.

6. 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.

7. When towing is completed, reconnect parking brake supply hose and steering cylinder hoses in their proper locations.

2.134

Tigercat 602 Carrier TOWING INSTRUCTIONS

Controls and Operation

(IF EQUIPPED WITH EHS TRANSMISSION) A malfunction of the machines equipment may make towing necessary.

Towing is only recommended over short distances.

It is always better to make repairs at the point where the machine is parked whenever possible.

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

IMPORTANT !

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

602-005

FRONT DRIVE SHAFT

602-025

MID DRIVE SHAFT

602-024

MID DRIVE SHAFT

Never tow a machine in gear. If the machine is subjected to hard pulling while in gear, the extremely high forces created will cause significant damage to the components of the hydrostatic drive system and the transmission Never tow the machine at over 2 mph.

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

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

3. Remove the mid drive shaft.

4. If equipped with an oscillation lock, use manual override to turn the oscillation lock feature OFF mechanically. Refer to OSCILLATION LOCK MANUAL OVERRIDE in THIS SECTION. 5. Raise the dozer blade and grapple or shield off the ground and turn off the engine.

6. 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.

STEERING CYLINDERS

7. 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.

STEERING CYLINDERS

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

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

SM47

NORMAL HOSE CONNECTIONS

HOSES ON ONE CYLINDER CROSS CONNECTED FOR TOWING

2.135

Controls and Operation

Tigercat 602 Carrier

2.136

Tigercat 602 Carrier SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3

ISSUE 2.1 AUGUST 2017

AFTERTREATMENT SYSTEM................................................................................................................ 3.42 AIR CLEANER MAINTENANCE.............................................................................................................. 3.39 AIR CONDITIONING SYSTEM, CHECKING........................................................................................... 3.26 APPROVED ANTI-SEIZE PASTES FOR EXHAUST / AFTERTREATMENT LINE (TIGERCAT BY FPT TIER 4F ENGINES)................................................................................................ 3.61 APPROVED HYDRAULIC OILS.............................................................................................................. 3.15 ARTICULATION LOCK............................................................................................................................. 3.75 AXLE AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS....................................................................... 3.63 LIMITED SLIP ADDITIVES................................................................................................................... 3.63 BATTERY CARE...................................................................................................................................... 3.32 CAB SAFETY CABLE.............................................................................................................................. 3.69 CAB SUPPORT BRACE.......................................................................................................................... 3.69 CARE OF POLYCARBONATE WINDOWS.............................................................................................. 3.78 CAUTIONS...........................................................................................................................................3.80 CLEANING INSTRUCTIONS................................................................................................................ 3.80 CONCEALING HAIRLINE SCRATCHES.............................................................................................. 3.81 FIRE PRECAUTIONS........................................................................................................................... 3.81 GRAFFITI REMOVAL........................................................................................................................... 3.81 INSPECTION AND MAINTENANCE.................................................................................................... 3.78 RESISTANCE TO CHEMICALS........................................................................................................... 3.79 RESISTANCE TO WATER.................................................................................................................... 3.79 CENTRE JOINT ARTICULATION JOINT MAINTENANCE............................................................................................. 3.66 OSCILLATION JOINT MAINTENANCE................................................................................................ 3.66 CLEANING A/C CONDENSER AND COOLER PACKAGE...................................................................... 3.82 COMMERCIAL WOOD – WEIGHTS........................................................................................................ 3.89 COOLER PACKAGE COMPONENTS..................................................................................................... 3.28 DRAINING ENGINE COOLANT........................................................................................................... 3.29 DENOX 2.2 SYSTEM............................................................................................................................... 3.42 DEPRESSURIZING SUSPENDED MACHINE ELEMENTS.................................................................... 3.74 DIESEL EXHAUST FLUID (DEF) TANK.....................................................................................................................................................3.45 CLEANING THE DEF FILL STRAINER............................................................................................ 3.48 DRAINING THE DEF TANK.............................................................................................................. 3.46 FILLING THE DEF TANK.................................................................................................................. 3.47 DIESEL EXHAUST FLUID (DEF) HANDLING AND STORAGE.............................................................. 3.49 DRAINING TRANSMISSION OIL............................................................................................................. 3.62 EMERGENCY EXITS, CHECK MONTHLY................................................................................................ 3.8 FILLING HYDRAULIC TANK.................................................................................................................... 3.21

Lubrication and Maintenance

Tigercat 602 Carrier

FILTERS CHARGE PRESSURE FILTER............................................................................................................. 3.24 DEF DOSING MODULE FILTER CHANGING DEF FILTER, DEF FLUSHING TEST AND UDST (UREA DOSING SYSTEM TEST).. 3.53 FUEL FILL STRAINER.......................................................................................................................... 3.37 FUEL FILTERS..................................................................................................................................... 3.32 CHANGING FUEL FILTER/WATER SEPARATOR............................................................................ 3.35 DRAINING FUEL FILTER/WATER SEPARATOR............................................................................. 3.34 HYDRAULIC OIL RETURN ELEMENT FILTERS................................................................................. 3.22 SERVICING GUIDELINES FOR OIL FILTERS..................................................................................... 3.22 TRANSMISSION FILTER..................................................................................................................... 3.25 FIRE PREVENTION................................................................................................................................... 3.9 FLUID ANALYSIS PROGRAM.................................................................................................................. 3.5 FLUID SAMPLE COLLECTION PROCEDURES....................................................................................... 3.6 FUEL, REFUELLING PROCEDURE........................................................................................................ 3.38 FUEL TANK..............................................................................................................................................3.36 DRAINING THE FUEL TANK................................................................................................................ 3.38 FUSE AND RELAY PANELS CAB......................................................................................................................................................3.30 ELECTRICAL BOX............................................................................................................................... 3.31 GENERAL MAINTENANCE....................................................................................................................... 3.8 HOUR METER – MAINTENANCE............................................................................................................. 3.4 HYDRAULIC FILL PUMP......................................................................................................................... 3.21 HYDRAULIC OIL TANK............................................................................................................................ 3.20 DRAINING HYDRAULIC TANK............................................................................................................ 3.20 HYDRAULIC TANK BREATHER.............................................................................................................. 3.21 LUBRICATION AND SERVICE POINTS DUAL WINCH SKIDDER...................................................................................................................... 3.18 SWING BOOM SKIDDER..................................................................................................................... 3.16 NEW MACHINE MAINTENANCE.............................................................................................................. 3.4 FIRST 125 HOUR INSPECTION AND SERVICE REPORT................................................................... 3.4 INITIAL PRE-DELIVERY INSPECTION.................................................................................................. 3.4 OIL LOST FROM LEAKAGE...................................................................................................................... 3.8 PRESSURIZED WATER SYSTEM MAINTENANCE............................................................................... 3.70 PREVENTIVE MAINTENANCE SCHEDULE............................................................................................. 3.4 REAR PILOT ACCUMULATOR CHECKING FOR PROPER OPERATION............................................................................................ 3.65 REFUELLING PROCEDURE................................................................................................................... 3.38 SCHEDULED MAINTENANCE 8 HOURS..............................................................................................................................................3.10 48 HOURS............................................................................................................................................ 3.11 125 HOURS.......................................................................................................................................... 3.11 250 HOURS.......................................................................................................................................... 3.12 500 HOURS.......................................................................................................................................... 3.12 1000 HOURS........................................................................................................................................3.13 2000 HOURS........................................................................................................................................3.13 2 YEARS...............................................................................................................................................3.13 SEASONAL...........................................................................................................................................3.14 SERPENTINE BELT INSPECTION/REPLACEMENT.............................................................................. 3.27 SERVICE AND LUBRICATION POINTS DUAL WINCH SKIDDER...................................................................................................................... 3.18 SWING BOOM SKIDDER..................................................................................................................... 3.16 3.2

Tigercat 602 Carrier

Lubrication and Maintenance

SERVICE BRAKE CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION.......................................... 3.64 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE.................................................................... 3.76 TILTING THE CAB................................................................................................................................... 3.68 TIRE PRESSURES.................................................................................................................................. 3.90 TORQUE CHART..................................................................................................................................... 3.84 TORQUE CHART, GENERAL.................................................................................................................. 3.85 TORQUE, FLUID CONNECTIONS.......................................................................................................... 3.86 WEIGHTS OF COMMERCIAL WOOD..................................................................................................... 3.89 WHEELS, INSTALLING.............................................................................................................................. 3.4 WINCH MAINTENANCE - CARCO.......................................................................................................... 3.72 WOOD, WEIGHTS OF COMMERCIAL WOOD....................................................................................... 3.89

3.3

Lubrication and Maintenance

Tigercat 602 Carrier

PREVENTIVE MAINTENANCE SCHEDULE FOR 602 Skidder NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBER 5339; "PDI AND 125 HOUR INSPECTION REPORT"

*FIRST 125 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBER 5339; "PDI AND 125 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 125 HOUR TIME FRAME. *IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY, THIS REPORT MUST BE COMPLETED AND RETURNED TO Tigercat Industries Inc. WARRANTY DEPARTMENT.

IMPORTANT!

TIGHTENING POINTS FOR:THE FIRST 125 HOUR INSPECTION REPORT:

WHEELS:

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

All hydraulic connections Hose clamps Centre joint pin securing bolts Transmission securing bolts Engine mounting bolts Axle mounting bolts Wheel retaining bolts Cab securing bolts Pin retainers Any other loose nut, bolt or fitting

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

HOUR METER – MAINTENANCE: Check the hour meter on a regular basis to determine your scheduled maintenance times.

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

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

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

Refer to engine OPERATION AND MAINTENANCE MANUAL for additional required maintenance.

3.4

Tigercat 602 Carrier

Lubrication and Maintenance

TIGERCAT FLUID ANALYSIS PROGRAM Effective for all 2007 model year 600'E' series skidders sold in North America, fluid sampling and analysis must be performed during the warranty period as per the schedule below.

Warranty coverage of powertrain components, specifically hydrostatic pumps and motors, auxiliary pumps, axles, transfer case and driveshafts is contingent on performance of regular fluid sampling at the owner’s expense during the warranty period.

Location Hydraulic Oil Transmission Axles – Front & Rear

602 Model

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

FIRST SAMPLE There will be no charge for the first fluid samples required to be taken during the 125-Hour Inspection Service that will be scheduled and performed by your Tigercat dealer. Refer to NEW MACHINE MAINTENANCE in THIS SECTION. FOLLOW-UP SAMPLES All follow-up samples must be taken as indicated in the chart above and will be the responsibility of the machine owner.

Copies of all fluid analysis results must be forwarded to the Tigercat Warranty Department for continued warranty coverage. If samples are taken using the Tigercat Fluid Analysis Program, a copy of all results will automatically be sent to Tigercat.

Tigercat Fluid Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required followup fluid samples.

Refer also to FLUID SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain plug locations.

TIGERCAT FLUID ANALYSIS KITS Each kit includes a Pre-paid Sample Bottle and Sample Information Form. Pre-printed mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

The same type of sample bottle can be used for all types of fluid testing including: Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.

To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on how properly collect, prepare and ship the fluid samples.

Contact your Tigercat Dealer Parts Department to order Kits.

3.5

Lubrication and Maintenance

Tigercat 602 Carrier

TIGERCAT FLUID ANALYSIS PROGRAM FLUID SAMPLE COLLECTION PROCEDURES

HYDRAULIC SAMPLE VALVE

Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple fluid samples, fill out all of the required SIF forms in their entirety, prior to taking any fluid samples.

Then, immediately package each completed SIF form together with the matching fluid sample in the black outer shipping container as each individual sample is taken. This will reduce the possibility of mixing up or incorrectly identifying the SIF forms and fluid samples. Incorrectly identified samples could result in a false warning alarm.

The accuracy of the lab analysis results is very dependent on the quality of the fluid sample taken. Collection of clean fluid samples that are representative of the main body of fluid are essential if meaningful lab results are to be obtained. Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all follow-up samples should be consistently taken from the same location using the same techniques as all previous samples.

•

Ensure that all sample valves and drain plugs are clean and free of debris.

•

Remove the sample bottle cap only when ready to take the sample. Keep the cap clean – do not put it in your pocket or let it get contaminated in any way.

•

Do not allow any airborne dirt, etc. to enter the sample bottle.

•

Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full.

602-031

MAIN HYDRAULIC OIL

Hydraulic Oil Samples:

All samples taken should be immediately forwarded to the lab for processing.

Contact your Tigercat dealer to purchase additional or replacement hydraulic sample valves or drain plugs.

In cases where fluid samples must be pumped or otherwise drawn out of a reservoir or housing, a hand operated fluid suction pump is also available from your Tigercat dealer.

3.6

•

Hydraulic oil samples should be taken from the circulating oil flow at operating temperature, with no functions actuated, using sample valves that are permanently located on the machine whenever possible.

•

To obtain a representative oil sample, sample valves must be purged before the actual oil sample is taken. Drain a minimum of 3 or 4 ounces of oil into a separate container and discard this oil using approved recycling methods.

•

Replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

Tigercat 602 Carrier

Lubrication and Maintenance

TIGERCAT FLUID ANALYSIS PROGRAM Transmission and Axle Oil Samples: •

These samples can be taken during the oil change process.

•

To obtain a representative oil sample, ensure the oil is warm and has not settled very long (within 30 minutes of shutdown).

•

Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

•

Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

AXLE LEVEL CHECK AND FILL

SAMPLE LOCATION / TRANSMISSION DRAIN 630C-100

PINION SEAL GREASE FITTING

TRANSMISSION OIL

AXLE LEVEL CHECK AND FILL (FAR SIDE)

AXLE DRAIN

67925B03

B14.5 STANDARD AXLE DRAIN AND FILL LOCATIONS

3.7

Lubrication and Maintenance

Tigercat 602 Carrier

GENERAL Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler.

Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

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

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

Plug or cap immediately

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

Clean up spills as soon as possible Always use clean oil and containers Drain dirty oil while still warm Do not exceed recommended fluid levels Service all hydraulic filters after the failure of a pump, motor, cylinder or valve. Failures of this nature could contaminate the entire hydraulic system

Always have a fire extinguisher at hand For safety; when leaving the cab or leaving machine unattended or during service, always lower the dozer blade and grapple or shield to the ground

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

For safety, always block or support grapple and dozer blade when working under them.

Before welding on machine be sure to disconnect all electrical connections and follow all servicing safety precautions as outlined in WELDING, PRIOR TO in SECTION 1 of THIS MANUAL.

CHECK EMERGENCY EXITS MONTHLY: Alternate exit routes are provided: the sliding windows in the cab doors. These are only to be used if the cab doors cannot be opened.

When welding secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings

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

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires

*OIL LOST FROM LEAKAGE LOST OIL (LITRES)

LEAKAGE RATE

PER DAY

PER MONTH PER YEAR

LOST OIL (US GALLONS) PER DAY

PER MONTH PER YEAR

ONE DROP IN TEN SECONDS

0.424

12.72

152.0

0.112

3.36

40.0

ONE DROP IN FIVE SECONDS

0.852

25.6

306.6

0.225

6.75

81.0

ONE DROP PER SECOND

4.26

127.76

1533.1

1.125

33.75

405.0

THREE DROPS PER SECOND

14.2

425.86

5110.31

3.75

112.5

1350.0

DROPS BREAK INTO STREAM

90.83

2725.5

32706.0

24.0

720.0

8640.0

3.8

Tigercat 602 Carrier

Lubrication and Maintenance

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

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

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

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

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

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

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

3.9

Lubrication and Maintenance

Tigercat 602 Carrier

SCHEDULED MAINTENANCE FREQUENTLY:

Clean: • Potentially damaging limbs or sticks from machine

• Check engine cooling air intake screens for possible restriction.

• A/C condenser, oil cooler, radiator refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in THIS SECTION.

EVERY 8 HOURS (EVERY SHIFT):

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

Refer to REAR PILOT ACCUMUULATOR – CHECKING FOR PROPER OPERATION in THIS SECTION. • All engine air intake system components (including charge air cooler) rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair immediately.

• Perform "frequently" maintenance check, and in addition: • Check engine coolant level • Check engine oil level • Drain fuel filter/water separator • Check air intake precleaner/inlet hood, clean as required • Check air cleaner unloader valve • Check air intake filter restriction indicator.

Replace primary filter if indicator is in red zone.

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

• Charge Air Cooler for damage, wear, cracks, or leaks and repair immediately.

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

• Check hydraulic tank oil level with the dozer blade and grapple or shield on the ground.

• Check winch sump oil level • Check transmission oil level with dipstick

• For loose nuts, bolts and fittings

• Lubricate mid drive shaft 1-fitting, purge Note: Lubrication of mid drive shaft slip joint should be done with machine fully articulated and locked. Refer also to ARTICULATION LOCK – ARTICULATED LOCKED POSITION in THIS SECTION. • Lubricate rear drive shaft bearing 1-fitting, purge • Lubricate centre articulation joint bearings, 2-fittings, purge • Lubricate centre joint oscillation lock cylinder ends, 4-fittings, purge • Lubricate steering cylinder ends, 4-fittings, purge

• Condition and tension of fan belts.

• Exhaust system for leaks.

• Water pressure (60 psi [4 bar]) 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.

• Conduct an overall visual inspection.

Refer to engine OPERATION AND MAINTENANCE MANUAL for additional required maintenance.

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

3.10

Tigercat 602 Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 48 HOURS

EVERY 125 HOURS:

• Check the centre joint for looseness. Refer to Centre JOINT – ARTICULATION JOINT MAINTENANCE in THIS SECTION for instructions. If a problem is found corrective action should be taken immediately. Refer also to CENTRE JOINT in SECTION 11 of the SERVICE MANUAL for more detailed checking and adjustment procedures.

• Perform "frequently" maintenance • Perform 8 hour maintenance And in addition: • Lubricate grapple rotator shaft, 2-fittings, 5-shots • Carry out A/C system inspection; Refer to AIR CONDITIONING SYSTEM, CHECKING in THIS SECTION Check: • Check oil level in front and rear axles. Refer to AXLE – AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS and AXLE – REAR (BOGIE) AXLE (IF APPLICABLE) in THIS SECTION. • Check fuel fill strainer (fuel tank filler screen) • Proper operation of pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. • Fluid level in batteries unless maintenance free • Engine rpm.

• All hydraulic pressures • Hydraulic pump and motor securing bolts • Torque tightening points as per new machine maintenance Visually check for damage to:• Arch and pivot linkage • Front and rear frame • Centre joint area • Attachment Make repairs immediately Visually inspect for:• Frayed electrical wiring and hydraulic hose • Wear in any other components Refer to engine OPERATION AND MAINTENANCE MANUAL for additional required maintenance.

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

3.11

Lubrication and Maintenance

Tigercat 602 Carrier

SCHEDULED MAINTENANCE EVERY 250 HOURS:

EVERY 500 HOURS:

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

And in addition: • Replace engine oil and filter.* • Replace engine fuel filter and fuel filter/water separator*

• Perform 250 hour maintenance And in addition : • Check DEF fill strainer for cleanliness.

Remove and clean if required.

• Replace crankcase ventilation filter *. Refer to Engine Operation and Maintenance Manual for replacement instructions.

• Replace hydraulic oil return element filters (3 elements) *

• Replace DEF dosing module filter.* NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

• Clean and thoroughly inspect all surfaces of the boom (if equipped) for cracks. All cracks must be properly repaired in their early stages.

Note that in most cases cracks will continue to grow in size and often lead to major structural damage. Failure to regularly inspect for cracks and immediately repair the boom system will void the structural warranty.

Contact your Tigercat dealer for specific procedures required to correctly repair any cracks found.

2 white, high performance element.

1 blue, water absorbing element.

• Replace charge pressure filter * • Replace transmission filter * • Replace oil in transmission. Sample transmission oil for testing. NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period. Refer to FLUID ANALYISIS PROGRAM in THIS SECTION for details.

Refer to engine OPERATION AND MAINTENANCE MANUAL for additional required maintenance.

• Lubricate front drive shaft 1-fitting, purge • Lubricate door hinges, 8-fittings, purge Refer to engine OPERATION AND MAINTENANCE MANUAL for additional required maintenance.

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

3.12

Tigercat 602 Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 1000 HOURS:

2000 HOURS:

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

• Perform 500 hour maintenance

• Perform 500 hour maintenance

And in addition: • Replace air cleaner unloader valve • Lubricate centre joint oscillation slew bearing, 4-fittings, purge. Refer to CENTRE JOINT – OSCILLATION JOINT MAINTENANCE in THIS SECTION. • Check centre joint preload with a dial indicator.

Refer to CENTRE JOINT – CHECKING CENTRE JOINT PRELOAD in SECTION 11 of the SERVICE MANUAL. If a problem is found corrective action should be taken immediately, refer to CENTRE JOINT PRELOAD ADJUSTMENT in SECTION 11 of the SERVICE MANUAL. • Replace oil in winch sump.

• Drain and refill front and rear axles. Refer to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils. Refer also to AXLE – AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION. Sample front and rear axle oil for testing. NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period.

Refer to FLUID ANALYISIS PROGRAM in THIS SECTION for details.

• Sample hydraulic oil from the main hydraulic tank for testing. NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period.

Refer to FLUID ANALYISIS PROGRAM in THIS SECTION for details.

• Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. • Lubricate front axle pinion grease seal.

• Lubricate rear axle pinion grease seal.

Refer to engine OPERATION AND MAINTENANCE MANUAL for additional required maintenance.

• Perform 1000 hour maintenance And in addition: • Replace all air intake rubber components such as elbows and connectors.

High temperatures in this area can cause the rubber to harden.

NOTE: High-temperature silicone connectors do not need to be replaced unless they are damaged.

Refer to AIR CLEANER MAINTENANCE in THIS SECTION • Check all air intake tubing, rubber couplings and band clamps for signs of wear and leakage • Replace hydraulic tank breather Refer to engine OPERATION AND MAINTENANCE MANUAL for additional required maintenance.

2 YEARS: • Replace engine coolant.

Refer to engine OPERATION AND MAINTENANCE MANUAL for additional required maintenance.

3.13

Lubrication and Maintenance

Tigercat 602 Carrier

SCHEDULED MAINTENANCE SEASONAL: • Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Fill tank with the dozer blade and grapple or shield on the ground until hydraulic oil level reaches the sight gauge full mark. Note that the oil level will drop 2 to 3 in (5 to 7.5 cm) when all cylinders are extended.

Check to ensure that the hydraulic oil type selected in the computer program matches the oil type being used. Adjust oil type if needed.

This will allow the program to optimize the cooling and s functions to best suite the oil being used.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge. Operating outside the recommended operating range will shorten hydraulic component life. Refer to COMPUTER – ADJUSTMENT MENU SERVICE SETTINGS – HYDRAULIC OIL GRADE in SECTION 2 for hydraulic oil grade selection settings information.

• Drain and refill front and rear axles. Refer to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils. Refer also to AXLE – AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION. Sample front and rear axle oil for testing. NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period.

Refer to FLUID ANALYISIS PROGRAM in THIS SECTION for details.

• Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. • Perform service brake wear plate inspection.

Refer to SECTION 8 in the SERVICE MANUAL.

3.14

Tigercat 602 Carrier

Lubrication and Maintenance

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

3.15

Lubrication and Maintenance SWING BOOM SKIDDER

Tigercat 602 Carrier

3.16

Tigercat 602 Carrier

Lubrication and Maintenance

Tigercat Model 602 Swing Boom Skidder SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

COOLING SYSTEM

2

ENGINE OIL/FILTER

3

CRANKCASE VENTILATION FILTER - T4F ONLY

4

FUEL FILTER

4A

FUEL FILTER/WATER SEPARATOR

CHANGE COOLANT EVERY 2 YEARS

CHK CHK

•

•

SEE ENGINE MANUFACTURER'S OPERATION AND MAINTENANCE MANUAL FOR REQUIRED ANTIFREEZE SOLUTION AND MIXTURE.

•

REP

1

•

REP DRN

QTY

USG

DESCRIPTION

32.0 8.5

REP

•

LITERS

CAPACITY 2000 

1000 

500 

250 

8

1

125 

SERVICE POINT NO.

SERVICE EVERY ITEM

•

1

REP

1

REP

1

• SEE ENGINE MANUFACTURER'S OPERATION AND MAINTENANCE MANUAL FOR PROCEDURES AND CAPACITIES. REFER TO SECTION 3 OF THE MANUAL FOR DETAILS.

5

DEF DOSING MODULE FILTER - T4F ONLY

6

FUEL TANK FILLER SCREEN

7

AIR INTAKE PRECLEANER/INLET HOOD

CHK

1

CLEAN AS REQUIRED.

AIR INTAKE PRIMARY ELEMENT

CHK

1

8

CHK

1

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

1

REFER TO SECTION 3 OF THE MANUAL.

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

1

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

REP †

3

NOTE: MUST USE: 1 BLUE FILTER ELEMENT. 2 WHITE FILTER ELEMENT.

CHARGE PRESSURE FILTER

REP †

1

TRANSMISSION FILTER (OPTIONAL)

REP †

1

AIR INTAKE SAFETY ELEMENT

CHK

9

AIR CLEANER UNLOADER VALVE

CHK

10

AIR INTAKE CONNECTIONS

CHK

11

HYDRAULIC TANK

CHK

12

HYDRAULIC FILTER, FULL FLOW, INCLUDES: 1 BLUE WATER ABSORBING ELEMENT 2 WHITE HIGH PERFORMANCE FILTER

13 14 15

HYDRAULIC TANK BREATHER

16

PRESSURIZED WATER SYSTEM (IF EQUIPPED)

17

TRANSMISSION TRANSMISSION, EHS (OPTIONAL)

18

AXLES, STANDARD DUTY

19

PINION GREASE SEAL - FRONT AND REAR AXLE

REP REP

89

TEST

CHK

D/R

CHK

1 50

13.2

SEASONAL DRAIN AND REFILL.

6 10

1.6 2.6

1

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

D/R ***

26

6.9

2

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

LUB

PURGE

2

ONE FITTING PER AXLE LITHIUM BASE EP2 GREASE 

D/R

LUB

MID DRIVE SHAFT

LUB **

REAR DRIVE SHAFT BEARING

LUB

CENTRE JOINT ARTICLUATION

LUB

CENTRE JOINT OSCILLATION SLEW BEARING 21

23

REP CHK

FRONT DRIVE SHAFT 20

1

1 PURGE

1

LITHIUM BASE EP2 GREASE 

1

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

PURGE

4

LITHIUM BASE EP2 GREASE  REFER TO SECTION 3 OF THE MANUAL

PURGE

4

LITHIUM BASE EP2 GREASE 

CENTRE JOINT OSCILLATION LOCK CYLINDER ENDS

LUB

CENTER JOINT BEARING PRELOAD

CHK 48 

22

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

23

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE 

24

DOZER GRAPPLE ARMS, CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE 

25

WINCH: CARCO

CHK

REFER TO SECTION 3 OF THE MANUAL FOR DETAILS.

CHK

D/R

LUBECHART 79971BENGR1 9/17

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

3.17

12

3

REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL.

Lubrication and Maintenance DUAL WINCH SKIDDER

Tigercat 602 Carrier

3.18

Tigercat 602 Carrier

Lubrication and Maintenance

Tigercat Model 602 Dual Winch Skidder SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

1

COOLING SYSTEM

2

ENGINE OIL/FILTER

3

CRANKCASE VENTILATION FILTER - T4F ONLY

4

FUEL FILTER

4A

FUEL FILTER/WATER SEPARATOR

CHANGE COOLANT EVERY 2 YEARS

CHK CHK

•

•

SEE ENGINE MANUFACTURER'S OPERATION AND MAINTENANCE MANUAL FOR REQUIRED ANTIFREEZE SOLUTION AND MIXTURE.

•

REP

1

•

REP DRN

QTY

USG

DESCRIPTION

32.0 8.5

REP

•

LITERS

CAPACITY 2000 

1000 

500 

250 

8

ITEM

125 

SERVICE POINT NO.

SERVICE EVERY

•

1

REP

1

REP

1

• SEE ENGINE MANUFACTURER'S OPERATION AND MAINTENANCE MANUAL FOR PROCEDURES AND CAPACITIES. REFER TO SECTION 3 OF THE MANUAL FOR DETAILS.

5

DEF DOSING MODULE FILTER - T4F ONLY

6

FUEL TANK FILLER SCREEN

7

AIR INTAKE PRECLEANER/INLET HOOD

CHK

1

CLEAN AS REQUIRED.

AIR INTAKE PRIMARY ELEMENT

CHK

1

AIR INTAKE SAFETY ELEMENT

CHK

1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENCE FOR DETAILS.

9

AIR CLEANER UNLOADER VALVE

CHK

1

REFER TO SECTION 3 OF THE MANUAL.

10

AIR INTAKE CONNECTIONS

CHK

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

11

HYDRAULIC TANK

CHK

1

DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE. (SEE HYDRAULIC OIL CHART)

12

HYDRAULIC FILTER, FULL FLOW, INCLUDES: 1 BLUE WATER ABSORBING ELEMENT 2 WHITE HIGH PERFORMANCE FILTER

REP †

3

NOTE: MUST USE: 1 BLUE FILTER ELEMENT. 2 WHITE FILTER ELEMENT.

13

CHARGE PRESSURE FILTER

REP †

1

14

TRANSMISSION FILTER (OPTIONAL)

REP †

15

HYDRAULIC TANK BREATHER

16

PRESSURIZED WATER SYSTEM (IF EQUIPPED)

CHK

17

TRANSMISSION TRANSMISSION, EHS (OPTIONAL)

CHK

8

18

AXLES, STANDARD DUTY

19

PINION GREASE SEAL - FRONT AND REAR AXLE

CHK

REP REP

89

TEST

1

D/R

CHK

1 50

13.2

6.2 1.6 12.6 2.6

D/R

LUB **

REAR DRIVE SHAFT BEARING

LUB

CENTRE JOINT ARTICLUATION

LUB

SEASONAL DRAIN AND REFILL. 1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE 75W-90.

D/R ***

26

6.9

2

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

LUB

PURGE

2

ONE FITTING PER AXLE LITHIUM BASE EP2 GREASE 

LUB

MID DRIVE SHAFT

CENTRE JOINT OSCILLATION SLEW BEARING 21

23

REP

FRONT DRIVE SHAFT 20

1

1 PURGE

1

LITHIUM BASE EP2 GREASE 

1

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

PURGE

4

LITHIUM BASE EP2 GREASE  REFER TO SECTION 3 OF THE MANUAL

PURGE

4

LITHIUM BASE EP2 GREASE 

CENTRE JOINT OSCILLATION LOCK CYLINDER ENDS

LUB

CENTER JOINT BEARING PRELOAD

CHK 48 

22

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

23

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE 

24

DOZER GRAPPLE ARMS, CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE 

REFER TO SECTION 3 OF THE MANUAL FOR DETAILS.

CHK

LUBECHART 81120BENGR1 9/17

NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

3.19

Lubrication and Maintenance MAIN HYDRAULIC OIL TANK

Tigercat 602 Carrier HYDRAULIC TANK

Located at the rear of the engine compartment.

Refer to SERVICE AND LUBRICATION POINTS chart in THIS SECTION for hydraulic tank capacity.

RETURN ELEMENT FILTERS

A sight gauge accessible through the right rear access panel, indicates the HIGH and LOW level of the main hydraulic oil tank.

BLUE ELEMENT

Always keep the hydraulic oil level between the HIGH and LOW calibrations. A low hydraulic oil level can result in severe damage to pumps.

Check hydraulic tank oil level with the dozer blade and grapple or shield on the ground. In this position the oil level should reach the full mark.

Note that the oil level will drop 2 to 3 in (5 to 7.5 cm) when all cylinders are extended.

SIGHT GAUGE LEVEL SWITCH

A hydraulic oil level switch is connected to the computer control system. The hydraulic oil level switch is incorporated into the base of the sight gauge. This switch triggers the hydraulic oil level low message.

CHARGE PRESSURE FILTER

Refer also to COMPUTER – MESSAGES CRITICAL – HYDRAULIC OIL LEVEL LOW in SECTION 2.

602-031

CAUTION Perform the hydraulic tank drain when the hydraulic oil temperature is below 100°F (38°C), but warm enough to be viscous.

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE

DRAINING HYDRAULIC TANK 1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels.

8. Install the articulation lock bar.

9. The hydraulic tank is equipped with a hose that routes from the bottom of the tank to the bottom of the front chassis belly pan.

10. The hose is plugged at the end and can be accessed by removing the belly pan door.

SIGHT GAUGE

602-032

11. The drain hose for the hydraulic tank can be lowered from the belly of the chassis and positioned in a drip pan.

MAIN HYDRAULIC OIL SIGHT GAUGE

12. Remove the plug in the hose end to drain tank.

13. Once fluid has been drained, replace the drain plug in the drain hose.

3.20

Tigercat 602 Carrier

Lubrication and Maintenance LOCATED ON THE RIGHT SIDE AT THE FRONT OF THE ENGINE COMPARTMENT

HYDRAULIC TANK BREATHER 602-040 HYDRAULIC TANK BREATHER The hydraulic tank breather is located on the hydraulic tank. This breather should be replaced every 2000 hours.

QUICK CONNECT TO SUCTION HOSE

HYDRAULIC FILL PUMP The electric hydraulic fill pump, located under the engine, is used to add oil to the hydraulic oil tank.

The pump switch is located on the right side at the front of the engine compartment.

PUMP SWITCH

602-020

HYDRAULIC FILL PUMP

620E-054

HYDRAULIC FILL PUMP

FILLING HYDRAULIC TANK Refer to APPROVED HYDRAULIC OILS in THIS SECTION. Refer to SERVICE AND LUBRICATION POINTS chart in THIS SECTION for hydraulic tank capacity.

1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION

5. Remove the ignition key.

6. Block wheels.

7. Install the articulation lock bar.

8. Open right front engine compartment access door.

9. Get the hydraulic oil fill suction hose from its storage location. Clean the suction hose, connect to hydraulic fill pump and remove cap.

Insert end of suction tube into supply drum.

10. Operate pump using the pump switch, located on the right side at the front of the engine compartment. The oil is pumped directly into the hydraulic tank via the return element filter.

11. Observe the level gauges on the rear of the tank to determine when to release the switch.

12. Fill tank with the dozer blade and grapple or shield on the ground. Fill tank until hydraulic oil level reaches the sight gauge FULL mark.

Note that the oil level will drop 2 to 3 in (5 to 7.5 cm) when all cylinders are extended.

13. Replace cap on suction tube, wipe dry, disconnect and store. Close all access doors.

HYDRAULIC OIL FILL SUCTION HOSE STORAGE LOCATION BELOW LEFT CAB DOOR 602-050 IMPORTANT !

Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in THIS SECTION. Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

3.21

Lubrication and Maintenance

Tigercat 602 Carrier

HYDRAULIC OIL RETURN ELEMENT FILTERS HYDRAULIC TANK

HYDRAULIC FILTER BYPASS (RED)

RETURN ELEMENT FILTERS

BLUE ELEMENT

When the filter restriction switch pressure reading reaches bypass level and hydraulic oil is bypassing the return filters the hydraulic oil filter bypass icon will be illuminated red and a critical message will be shown on the computer screen.

Hydraulic Oil Filter Bypass

SIGHT GAUGE LEVEL SWITCH

CHARGE PRESSURE FILTER

602-031

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE

The hydraulic oil cooling circuit contains a triple filter head. It is recommended that all machines use two different filter elements:

IMPORTANT !

Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in THIS SECTION. Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

HYDRAULIC FILTER SERVICING GUIDELINES

2 white, Tigercat high performance, full flow hydraulic oil filter element 1 blue, Tigercat water absorbing, full flow hydraulic oil filter element.

NEVER PRE-FILL HYDRAULIC FILTERS

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION AND SERVICE POINTS in THIS SECTION.

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil. Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit.

Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors. The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

There is a bypass valve built into each filter head preset at 25 psi (1.7 bar). 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. A filter restriction sensor also sends a signal to the computer control system.

HYDRAULIC FILTER BYPASS (YELLOW)

When the filter restriction pressure reading approaches the bypass level the hydraulic oil filter bypass icon will be illuminated yellow.

3.22

Tigercat 602 Carrier

Lubrication and Maintenance

Changing the filters:

FILTER HEAD

1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

GASKET

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels

FILTER ELEMENT FILTR_SEALS 2

SQUARE SECTION GASKET INSTALLATION

 Square Section Gasket Remove used gasket and clean groove in head.

Apply clean oil to new gasket surfaces.

Install new gasket into groove in filter head.

Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

8. Install the articulation lock bar.

9. Wipe clean the area around the filter and head.

10. Place rags below to catch the spillage of oil.

11. Wearing face protection (in case of an oil squirt), unscrew the old filter. Dispose of old filter and any oil properly.

FILTER HEAD

12. 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.

GASKET FILTER ELEMENT FILTR_SEALS 2

O-RING GASKET INSTALLATION

 O-Ring Gasket Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

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)

WARNING

WARNING, HOT FLUIDS AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS! •

13. Turn ON the battery disconnect switch.

Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

14. Check that all personnel are clear of the machine before starting the engine.

•

Use a thermometer to check surface and system temperatures to ensure it is safe to begin service work.

16. Sound horn to warn personnel of machine start-up.

•

DO NOT begin service work until the surface or system temperature has cooled down to below 100°F (38°C)!

15. Insert the ignition key and turn to the RUN position.

17. Start the engine.

18. Check for leaks.

3.23

Lubrication and Maintenance

Tigercat 602 Carrier

CHARGE PRESSURE FILTER

HYDRAULIC FILTER SERVICING GUIDELINES

The charge circuit contains a single element, full flow Tigercat hydraulic filter with a 50 psi (3.5 bar) third port bypass valve. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the charge circuit.

NEVER PRE-FILL HYDRAULIC FILTERS

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil. Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit.

Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors. The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

Changing a pressure filter: 1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels 8. Install the articulation lock bar.

9. Wipe clean the area around the filter and head.

10. Place rags below to catch the spillage of oil.

11. Wearing face protection (in case of an oil squirt), unscrew the old filter.

IMPORTANT !

Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in THIS SECTION. Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

12. Drain filter and dispose of any oil properly.

13. Check the seating area for the gasket on the filter head and wipe it clean.

14. This filter has an o-ring gasket. Replace o-ring as required and apply hydraulic oil to the gasket surface.

HYDRAULIC TANK

RETURN ELEMENT FILTERS

15. Screw on the new filter until the gasket makes contact with the seat in the filter head.

16. Hand tighten filter an additional 1/2 turn only.

17. Turn ON the battery disconnect switch.

BLUE ELEMENT

18. Check that all personnel are clear of the machine before starting the engine.

19. Insert the ignition key and turn to the RUN position.

SIGHT GAUGE

20. Sound horn to warn personnel of machine start-up.

LEVEL SWITCH

21. Start the engine.

22. Check for leaks.

CHARGE PRESSURE FILTER

602-031

3.24

HYDRAULIC TANK, FILTERS AND SIGHT GAUGE

Tigercat 602 Carrier

Lubrication and Maintenance

TRANSMISSION FILTER

TRANSMISSION FILTER

The transmission circuit is equipped with a full flow pressure filter with a 50 psi (3.5 bar) third port bypass valve. When a restriction is encountered the bypass valve diverts oil back to the transmission circuit reservoir in the transmission to prevent unfiltered oil from entering the transmission circuit.

Refer to SERVICE AND LUBRICATION POINTS for transmission oil specifications.

LOCATED IN THE LEFT STEP COMPARTMENT BELOW THE CAB DOOR

Changing a transmission filter: 1. Park the machine on level ground.

602-022

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels 8. Install the articulation lock bar.

9. Wipe clean the area around the filter and head.

10. Place rags below to catch the spillage of oil.

11. Wearing face protection (in case of an oil squirt), unscrew the old filter.

12. Drain filter and dispose of any oil properly.

13. Check the seating area for the gasket on the filter head and wipe it clean.

14. This filter has an o-ring gasket. Replace o-ring as required and apply transmission oil to the gasket surface.

15. Screw on the new filter until the gasket makes contact with the seat in the filter head.

16. Hand tighten filter an additional 1/2 turn only.

17. Turn ON the battery disconnect switch.

18. Check that all personnel are clear of the machine before starting the engine.

19. Insert the ignition key and turn to the RUN position.

20. Sound horn to warn personnel of machine start-up.

21. Start the engine.

22. Check for leaks.

3.25

TRANSMISSION FILTER

Lubrication and Maintenance CHECKING THE AIR CONDITIONING SYSTEM

Tigercat 602 Carrier CAUTION Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

If using compressed air for cleaning, use at 30psi or less.

Always use personal protective equipment to guard against flying debris.

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant only. PAG (polyalkeylene glycol) oil should be present in the system and must be used on o-rings and fittings during assembly.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

1.76 kg (3 lbs 14 oz)

0.25 kg (9.0 oz)

CAUTION Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

The compressor and charge ports are accessed from the right side engine compartment.

The receiver drier is mounted in the left step compartment IMPORTANT !

It is recommended that during cold weather when the A/C system is not in use, that it be run for a period of 5 minutes every 2 weeks. This will circulate oil to all components of the A/C system.

c. Check for dirt and debris; on the evaporator coil located inside the A/C-heater unit and also the inside of the A/C-heater unit. Clean as required.

Perform following inspection along with 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION.

COMPRESSOR DRIVE BELT

a. Check re-circulating and fresh air filters in operator's cab. Refer to SECTION 2.

CHECK A/C CONDENSER CORE

602-002

d. With engine turned OFF, check and adjust compressor drive belt tension.

602-015

CHECK A/C CONDENSER CORE

b. Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER AND COOLER PACKAGE in SECTION 3.

NOTE: Belt tension specifications are 55±2 kgf (121 ± 5 lbf). e. Check all A/C hoses for kinks.* f.

Run air conditioning system for 3 - 5 minutes.

g. Check air temperature exiting vents in cab.

3.26

Tigercat 602 Carrier

Lubrication and Maintenance INSPECTION/REPLACEMENT OF SERPENTINE BELT

h. Listen to compressor and blower motor for abnormal noises.* i.

Check to see that compressor clutch will engage.* SIGHT GLASS INDICATES CONDITION OF CHARGE BINARY SWITCH, SYSTEM PROTECTION MOISTURE INDICATOR BLUE - OK. PINK - REPLACE DRIER, RECHARGE SYSTEM A/C RECEIVER/DRIER

SERPENTINE BELT

602-002

All belts should be inspected periodically for signs of incision, cracks, excessive wear in grooves and signs of end or surface grinding.

LOCATED IN COMPARTMENT BELOW LEFT CAB DOOR 602-030

j.

Drive belt tensioning is controlled by the automatic tensioner, therefore checking belt tension is not required.

A/C RECEIVER/DRIER

Inspect sight glass on receiver drier with A/C ON. A constant stream of bubbles indicates system requires charging.*

Refer to engine OPERATION AND MAINTENANCE MANUAL for inspection/ replacement information.

Check colour in moisture indicator; BLUE is OK. PINK indicates desiccant material in drier is saturated with moisture. In this situation replace receiver/drier, evacuate system and recharge system with both refrigerant and PAG oil.* * Indicates that these repairs must only be carried out by a certified A/C technician.

For additional SERVICE information refer to the Tigercat A/C SERVICE MANUAL part number 18795A, available from Tigercat parts department.

3.27

Lubrication and Maintenance COOLER PACKAGE COMPONENTS

A/C CONDENSER

Tigercat 602 Carrier

CHARGE AIR HYDRAULIC COOLER (CAC) OIL COOLER

RADIATOR

EHS TRANSMISSION COOLER (IF EQUIPPED)

602-015

A/C CONDENSER AND COOLER PACKAGE SURGE TANK

602-034

ENGINE FAN 3.28

Tigercat 602 Carrier

Lubrication and Maintenance

DRAINING ENGINE COOLANT

CAUTION

RADIATOR FILL CAP

DO NOT remove the radiator fill cap from a hot engine. Wait until coolant temp is below 122°F (50°C) before removing cap.

Only remove radiator fill cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

33952AUNI R0

RADIATOR FILL CAP

620E-025

1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

A/C CONDENSER

6. Turn OFF the battery disconnect switch

CHARGE AIR HYDRAULIC COOLER (CAC) OIL COOLER

RADIATOR

7. Block wheels 8. Install the articulation lock bar.

9. The radiator is equipped with a hose to drain the contents of the radiator system fluid into a storage container.

EHS TRANSMISSION COOLER (IF EQUIPPED)

10. Remove the front nose belly pan in the front chassis.

11. Remove the radiator pressure cap.

12. The radiator is located on the right side of the heat exchanger.

SHUT-OFF VALVE

602-015

DRAIN HOSE

A/C CONDENSER AND COOLER PACKAGE

14. Slowly open the shut-off valve to drain the radiator fluid.

632E-010

LOWER RADIATOR TUBE SPUD AND SHUT-OFF VALVE

15. Once fluid has been drained, close the shut-off valve and replace the gear clamp and bolt on the drain hose.

The lower radiator tube is equipped with a spud and shut-off valve. The drain hose is attached to the shut-off valve.

13. Place the free end of the drain hose in a storage container and remove the gear clamp and bolt from the end of the hose.

3.29

Lubrication and Maintenance CAB FUSE AND RELAY PANEL

Tigercat 602 Carrier

The fuse panel is located in the left rear of the cab behind the seat. The fuses and relays are protected beneath a panel which can be opened by removing two screws.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

620E-007

2

4

6

8

1

3

5

7

16

9

15

10

14

11

13

12

14

20A

28

10A

13

20A

27

10A

12

20A

26

3A

11

20A

25

3A

24

5A

10 9

15A

23

3A

8

40A

22

5A

7

10A

21

2A

6

5A

20

3A

19

2A

5 4

5A

18

20A

3

30A

17

20A

2

10A

16

20A

15

20A

1

FUSE AND RELAY PANEL

FUSES

1 - SPARE 2 - CIGARETTE LIGHTER 3 - HVAC SYSTEM 4 - KEY POWER 5 - SPARE 6 - HORN 7 - AIR SEAT 8 - ACCESSORY POWER 9 - 12V CONVERTER 10 - SPARE 11 - WORK LIGHTS FRONT 12 - WORK LIGHTS REAR 13 - WORK LIGHTS AUXILIARY 1 14 - WORK LIGHTS AUXILIARY 2 15 - XA2-A1 MODULE 16 - XS2 MODULE 17 - MC43 MODULE C1 18 - MC43 MODULE C2 19 - TELEMATICS SW 20 - MD3 MODULE 21 - XC21 MODULE 22 - KEY ON SIGNAL 23 - SENSORS 24 - SWITCHES 25 - INTERIOR LIGHT 26 - HVAC SWITCHES 27 - START/PARK BRAKE 28 - AC COMPRESSOR/FRESH AIR BLOWER

RELAYS

1 - PARK BRAKE OFF 2 - PARK BRAKE ON 3 - START SOLENOID 4 - UNLOADING VALVE OFF 5 - WORK LIGHTS AUXILIARY 2 6 - WORK LIGHTS AUXILIARY 1 7 - WORK LIGHTS FRONT 8 - WORK LIGHTS REAR 9 - A/C COMPRESSOR/FRESH AIR BLOWER 10 - HVAC FAN 11 - SPARE 12 - SPARE DIODE HOLDER 13 - SPARE 14 - SPARE 15 - SEAT POWER 16 - ACCESSORY POWER

80137BENG R0

CAB FUSE AND RELAY PANEL 3.30

Tigercat 602 Carrier FUSES AND RELAYS (ELECTRICAL BOXES)

Lubrication and Maintenance *NOTE: The aftertreatment system and its related components are applicable to Tier 4f machines only.

MOUNTED ON HYDRAULIC TANK

IN RIGHT SIDE STEP COMPARTMENT

ELECTRICAL BOX

602-019

ELECTRICAL BOX

602-014

RESISTORS

7.

20A

8.

20A

9.

20A

10.

15A

11.

15A

1. 5.1K

4.

2. 5.1K

5.

12.

5A

3. 5.1K

6.

13.

30A

14.

16.

15.

18.

17.

19.

80145BENG R0

HYDRAULIC OIL TEMP TRANSMISSION OIL FILTER BY-PASS CHARGE FILTER BY-PASS SPARE SPARE SPARE

7.

8.

9.

10.

11.

12.

13.

ATS SENSORS EXHAUST FLAP DEF HEATED LINES FUEL HEATER 2 FUEL HEATER 1 FILL PUMP SWITCH ECU POWER

14.

15.

16.

17.

18.

19.

ENGINE ECU RELAY ATS RELAY AFTER-RUN DISCONNECT RELAY STARTER SOLENOID RELAY DEF HEATED LINES RELAY FUEL HEATER RELAY

FUSES

RELAYS

4.

3.

100

A

1.

2.

3.

4.

5.

GRID HEATER FILL PUMP CAB POWER GRID HEATER SOLENOID FILL PUMP SOLENOID

5.

150

A

1.

60A

2.

1.

2.

3.

4.

5.

6.

52158AENG R0

ELECTRICAL BOX FUSES AND RELAYS 3.31

Lubrication and Maintenance BATTERY CARE Tigercat uses two types of batteries dependant on the machine application, model and design.

• Absorbed Glass Mat (AGM) • Flooded Lead Acid (FLA).

NOTICE Before charging the battery, it is important to identify which type of battery you have.

Always read and follow the battery and charger manufacturer's instructions prior to connecting or charging a battery.

All batteries are sensitive to overcharging.

Charging or maintaining AGM batteries requires the use of a smart charger with an AGM setting.

The peak charging voltage for AGM batteries varies slightly between battery manufacturer's.

Exceeding this voltage will cause permanent battery damage. Refer to the BATTERY MANUFACTURER'S charging instructions for more information.

Charging or maintaining FLA batteries requires the fluid levels to be checked. Refer to BATTERY MANUFACTURER'S instruction.

Also refer to BATTERY BOOSTING in SECTION 2.

Tigercat 602 Carrier FUEL FILTERS IMPORTANT !

Failure to service and replace filters at the proper intervals specified in the manufacturer's manuals, could cause damage to the machine and result in the product warranty becoming NULL and VOID. Check Tigercat parts catalog for replacement filters.

ENGINE FUEL FILTER AND FUEL FILTER/ WATER SEPARATOR This machine is equipped with two fuel filters. The engine fuel filter and the fuel filter/water separator.

The fuel filter/water separator 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.

IMPORTANT !

Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced according to the engine OPERATION AND MAINTENANCE MANUAL. The engine fuel injection system requires extremely clean fuel. To accomplish this, the engines typically use filters with a finer micron rating.

These engines use filters with a very fine micron rating. If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in the owner’s manual. Operating the machine with a clogged fuel filter will result in low engine power and severe fuel injection system damage.

It is also recommended that the fuel/water separator bowl be drained daily.

When installing a new fuel filter, DO NOT pre-fill with diesel fuel, or engine fuel pump damage will result. This type of failure is not warrantable by the engine manufacturer.

To prolong the operating life of the fuel filter, make sure that the fuel supply storage tank is clean and free of water and that the fuel is pre-filtered prior to adding it to the machine.

3.32

Tigercat 602 Carrier

Lubrication and Maintenance LOCATED ON LEFT SIDE

LOCATED ON LEFT SIDE HAND PRIMER

FUEL FILTER/ WATER SEPARATOR

ENGINE FUEL FILTER CHANGING THE ENGINE FUEL FILTER: 602-023

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine fuel filter replacement instructions.

WARNING To lower the risk of causing accidental fires, DO NOT leave fuel or oil soaked rags laying around.

602-012

FUEL WATER SEPARATOR

WARNING

WARNING

The fuel pump high-pressure fuel lines and fuel rail contain very high pressure fuel.

Never loosen any fittings while the engine is running. Personal injury and property damage can result.

Drain fuel filter into a container and dispose of all fluids properly.

IMPORTANT!

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

Use only Ultra Low Sulfur Diesel (ULSD) fuel in Tigercat FPT engines equipped with Tier 4f aftertreatment systems. Using fuel with sulfur levels greater than 15 ppm (S≤15 mg/ kg) maximum will permanently damage the engine and aftertreatment system within a short period of time.

3.33

Lubrication and Maintenance

Tigercat 602 Carrier

DRAINING THE FUEL FILTER/WATER SEPARATOR:

LOCATED ON LEFT SIDE HAND PRIMER

Water is heavier than diesel fuel and will settle to the bottom of the bowl and appear a different colour.

It is recommended that the fuel/water separator bowl be checked daily and drained if water is present.

FUEL FILTER/ WATER SEPARATOR

1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels.

8. Install the articulation lock bar.

9. Place a suitable container under the drain valve at the base of the fuel/water separator

602-012

10. Loosen the vent plug on the filter head.

O-RING

11. Turn the drain valve open on the separator bowl.

FUEL WATER SEPARATOR SEPARATOR BOWL

FUEL FILTER

VENT PLUG

NOTE: A drain hose can be attached to the drain valve if required. Use hand primer pump to start flow if required.

12. Water will flow into the container. When fuel begins to flow out of the drain, close the drain valve. Drain the minimum amount of fuel possible.

HAND PRIMER PUMP DRAIN KNOB WITH HOSE BARB

13. Close the vent plug.

14. Turn ON the battery disconnect switch.

15. Check that all personnel are clear of the machine before starting the engine.

822D-025

16. Insert the ignition key and turn to the RUN position.

17. Sound horn to warn personnel of machine start-up.

18. Start the engine.

19. Raise the RPM for one minute to purge the air from the system.

3.34

FILTER HEAD

HARNESS, HEATER (ELEMENT NOT SHOWN) SENSOR, WATER IN FUEL

FUEL FILTER/WATER SEPARATOR COMPONENTS

Tigercat 602 Carrier

Lubrication and Maintenance

CHANGING THE FUEL FILTER/WATER SEPARATOR:

23. Prime the filter by operating the hand primer pump until fuel spills out the vent plug.

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION SCHEDULE in this section for filter replacement intervals.

24. Close the vent plug.

25. Turn ON the battery disconnect switch.

26. Check that all personnel are clear of the machine before starting the engine.

1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

27. Insert the ignition key and turn to the RUN position.

3. Engage the parking brake.

4. Turn OFF the engine.

28. Sound horn to warn personnel of machine start-up.

5. Remove the ignition key.

29. Start the engine and check for leaks.

6. Turn OFF the battery disconnect switch

30. Clean up any spilled fuel before returning machine to operation.

7. Block wheels.

8. Install the articulation lock bar.

9. Wipe clean the area around the fuel filter and filter head.

10. Disconnect the fuel heater and 'water in fuel' sensor from the respective wiring harnesses.

11. Place a drain pan under the separator bowl.

12. Loosen the vent plug on the filter head.

13. Turn the drain valve open on the separator bowl to allow the fuel to drain completely from the separator bowl into a suitable container.

NOTE: A drain hose can be attached to the drain valve if required. Use hand primer pump to start flow if required.

14. Close the drain valve.

15. Use a strap wrench to remove the water separator bowl from the filter head. An optional wrench (Tigercat Part Number: BH814) is also available from your dealer.

16. Remove and discard the O-ring from the top of the separator bowl.

17. Clean the separator bowl.

18. Remove the fuel filter from the filter head (pressure fit) and discard properly.

19. Place the new fuel filter into position on the filter head.

20. Lubricate the new O-ring with clean engine oil and install at the top of the separator bowl.

21. Install (screw) separator bowl onto the filter head, hand tight, then turn an additional 3/4 turn only.

22. Reconnect the fuel heater and 'water in fuel' sensor to their respective wiring harness.

3.35

Lubrication and Maintenance FUEL TANK

Tigercat 602 Carrier

IMPORTANT!

Located in the rear chassis, the fuel reservoir consists of two tanks interconnected. There is one filling location (right tank). The fill tube also contains a fuel fill strainer.

The fuel fill strainer located under the fill cap should be removed and cleaned every 125 Hours (reach in and lift it out). Replace the screen if it is damaged.

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

A sending unit is installed and connected to the computer display on the instrument panel.

Use only Ultra Low Sulfur Diesel (ULSD) fuel in Tigercat FPT engines equipped with Tier 4f aftertreatment systems. Using fuel with sulfur levels greater than 15 ppm (S≤15 mg/ kg) maximum will permanently damage the engine and aftertreatment system within a short period of time.

The standard fuel tank has a capacity of 190 L (50 US gal).

3.36

Tigercat 602 Carrier

Lubrication and Maintenance

FUEL FILL STRAINER This is a stainless steel fuel fill strainer, screwed on to the inlet pipe of the engine fuel feed line inside at the bottom of the fuel tank.

D

Changing or cleaning the strainer: NOTE: This should only be required if excessive quantities of foreign material has built up inside the tank.

1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels.

8. Install the articulation lock bar.

9. Drain the fuel tank. Refer to DRAINING THE FUEL TANK in THIS SECTION. 10. Remove the round fuel tank cover plate and “O” ring from the access hole.

11. Before removing the strainer, clean any debris from the bottom of the tank and wipe it clean.

12. Remove the fuel fill strainer using the hex on the end of strainer. Carefully clean the strainer (it may be damaged by rough handling).

13. Check for a buildup of foreign materials where the strainer threads on to the pipe and elbow.

14. Reinstall the strainer using the hex on end.

15. Reinstall fuel tank cover plate with “O” ring.

16. Refuel and check for leaks.

17. Turn ON the battery disconnect switch.

18. Check that all personnel are clear of the machine before starting the engine.

19. Insert the ignition key and turn to the RUN position.

20. Sound horn to warn personnel of machine start-up.

21. Start the engine.

22. Check for leaks again.

3.37

Lubrication and Maintenance DRAINING THE FUEL TANK

Tigercat 602 Carrier

1. Park the machine on level ground.

REFUELLING PROCEDURE 1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

3. Engage the parking brake.

4. The fuel system is equipped with either two standard saddle tanks or a single high capacity tank.

4. Turn OFF the engine and allow machine to cool.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels.

5. Use the fuel gauge on the computer display or the dipstick to estimate the container capacity required to properly drain the fuel. Refer to FUEL TANK in THIS SECTION for tank capacities.

6. Turn OFF the engine.

8. Install the articulation lock bar.

9. Do not refuel while smoking or near an open flame or sparks.

10. Clear obstructions from steps and handles needed to access fuel tank.

11. Open cover on top of fuel tank (if equipped) and clear any debris from around the fill cap.

7. Remove the ignition key.

8. Turn OFF the battery disconnect switch 9. Block wheels.

10. Install the articulation lock bar.

11. Remove the fuel tank fill cap.

12. Remove the drain plugs and drain the fuel into a suitable container.

13. Note that both the left and right sides of the high capacity tank need to be drained to fully empty this tank.

14. Once the fluid has been drained replace the drain plugs and fill cap.

D

12. Remove fuel fill cap slowly to allow pressure to escape from tank.

13. Inspect fuel fill cap gasket.

14. Inspect fuel fill strainer located under the fill cap for debris or damage.

15. Attach a grounding strap to an unpainted metal surface on the machine if the refuelling tank or nozzle is so equipped.

16. Fill the fuel tank until the fuel level reaches the strainer or the full mark on the sight gauge if equipped.

17.

Do not leave nozzle unattended or spillage may occur.

18. Remove nozzle and ground strap (if applicable).

19. Install fuel fill cap hand tight before closing fuel fill cap cover.

20. Turn ON the battery disconnect switch.

21. Check that all personnel are clear of the machine before starting the engine.

22. Insert the ignition key and turn to the RUN position.

23. Sound horn to warn personnel of machine start-up.

24. Start the engine.

3.38

Tigercat 602 Carrier AIR CLEANER MAINTENANCE

Lubrication and Maintenance Note that the air filter restriction indicator may not function properly if the air intake tube is damaged.

Engine failures due to improper maintenance are not covered by Tigercat or Engine Manufacturer’s Warranty and any such claim will be denied.

602-033

IMPORTANT !

For peak engine performance and maximum fuel economy, please ensure that the air precleaner is regularly checked and cleaned as required. All intake air tubes and clamps should be thoroughly inspected on a regular basis and any damaged or missing components should be replaced immediately.

INLET HOOD

INLET HOOD (IF EQUIPPED) The optional inlet hood protects the air inlet from rain, snow and debris. The inlet hood should be checked every 8 hours to make sure that foreign materials have not plugged air inlet area. Clean as required.

3

3 4

2 ENGINE AIR PRECLEANER

1 5

630C-19

630E-308

ENGINE AIR PRECLEANER

AIR PRECLEANER (IF EQUIPPED) The optional engine air precleaner cleans engine air before it reaches the air cleaner filter elements.

It removes contaminants such as dust, powder, insects, rain and snow. The air precleaner should be checked every 8 hours to make sure that foreign materials have not plugged the intake area or the discharge louver area. Clean as required.

CENTRI® PRECLEANER OPERATION

OPERATION: 1. Air enters the precleaner.

2. Specially designed vanes move dirty air toward the impeller.

3. The spinning impeller spins the air creating centrifugal force to separate contaminants from the clean air.

4. Contaminants are blown out the discharge louver.

5. Clean air enters the intake to the air cleaner.

IMPORTANT !

The air precleaner must be check every 8 hours and cleaned as required.

If the inlet/precleaner is plugged causing a restriction to airflow, reduced engine performance and increased fuel consumption may result.

If a plugged inlet/precleaner is left too long excessive air intake restriction may damage the rubber air intake tube. A damaged air intake tube will lead to ingestion of dirt into the engine which may result in engine failure.

3.39

Lubrication and Maintenance

Tigercat 602 Carrier 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.

AIR CLEANER

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.

AIR CLEANER UNLOADER VALVE

When operating in high dust conditions, the unloader valve should be checked and squeezed every 2 hours to release dust buildup.

ENGINE AIR CLEANER AIR CLEANER 602-017

The air cleaner on this machine uses two filter elements, a primary element and a safety element accessible from the right side of the engine compartment.

FILTER RESTRICTION SWITCH FILTER RESTRICTION INDICATOR

To ensure maximum engine protection, it is important that the elements be serviced correctly and at proper servicing intervals.

AIR CLEANER

A filter restriction indicator is mounted to the output side of the filter, this should show green when the engine is running under load. Service is required if the indicator shows red. This machine is also equipped with a switch used to send a signal to the computer control system in the event of a filter restriction.

Engine Air Intake Filter Restricted. Service Machine to correct.

602-016

ENGINE AIR CLEANER

FILTER RESTRICTION INDICATOR A filter restriction indicator is connected to the outlet side of the air filter. Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

NOTE: Replace the safety element every third primary filter change.

When a signal is received from the restriction indicator switch on the engine air cleaner a message will be displayed. Refer to COMPUTER – MESSAGES - ALERT – ENGINE AIR INTAKE FILTER RESTRICTED in SECTION 2.

3.40

Tigercat 602 Carrier

Lubrication and Maintenance

INTAKE TUBING AND JOINTS

OUTLET TUBE

Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware at the beginning of every shift. (8 hours). Repair or replace defective parts immediately.

PRIMARY ELEMENT

Replace all air intake rubber components such as elbows and connectors every 2000 hours - High temperatures in this area can cause the rubber to harden.

SAFETY ELEMENT

Note: High-temperature silicone connectors do not need to be replaced unless they are damaged.

In addition to the LUBRICATION AND MAINTENANCE SCHEDULE, the following instructions should also be noted.

AIRCLEANER

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS

The most common and damaging servicing problems are:

1. Release the cover latch gently to reduce the amount of dust dislodged.

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.

NOTE: This does not apply to oil filters.

2. Avoid dislodging dust from filter element(s) by gently pulling the element off the outlet tube.

3. Always clean the sealing surface of the outlet tube before inserting a new filter element.

4. Always clean the inside of the outlet tube and filter housing.

5. Check your old filter, It can help you detect foreign material on the sealing surface that is causing leakage.

NOTE: Filter elements should never be cleaned and reused. Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media. The dust is then drawn directly into the engine.

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.

AIR FILTER ELEMENTS

6. Inspect the new filter for damage.

7. Insert the new filter properly. Apply pressure to the outer rim of the filter not the flexible centre.

8. Inspect connections and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points and replace as needed. Leaks in these locations send dust directly to the engine.

3.41

Lubrication and Maintenance

Tigercat 602 Carrier

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY.

8

7

AFTERTREATMENT SYSTEM (DENOX 2.2 SYSTEM - TIER 4 FINAL) The engine on this machine is equipped with a combination Diesel Oxidation Catalyst (DOC) and high efficiency Selective Catalytic Reduction (SCR) aftertreatment system to limit the nitrogen oxide exhaust gas values (NOX) to meet Tier 4f emission standard requirements with low fuel consumption. This process is electronically controlled by the DENOX 2.2 system.

15

14

16

The diesel oxidation catalyst (DOC) uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). In addition the DOC converts nitrogen oxide (NO) into nitrogen dioxide (NO2).

Increased NO2 levels enhance the performance of the SCR catalyst at low temperatures and increase the effectiveness of the DOC/SCR aftertreatment system as a whole.

4

12 602-065

View A

The high efficiency SCR process is based on a series of chemical reactions which involve the reaction of ammonia with the oxygen in the exhaust gas to reduce nitrogen oxides (NOX) in the exhaust gas by transforming it into inert compounds: free nitrogen (N2) and water vapour (H2O). In addition the high efficiency catalytic converter includes a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

IMPORTANT !

When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the aftertreatment system and the engine.

602-056

3.42

DEF TANK

Tigercat 602 Carrier

Lubrication and Maintenance

The aftertreatment system consists of the following components: 1.

2.

3.

4.

Inlet Humidity Sensor Diesel Exhaust Fluid (DEF) Tank Heater Valve and Heated DEF Supply Lines DENOX 2.2 control system (incorporated into the engine control unit ) 5. Supply module 6. Exhaust Flap 7. Inlet NOX Sensor

8.

9.

10.

11.

12.

13.

DOC Inlet Temperature Sensor Diesel Oxidation Catalyst (DOC) Dosing Module (DEF Injector) Mixer Tube Inlet Temperature Sensor Catalytic Converter with Clean Up Catalyst (CUC) incorporated 14. Outlet Temperature Sensor 15. NH3 Sensor 16. Outlet NOX Sensor

A

10

16

15

9 11

13

6 3 1

5 2

602-064

AFTERTREATMENT SYSTEM COMPONENTS 3.43

Lubrication and Maintenance

Tigercat 602 Carrier HUMIDITY SENSOR

HC - HYDROCARBONS NOX - NITROGEN OXIDES CO - CARBON MONOXIDE NH3 - AMMONIA N2 - FREE NITROGEN H2O - WATER CO2 - CARBON DIOXIDE

DEF DOSING MODULE FILTER AIR FILTER

SUPPLY MODULE

EXHAUST FLAP

ECU

HC

NOx SENSOR

NOX CO

DEF QUALITY SENSOR

ENGINE

NOx SENSOR

NH3 SENSOR

N2

DOC

TEMPERATURE SENSORS

HEATER VALVE (CIRCULATING ENGINE COOLANT)

MIXER TUBE CUC

H 2O

DEF LEVEL SENSOR

SCR NH3

CO2

DEF TANK

DOSING MODULE

CATALYTIC CONVERTER

630E-276

AFTERTREATMENT SYSTEM

The aftertreatment system is electronically managed by the DENOX 2.2 system incorporated into the engine control unit (ECU). The ECU calculates and adjusts the flow rate of the DEF solution into the system based on current engine speed, torque delivered, exhaust temperature, amount of nitrogen oxides and ammonia present.

into ammonia (2NH3) and carbon dioxide (CO2).

Evaporation of the solution lowers exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The exhaust passes through the diesel DOC which uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O). It also converts nitrogen oxide (NO) into nitrogen dioxide (NO2) which enhances the performance of the SCR catalyst.

The supply module pump picks up the DEF solution from the tank and sends it under pressure to the dosing module (DEF injector) to be injected into the exhaust at the outlet of the DOC and pass through the mixer tube upstream of the catalytic converter.

The first phase of the SCR process takes place in the first part of the catalytic converter: high temperature exhaust gas evaporates the DEF solution instantly and, by hydrolysis, converts it

The exhaust fumes and ammonia at the proper reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place: by reacting with the oxygen in the exhaust gases the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

Finally the high efficiency catalytic converter incorporates a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

IMPORTANT !

Engine should not idle longer than 9 consecutive hours. Damage to the emission control system will result. When this machine idles for an extended period excess hydrocarbon buildup is created in the DOC/SCR aftertreatment system. Burn off of excess hydrocarbon at full load immediately after a long idle period will generate excess heat which will cause damage to emission control system components.

3.44

Tigercat 602 Carrier

Lubrication and Maintenance

DIESEL EXHAUST FLUID (DEF) TANK

The DEF tank is located in the step compartment below the right cab door.

A 41581AUNI R0

NOTE: Extremely low DEF levels or quality problems, may result in derating of engine performance to meet exhaust emission requirements. Action to correct DEF levels or quality problems should be taken immediately to avoid affecting engine performance and damage to the DOC/SCR aftertreatment system components.

Refer also to COMPUTER – MESSAGES in SECTION 2.

The DEF tank includes a fill inlet with cap and a heater unit.

602-057

A DEF Tank Blue Fill Cap With Quick Connect

The DEF fill cap can be accessed through an access cover at the rear of the compartment for filling. The DEF tank fill point is equipped quick connect and a filter to prevent contaminants from entering the tank.

B A

The DEF tank and DEF supply lines are heated when temperatures are low, the system will thaw DEF within 30 minutes of engine start for proper operation of the diesel oxidation catalyst /selective catalytic reduction (DOC/SCR) aftertreatment system.

NOTE: Whenever the engine is stopped all DEF is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds. Refer to AFTERTREATMENT SYSTEM in THIS SECTION. The heater unit incorporates a heater coil, heating system inlet/outlet connections, DEF inlet/ outlet connections, a breather, a level sensor, a temperature sensor and a DEF quality sensor.

DIESEL EXHAUST FLUID (DEF) DEF is used by the DOC/SCR aftertreatment system to lower the concentration of nitrogen oxides from the diesel engine exhaust.

Diesel Exhaust Fluid (DEF) is an aqueous urea solution with 32.5% high purity urea and 67.5% deionized water.

602-055

A DEF Tank B Heater Unit

30L DEF Tank

DEF tank capacity is 30L (7.9 US gal). DO NOT overfill tank. This tank is equipped with an expansion capacity of 7% required to allow for the expansion of DEF in cold temperature conditions.

DEF freezes at -11°C (12°F).

A DEF level indicator is shown on the main menu of the computer display.

When a problem with DEF levels or quality is detected, information messages are shown on the computer.

NOTE: DEF may also be referred to as AUS32 or AdBlue. All DEF must be American Petroleum Institute (API) Certified DEF or meet ISO 22241 specifications.

IMPORTANT! DEF should be stored between -11°C (12°F) and 30°C (86°F) and out of direct sunlight to maximize shelf life and to avoid DEF quality problems caused by improper storage.

It is important to avoid contamination of the DEF when filling the tank as this may cause costly damage to the aftertreatment system components and affect the proper operation of the aftertreatment system and the engine.

NOTE: DEF quality problems may result in derating of engine performance to meet emission standard requirements. Action to correct DEF quality problems should be taken immediately 3.45

Lubrication and Maintenance

Tigercat 602 Carrier DRAINING THE DIESEL EXHAUST FLUID TANK

to avoid affecting engine performance and damage to the DOC/SCR aftertreatment system components.

NOTE: DEF and its related components are applicable to Tier 4f machines only.

Refer also to COMPUTER – MESSAGES in SECTION 2.

Draining the DEF tank is recommended in the case of DEF quality concerns and/or known contamination. The DEF tank must be completely drained and all contaminants must be removed before refilling.

TO DRAIN THE TANK: 1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

WARNING Use only Diesel Exhaust Fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

6. Turn OFF the battery disconnect switch 7. Block wheels.

8. Install the articulation lock bar.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

9. Use the DEF level indicator on the computer display to estimate the container capacity required to properly drain the DEF solution. Total tank capacity is 30 L (7.9 US gal).

NOTE: Whenever the engine is stopped all DEF is pumped back to tank before the engine power system is turned OFF. This process takes approximately 90 seconds.

10. Remove the DEF tank drain access cover.

11. Remove the DEF fill cap.

Refer to AFTERTREATMENT SYSTEM in this section for more information regarding the use of DEF and its function in the DOC/SCR aftertreatment system.

12. Remove the drain plug and drain the DEF solution into a suitable container.

Refer to DRAINING DEF TANK in THIS SECTION.

13. Once the fluid has been drained, clean the inside of the tank with DEF or distilled/ demineralized water only if required.

Thoroughly drain the tank after cleaning 14. Replace the drain plug and DEF fill cap.

15. If any DEF has spilled, rinse well with water.

NOTE: To avoid contamination and ensure clean fluid, do not re-use DEF. Re-fill tank with new DEF only.

IMPORTANT! It is important to avoid contamination of DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine.

3.46

Tigercat 602 Carrier

Lubrication and Maintenance

FILLING THE DEF TANK

IMPORTANT! It is important to avoid contamination of DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine.

1. Park the machine on level ground.

A

2. Lower the dozer blade and grapple (if equipped) to rest firmly on the ground.

B

C

602-086

3. Engage the parking brake.

A Access Door, DEF Fill B DEF Tank Blue Fill Cap With Quick Connect C Left Step Compartment, Below Cab Door

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels.

8. Install the articulation lock bar.

11. Open quick connect flap and insert the filling container spout through the fill cap into the flap on the top of the fill strainer and fill the tank.

Do NOT remove the fill strainer to fill the tank.

NOTE: A section of the DEF tank remains empty when the DEF level reaches the strainer to accommodate DEF expansion when it freezes.

A

NOTICE

41581AUNI R0

Do NOT remove the DEF fill strainer when filling the tank. Contamination of the DEF can occur.

602-057

A DEF Tank Blue Fill Cap With Quick Connect

9. Open the access door at the rear of the left step compartment to access the DEF tank fill cap.

10. Clean the area around the top of the fill cap to prevent DEF contamination.

NOTE: To avoid contamination and ensure clean fluid, do not re-use DEF. Re-fill the tank with new DEF only. Refer to DIESEL EXHAUST FLUID (DEF) in THIS SECTION regarding DEF specifications.

12. Release the quick connect flap to close.

13. Close and secure the access door.

3.47

Lubrication and Maintenance

Tigercat 602 Carrier

CLEANING THE DEF FILL STRAINER

Remove and clean particles and debris from the DEF fill strainer every 500 hours:

A

1. Park the machine on level ground.

2. Lower the dozer blade and grapple (if equipped) to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels.

1000001

8. Install the articulation lock bar.

A Area under the Fill Cap

11. Remove the fill cap.

Clean the area under the fill cap to prevent DEF contamination.

A

A

B

C

602-086

A Access Door, DEF Fill B DEF Tank Blue Fill Cap With Quick Connect C Left Step Compartment, Below Cab Door

9. Open the access door at the rear of the left step compartment to access the DEF tank fill cap.

10. Clean the area around the outside of the fill cap to prevent DEF contamination.

1000002

A Fill Strainer

12. Rotate the fill strainer counterclockwise and pull it straight out.

13. Hold the flap open, invert the strainer and lightly tap it against a clean, hard surface to dislodge and remove any particles.

14. Rinse the fill strainer with either of the following solutions: • DEF • demineralized water • distilled water 15. Replace the clean strainer. Turn it clockwise to tighten.

16. Install the fill cap.

17. Close and secure the access door.

3.48

Tigercat 602 Carrier

Lubrication and Maintenance

DIESEL EXHAUST FLUID (DEF) HANDLING AND STORAGE

WARNING

Diesel exhaust fluid (DEF) is an aqueous urea solution with 32.5% high purity urea and 67.5% deionized water.

Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

NOTE: DEF may also be referred to as AUS32 or AdBlue and should meet ISO 22241 specifications.

Use only DEF meeting this standard.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

It is important to avoid contamination of DEF as this may cause costly damage to SCR system components and affect the proper operation of the SCR system and the engine.

When a problem with DEF quality is detected information messages will be shown on the computer display.

NOTE: DEF quality problems may result in derating of engine performance to meet emission standard requirements. Action to correct DEF quality problems should be taken immediately to avoid affecting engine performance and damage to SCR aftertreatment system components.

Refer also to COMPUTER – MESSAGES in SECTION 2.

For safety information refer to DIESEL EXHAUST FLUID (DEF) in SECTION 1 of THIS MANUAL. AVOID DEF QUALITY PROBLEMS WITH PROPEr HANDLING PRACTICES Most DEF quality problems can be avoided entirely with a little care and proper handling of DEF. FILLING THE DEF TANK •

•

Always clean the area around the fill cap and avoid introducing contaminants into the DEF tank when filling.

Always use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications.

Use of any other fluid will contaminate the aftertreatment system and may pose a safety hazard.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

USE OF PROPER STORAGE CONTAINERS •

To prevent contaminants from affecting DEF quality it should be handled only in storage, transport and filling containers intended exclusively for that purpose.

•

Polyethylene or stainless steel containers are recommended. Refer also to DEF manufacturer's recommendations.

•

DEF is corrosive to metals other than stainless steel. Transport in metal containers other than stainless steel will result in contamination.

PROPER STORAGE CONDITIONS TO MAXIMIZE SHELF LIFE •

DEF should be stored between -11°C (12°F) and 30°C (86°F) and out of direct sunlight to maximize shelf life and to avoid DEF quality problems caused by improper storage.

•

DEF quality problems can often be avoided with proper storage and handling practices to maximize shelf life.

•

DEF storage areas should always be out of direct sunlight and away from heat sources to avoid reducing shelf life.

•

DEF shelf life is limited. It should be consumed on a first in first out basis, within manufacturer's recommended shelf life limits.

DEF beyond manufacturer's recommended shelf life limits may not meet ISO 22241 specifications.

3.49

Lubrication and Maintenance

Tigercat 602 Carrier

HEATER VALVE / HEATED DEF SUPPLY LINES

Heating is switched OFF when: • DEF tank temperature >16°C (61°F) • Supply module temperature >10°C (50°F) • Ambient air temperature >-4°C (25°F)

CONNECTOR

Heating is switched ON when: • DEF tank temperature <15°C (59°F) • Supply module temperature: +8°C (46°F) • Ambient air temperature: -5°C (23°F)

COOLANT OUTLET

COOLANT BYPASS

COOLANT INLET 630E-265

When conditions require heating the system will thaw DEF within 30 minutes of engine start for proper operation of the aftertreatment system.

Note also that whenever the engine is stopped all DEF is pumped back to tank before the engine power system is turned off. This process takes approximately 90 seconds.

HEATER VALVE

The heater valve is located on a bracket on the right side of the engine compartment.

RIGHT SIDE OF ENGINE COMPARTMENT

620E-272

HEATER VALVE

The heater valve controls the flow of engine coolant through the DEF tank heater coil and the supply module when heating of the DEF is required. The heater valve also controls the constant flow of engine coolant to the dosing module for cooling purposes. This machine is equipped with electrically heated DEF supply lines.

DEF freezes at -11°C (12°F).

Temperature sensors signals control the operation of both the electrically heated DEF supply lines and the heater valve which, depending on the temperature, opens or closes the flow of hot engine coolant to the heater coil and supply module.

3.50

Tigercat 602 Carrier THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY.

Lubrication and Maintenance EXHAUST FLAP

DENOX 2.2 DOSING SYSTEM

EXHAUST FLAP

602-021

An exhaust flap is located at the exhaust outlet from the engine. The exhaust flap is used to regulate temperature of the exhaust entering the diesel oxidation catalyst (DOC) to optimum levels for proper operation of the aftertreatment system.

602-058

ENGINE ECU

DENOX 2.2 control system is incorporated into the engine control unit (ECU).

The DOC/SCR aftertreatment system is electronically managed by the DENOX 2.2 control system. The ECU calculates and adjusts the flow rate of the DEF solution into the system based on current engine speed, torque delivered, exhaust temperature, amount of nitrogen oxides and ammonia present and the humidity levels in incoming air.

3.51

Lubrication and Maintenance DIESEL OXIDATION CATALYST (DOC)

602-059

Tigercat 602 Carrier SUPPLY MODULE

DIESEL OXIDATION CATALYST (DOC)

The diesel oxidation catalyst (DOC) uses oxidation at high temperatures to convert carbon monoxide (CO), hydrocarbons (HC) and the soluble organic fraction (SOF) of diesel particulates into inert compounds, carbon dioxide (CO2) and water vapour (H2O).

In addition the DOC converts nitrogen oxide (NO) into nitrogen dioxide (NO2). Increased NO2 levels enhance the performance of the SCR catalyst at low temperatures and increase the effectiveness of the DOC/SCR aftertreatment system as a whole.

630E-267

SUPPLY MODULE

The supply module pump picks up the DEF solution from the tank and sends it under pressure to the dosing module, mounted on the mixer tube incorporated into the diesel oxidation catalyst.

DEF is injected into the exhaust at the outlet of the diesel oxidation catalyst and upstream of the catalytic converter.

The DOC is located upstream of the catalytic converter (SCR & CUC) and at its outlet incorporates the mixer tube and the mounting for the dosing module.

3.52

Tigercat 602 Carrier THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY. DEF DOSING MODULE FILTER NOTE: DEF and its related components are applicable to Tier 4f machines only.

The DEF dosing module filter should be replaced as part of scheduled maintenance every 250 hours.

If DEF and/or aftertreatment fault codes have occurred then Tigercat recommends performing a DEF flushing test and Urea Dosing System Test (UDST) at every DEF dosing module filter change to ensure proper operation of the DEF supply module.

If no DEF and/or aftertreatment fault codes have occurred then only the DEF dosing module filter replacement is required.

CHANGING DEF DOSING MODULE FILTER, DEF FLUSHING TEST AND UDST (UREA DOSING SYSTEM TEST)

Lubrication and Maintenance REMOVE DEF DOSING MODULE FILTER 1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Make sure the engine is at operating temperature.

4. Engage the parking brake.

5. Turn OFF the engine.

6. Remove the ignition key.

7. Block wheels.

8. Install the articulation lock bar.

9. Wipe clean the area around the DEF supply module and filter including the supply module ports with particular attention to the inlet port and filter cap to avoid introducing contamination into the filter housing while performing this procedure.

10. Place container below to catch the spills.

TOOLS REQUIRED • 27 mm (1 1/16 in) wrench • Container to catch DEF and flushing water • Clean distilled/demineralized water • 1 litre (0.25 US gal) plastic water bottle with hose attached* • Laptop computer with Tigercat by FPT E.A.SY. software to run UDST test* • PT-Box* IMPORTANT! Do not contaminate the DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine.

630E-281

11. Turn the filter cover counterclockwise to remove from the supply module. Use a 27 mm (1 1/16 in) wrench.

*Items required if performing a DEF flushing test and UDST.

630E-282

12. Remove the equalizing element and note the colour of the filter inside (black or grey).

3.53

Lubrication and Maintenance

Tigercat 602 Carrier

630E-285

13. Find the filter removal tool provided with the replacement parts select the correct edge BLACK (B) for black filters or GREY (G) for grey filters.

630E-287

16. Clean surfaces with distilled/demineralized water only to avoid DEF contamination.

Check the area around the filter for cracks. If cracks are found the supply module must be replaced.

17. Thoroughly clean the filter cover to avoid introducing contamination.

DEF FLUSHING TEST A

630E-284

14. Insert the tool edge completely until a click is felt or heard.

630E-286

15. Pull out the filter, using a tool in the slot on the filter removal tool if required.

630E-333

A Inlet Port

18. Disconnect the DEF hose from the inlet port of DEF supply module.

3.54

Tigercat 602 Carrier

Lubrication and Maintenance

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY. 19. Fill the plastic bottle with distilled/ demineralized water.

A

630E-331

24. Distilled water will be drawn from the bottle and flushed through the DEF supply module.

Suction may begin to collapse the bottle and water flow out the bottom of the module will increase.

630E-332

A Inlet Port

20. Connect the water bottle hose to the inlet port of the DEF supply module.

630E-328

25. The results of the UDST will show a flat line for DEF pressure (red line) because the pump cannot build pressure without the filter in place.

26. Repeat the UDST test a second time to ensure the DEF supply module is thoroughly flushed and working correctly.

630E-334

21. Raise the water bottle above the DEF supply module.

27. When the UDST flushing procedure has been performed twice successfully remove the bottle and hose.

28. Reinstall the DEF module inlet hose.

22. A small amount of water will flow through the DEF supply module and out the bottom where the filter has been removed.

23. With the aid of an assistant run a UDST test from the laptop computer. Refer to PT Box Manual for UDST test information.

3.55

Lubrication and Maintenance REPLACE FILTER

Tigercat 602 Carrier 35. Start the engine.

36. Check for leaks.

37. Turn OFF the engine.

IMPORTANT! Do not contaminate the DEF when performing maintenance on the system as this may cause costly damage to SCR system components and affect the proper operation of the aftertreatment system and the engine.

WARNING

630E-288

Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. NEVER fill the DEF tank with any other fluid.

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

29. Install the new filter. Lubricate the o-rings on the filter with clean DEF solution for easy installation.

UDST (UREA DOSING SYSTEM TEST) 38. With the aid of an assistant run a UDST test from the laptop computer. Refer to PT Box Manual for UDST test information.

630E-289

30. Install the new equalizing element.

NOTE: The equalizing element must be replaced with each filter change.

630E-327

630E-290

39. If the DEF supply module is functioning correctly the test should show a characteristic curve as shown above, DEF pressure (red line).

31. Reinstall the clean filter cover, tighten to 20 Nm (15 lbf-ft). Use a 27 mm (1 1/16 in) wrench.

32. Check that all personnel are clear of the machine before starting the engine.

33. Insert the ignition key and turn to the RUN position.

34. Sound horn to warn personnel of machine start-up.

3.56

Tigercat 602 Carrier

Lubrication and Maintenance

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY. 40. A confirmation screen will indicate System is OK if the DEF supply module is functioning correctly.

41. Repeat the UDST test a second time to confirm results.

630E-330

42. If the UDST test passes twice the DEF supply module is OK.

630E-329

43. If the UDST test fails twice note the error mode(s) and contact customer service.

3.57

Lubrication and Maintenance DOSING MODULE (DEF INJECTOR)

630E-274

Tigercat 602 Carrier MIXER TUBE

T250D-119

DOSING MODULE

The dosing module is mounted on the DOC outlet upstream of the catalytic converter. The dosing module injects DEF into the exhaust pipe. Note that this module must be mounted at the correct specified angle to function properly.

The dosing module is cooled by a constant flow of engine coolant supplied by the heater valve to maintain optimum temperature for the aftertreatment process.

MIXER TUBE

The mixer tube is incorporated into the outlet of the DOC upstream from the catalytic converter.

The insulated high-turbulence mixer tube is used to mix the DEF solution and exhaust gases together before they enter the catalytic converter.

3.58

Tigercat 602 Carrier CATALYTIC CONVERTER

Lubrication and Maintenance HUMIDITY SENSOR

620E-089

HUMIDITY SENSOR

The humidity sensor is located on the air intake just past the air cleaner. This sensor monitors the temperature and humidity of intake air sending signals to the DENOX 2.2 control system. This information is used to calculate the amount of DEF to be injected into the system.

602-060

CATALYTIC CONVERTER

The catalytic converter is located on the left side of the engine compartment. Chemical reactions inside the catalytic converter reduce nitrogen oxides (NOX) in the exhaust gas.

The catalytic converter is equipped with soundproofing material and replaces the exhaust silencer. It incorporates both the selective catalytic reduction (SCR) and the cleanup catalyst (CUC) components of the aftertreatment system.

The first phase of the SCR process takes part in the first part of the catalytic converter: high temperature exhaust gas evaporates the DEF solution instantly and, by hydrolysis, converts it into ammonia (2NH3) and carbon dioxide (CO2).

Evaporation of the solution lowers exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The exhaust fumes and ammonia at the proper reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place: by reacting with the oxygen in the exhaust gasses the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

Finally the high efficiency catalytic converter incorporates a clean up catalyst (CUC) which reduces any excess ammonia (NH3) which may result from the SCR process.

3.59

Lubrication and Maintenance

Tigercat 602 Carrier

THE AFTERTREATMENT SYSTEM AND ITS RELATED COMPONENTS ARE APPLICABLE TO TIER 4F ENGINES ONLY.

NH3 SENSOR ELECTRONIC CONTROL UNIT

TEMPERATURE SENSORS TAG

SENSOR

630E-264

NH3 SENSOR

The NH3 sensor is mounted at the outlet of the catalytic converter. The NH3 sensors detect and send information about the NH3 levels in the exhaust. This information is used to calculate the amount of DEF to be injected into the system and to monitor DOC/SCR aftertreatment system operation.

620E-087

TEMPERATURE SENSOR

Temperature sensors are mounted at the inlet of the diesel oxidation catalyst, the inlet of the catalytic converter and the outlet of the catalytic converter. These 3 sensors send exhaust temperature signals to the DENOX 2.2 control system. The control system uses this information to calculate the amount of DEF to be injected into the system.

Refer to APPROVED ANTISEIZE PASTES FOR EXHAUST / AFTERTREATMENT LINE (TIGERCAT BY FPT Tier 4F ENGINES) in THIS SECTION.

NOTE: All three temperature sensors are identical, however location should be noted for analysis purposes when replacing a temperature sensor.

3.60

Tigercat 602 Carrier NOX SENSOR

Lubrication and Maintenance APPROVED ANTI-SEIZE PASTES FOR EXHAUST / AFTERTREATMENT LINE (TIGERCAT BY FPT Tier 4F ENGINES)

ELECTRONIC CONTROL UNIT

NOX sensors-Weicon High Tech Anti-Seize only NH3 sensor-Loctite X203 Dry Film Moly Anti-Seize

CERAMIC SENSOR

620E-088

NOX SENSOR

The inlet NOX sensor is mounted upstream of the diesel oxidation catalyst. The outlet NOX sensor is mounted at the outlet of the catalytic converter.

The NOX sensors detect and send information about the dosing of DEF solution and the efficiency of the catalytic converter to the DENOX 2.2 control system. This information is used to calculate the amount of DEF to be injected into the system and to monitor DOC/SCR aftertreatment system operation.

IMPORTANT! When checking or replacing any sensor or plugs in the exhaust or the aftertreatment system it is important to use only approved anti-seize as specified by Tigercat.

Use of non-approved compounds can affect the operation of the NOX and NH3 sensors and cause a malfunction of the aftertreatment system. This may result in poisoning of the SCR catalyst and require replacement of expensive aftertreatment system parts.

Each NOX sensor consists of ceramic sensor and an electronic control unit linked by a cable.

The sensor detects the concentration of nitrogen oxides in the exhaust.

The sensor, cable and control unit are considered to be one part for service/replacement purposes.

Note that cable length cannot be changed as this will affect the proper operation of the sensor.

IMPORTANT! When checking or replacing any sensor or plugs in the exhaust or the aftertreatment system it is important to use only approved anti-seize as specified by Tigercat. Use of non-approved compounds can affect the operation of the NOX sensor and a malfunction of the DOC/ SCR aftertreatment system. This may result in poisoning of the catalytic converter and require replacement of expensive aftertreatment system parts.

Refer to APPROVED ANTISEIZE PASTES FOR EXHAUST / AFTERTREATMENT LINE (TIGERCAT BY FPT Tier 4F ENGINES) in THIS SECTION.

3.61

Lubrication and Maintenance

Tigercat 602 Carrier

DRAINING TRANSMISSION OIL 1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch 7. Block wheels.

8. Install the articulation lock bar.

9. The transmission is equipped with a plug to drain the contents of the transmission into a storage container.

10. Remove the belly pan in the front chassis closest to the articulation joint.

11. Remove the drain plug on the hydraulic motor side of the transmission (pic).

12. Once fluid has been drained, replace the drain plug in the transmission housing once draining has completed.

TRANSMISSION DRAIN 630C-100

TRANSMISSION OIL

3.62

Tigercat 602 Carrier AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS

Lubrication and Maintenance CAUTION

Refer to LUBRICATION AND SERVICE CHART and SCHEDULED MAINTENANCE in THIS SECTION for service intervals and recommended gear oils.

Fluid spray hazard. Contact with fluid under pressure may cause injury.

NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period. Refer to FLUID ANALYISIS PROGRAM in THIS SECTION for details.

Pressure may build up inside axle due to temperature changes. Use caution when removing drain and fill plugs, slowly loosen plug to relieve pressure before removing completely.

LIMITED SLIP ADDITIVES Front and rear axles are equipped with brakes.

It is permissible to use a limited slip additive in the axles to reduce brake chatter noise. Do not exceed the maximum recommended amount of additive as this may cause a loss of differential lock slipping torque and brake holding torque.

Refer to LUBRICATION AND SERVICE CHART for additive recommendation details.

PINION SEAL GREASE FITTING

602-001

AXLE LEVEL CHECK AND FILL

PINION SEAL GREASE FITTING

AXLE LEVEL CHECK AND FILL (FAR SIDE)

AXLE DRAIN

67925B03

B14.5 STANDARD AXLE DRAIN AND FILL LOCATIONS

3.63

Lubrication and Maintenance SERVICE BRAKE

Tigercat 602 Carrier 14. Engage the parking brake.

CHECKING BRAKE AND ACCUMULATOR FOR PROPER OPERATION

15. Fully apply the brake pedal 5 times. The accumulator pressure should remain above 800 psi (no message on the computer display).

The main pump supplies oil directly to the brake accumulator, via a check valve inside the main pump block to charge the accumulator to specified pressure. The accumulator is installed to ensure that the brake control remains responsive at all times by maintaining an optimum pilot pressure of 3000psi to the brake pilot valve. This oil from the accumulator side of the check valve is sent to the brake foot control valve.

As the pressure drops in the accumulator the brake pedal will become spongy.

Once the pressure falls below 800 psi the Service Brake Pressure Low warning will appear on the screen.

The accumulator when functioning properly will hold sufficient pressure for up to 5 brake applications after the engine stalls or is turned off, beyond this the pressure drops substantially.

Service Brake Pressure Low. Service machine to correct.

For more information about the service brake circuit refer to SECTION 9 of THE SERVICE MANUAL. PROCEDURE: 1. Park the machine on level ground.

16. If the Service Brake Pressure Low warning appears on the screen before the brake has been pumped 5 times from a full charge investigate the cause.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

Check first for leaks in the brake circuit. If no leaks are found check for proper operation of the brake pedal valve, accumulator, check valve and brake pressure sensor.

4. Turn OFF the engine.

5. Remove the ignition key.

6. Block wheels.

For more information about the service brake circuit refer to SECTION 9 of THE SERVICE MANUAL.

7. Install the articulation lock bar.

8. Release the pressure stored in the brake accumulator by fully applying the brake foot pedal repeatedly until there is no pedal resistance. This may take a minimum of 150 applications.

9. Check that all personnel are clear of the machine before starting the engine.

10. Insert the ignition key and turn to the RUN position.

11. Sound horn to warn personnel of machine start-up.

12. Start the engine.

NOTE: The engine will not turn over unless the parking brake is ENGAGED. 13. Disengage parking brake to fully charge the accumulator. Run engine for 10 seconds, then shut engine off.

NOTE: When the parking brake is DISENGAGED full pressure is available from the main pump to the brake accumulator.

3.64

Tigercat 602 Carrier REAR PILOT ACCUMULATOR

Lubrication and Maintenance 10. Repeat step 8 to 10 for all raised implements.

CHECKING FOR PROPER OPERATION

11. Remove the ignition key.

The rear pilot accumulator is intended to supply pressure to safely lower all elements to the ground in the event of an engine stall or other machine malfunction.

12. It should be possible dozer, arch and boom to the ground.

13. If it is not possible investigate the cause.

Check accumulator for proper operation.

The accumulator when functioning properly will allow the operator to lower the dozer, arch and boom to the ground with the engine off.

For more information about the rear pilot accumulator refer to SECTION 12 of THE SERVICE MANUAL.

PROCEDURE: 1. Park the machine on level ground.

2. Check that all personnel are clear of the machine.

3. Raise the dozer blade and grapple or shield fully.

4. Engage the parking brake.

5. Turn OFF the engine.

6. Turn the ignition key to the RUN position.

7. Using the computer from the main menu navigate to INFORMATION MENU (F3) – More...(F3) – Accumulator (F1) Refer to COMPUTER – INFORMATION MODE MENU in SECTION 2 of the OPERATOR'S or SERVICE MANUAL. 8. Check that all personnel are clear of the machine element to be lowered.

9. Press and hold the F1 button (test functions) and operate the control to lower suspended element until it is on the ground.

3.65

Lubrication and Maintenance CENTRE JOINT

Tigercat 602 Carrier MAINTENANCE OF OSCILLATION JOINT Maintenance in this area is usually limited to:

FRONT CHASSIS

•

Regular lubrication of the 4 oscillation lock cylinder ends, 4 fittings to purge.

•

Regular lubrication of the oscillation slew bearing 4 fittings to purge. See procedure below.

REAR CHASSIS CENTER JOINT

OSCILLATION SLEW BEARING LUBRICATION The slew bearing has a lifetime lubrication in the raceway grease chamber and needs no service.

The only service work is the replacement of soiled grease in pre-chambers (buffer chambers).

CHECK FOR MOVEMENT IN THIS JOINT AREA

1. Clean the area around all the grease nipples (4 fittings) and outlet plugs (4 fittings).

602-043

CENTER JOINT

MAINTENANCE OF ARTICULATION JOINT Maintenance in this area is usually limited to: a) Regular lubrication of the two centre joint articulation grease fittings to purge the articulation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide.

A

b) Visually checking the centre joint articulation for looseness every 48 hours. With an observer on the ground, keeping well clear of the centre joint area, perform the following test to check for looseness of centre joint articulation.

1. Have operator lift the dozer blade off the ground and then rapidly raise and lower blade several times to "bounce" machine.

2. As the machine bounces, check for motion between the rear chassis and centre joint lugs. Also check for a “clunking” sound at the centre joint area.

3. Movement between rear chassis and centre joint lugs or clunking of the pivot indicates a loose articulation joint and articulation joint preload must be checked.

Refer SECTION 11 of the SERVICE MANUAL for more information.

77905-6A

2. Open outlet plug A (hex head - top rear of slew bearing).

3. Fill at the two corresponding (rear) grease nipples using standard grease with a hand grease gun until grease squeezes out thumb wide from the outlet opening A. 4. Close outlet plug A (hex head - top rear of slew bearing).

CENTRE JOINT

REAR CHASSIS

A

602-075

3.66

C

Tigercat 602 Carrier

77905-6A

Lubrication and Maintenance

D

B

77905-6B

5. Open outlet plug B (hex head bottom rear of slew bearing).

6. Fill at both corresponding (rear) grease nipples using standard grease with a hand grease gun until grease squeezes out thumb wide from the outlet opening B. 7. Close outlet plug B (hex head - bottom rear of slew bearing).

11. Open outlet plug D (socket head bottom front of slew bearing).

12. Fill at both corresponding (front) grease nipples using standard grease with a hand grease gun until grease squeezes out thumb wide from the outlet opening D. 13. Close outlet plug D (socket head - bottom front of slew bearing).

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide.

C

77905-6B

8. Open outlet plug C (socket head - top front of slew bearing).

9. Fill at the two corresponding (front) grease nipples using standard grease with a hand grease gun until grease squeezes out thumb wide from the outlet opening C. 10. Close outlet plug C (socket head - top front of slew bearing).

3.67

Lubrication and Maintenance TILTING THE CAB

Tigercat 602 Carrier 3. Engage the parking brake.

4. Turn OFF the engine.

WARNING Before tilting the cab, ensure that the machine is parked on level ground. Lower the dozer blade and grapple or shield to the ground. Engage the parking brake and turn the ignition switch off.

NOTE: The cab tilt circuit is closed and does not normally require scheduled maintenance other than lubrication of cylinders and pivot points.

Tigercat recommends the use of DEXTRON III TYPE transmission fluid in this circuit (total circuit capacity 1 L [0.25 US gal]). The fill port is located on the pump.

A

B

C

D

B

C

5. Remove the ignition key.

6. Turn OFF the battery disconnect switch.

7. Block wheels.

8. Install the articulation lock bar.

9. Remove the sweep mounting bolts at the cab.

(2 bolts) 10. Remove the right side Cab Locking Pins (2 pins). This is done by first removing the locking bolts. (2 bolts) 11. Open the maintenance door on the right front access panel to access the cab tilt hand pump.

LOCATED IN COMPARTMENT BELOW RIGHT CAB DOOR

A

PUMP

PUMP LEVER SHOWN IN "RAISE" POSITION

A

58309B 602-028

PUMP HANDLE

PUMP CONTROL LEVER IN RAISE CAB POSITION

12. Turn the lever on the pump manifold to RAISE (pointing to the outside of the machine).

13. Insert handle into pump and pump in a steady manner to raise the cab to the tilt position.

The pump handle is stored in brackets inside the cab.

CAUTION 620E-070

620E-067

A B C D E

E

Cab Sweep Bolt Small Washer Large Washer Nut Cab Locking Pin

RAISING THE CAB 1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

620E-017

PUMP HANDLE STORAGE

Keep hands away from the locking pin area.

As the cab passes "top dead centre" it will slowly move on its own to the full extent of the safety cable. DO NOT PUMP BEYOND LIMIT OF SAFETY CABLE.

14. Insert CAB SUPPORT BRACE for partial tilt.

Secure brace at each end with the cab locking pins. Full tilt is limited to the length of the safety cable and is beyond centre of gravity.

The cab will stay at this limit provided Skidder is on level ground.

3.68

Tigercat 602 Carrier

Lubrication and Maintenance LOWERING THE CAB

WARNING

1. Clear the area under the cab of obstructions and secure all lines and wires.

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.

2. If the Cab Support Brace was used, you may have to take the weight off of it by slightly raising the cab before removing it.

LOCATED IN COMPARTMENT BELOW RIGHT CAB DOOR PUMP PUMP HANDLE PUMP LEVER SHOWN IN "LOWER" POSITION

620E-072

CAB SAFETY CABLE (3361B)

PUMP CONTROL LEVER IN LOWER CAB POSITION

3. Turn the lever on the pump manifold to LOWER (pointing to the inside of the machine)

CAUTION

620E-033

Keep hands away from the locking pin area as the cab is being lowered.

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE

4. Pump the handle in a steady motion to lower the cab.

CAB LOCKING PIN

SAFETY CABLE

5. Watch closely for pinching of hydraulic lines and wires.

CAB SUPPORT BRACE (3291B).

MUST USE CAB & CHASSIS LUGS SHOWN

6. When fully lowered, insert Cab Locking Pins and tighten locking bolts (2 pins) (2 bolts) 7. Turn the lever on the pump manifold to point toward the front of the machine and store the pump handle inside the cab.

CAB LOCKING PIN

620E-064

8. Close the maintenance door securely.

PARTIAL TILT WITH CAB SUPPORT BRACE

9. Replace the Cab Sweep Bolts. (2 bolts)

WARNING

CAB SUPPORT BRACE

If cab support brace is damaged or lost, it must be replaced immediately with Tigercat brace PART NO. 3291B. DO NOT attempt to work under a raised cab supported only by the hydraulic cylinder or a substitute device.

WARNING 602-018

CAB SUPPORT BRACE STORED IN COMPARTMENT BELOW RIGHT CAB DOOR

If cab safety cable is damaged or lost, it must be replaced immediately with Tigercat PART NO. 3361B. DO NOT attempt to work under a raised cab supported only by the hydraulic cylinder or a substitute device.

3.69

Lubrication and Maintenance PRESSURIZED WATER SYSTEM MAINTENANCE (IF EQUIPPED) WATER WATER TANK CONTROL VALVE

SHUT-OFF VALVE IN CLOSED POSITION 620E-004

DOZER BLADE

HOSE STORAGE COMPARTMENT

PRESSURIZED WATER SYSTEM

A water tank is incorporated into the dozer blade and is pressurized to 60 psi (4 bar). A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade.

The control valve incorporates an air charge valve, a pressure gauge and a relief valve on the outlet side of the valve. A ball valve is installed on the outlet side of the valve and is used to shut off the water supply to the hose. This shut-off valve should be in the CLOSED position when the system is not in use.

The pressure gauge on the valve should read 60 psi (4 bar) check system pressure daily. The pressurized water system should be drained and refilled every 1000 hours as per the maintenance schedule.

Tigercat 602 Carrier SYSTEM TEST This system should be tested once every month by turning the shut-off valve ON and expelling water from the hose end nozzle. A very forceful discharge of water should be obtained. If the water does not come out with force (with pressure gauge reading 60 psi [4 bar]) the system needs to be PURGED. Refer to PURGING PRESSURIZED WATER SYSTEM in THIS SECTION. After testing, the tank must be refilled and pressurized to 60 psi (4 bar). Refer to the following FILL AND CHARGE procedure. This FILL AND CHARGE procedure should be carried out yearly.

FILL & CHARGE PRESSURIZED WATER SYSTEM DOZER BLADE FILL PLUG

620E-010

WATER TANK

PRESSURIZED WATER SYSTEM

1. Park the machine on level ground.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

4. Turn OFF the engine.

5. Remove the ignition key.

PRESSURE GAUGE OUTLET CONNECTION

6. Turn OFF the battery disconnect switch 7. Block wheels.

8. Install the articulation lock bar.

AIR CHARGE VALVE

9. Open water shut-off valve and completely discharge all water and compressed air from the tank via the hose end nozzle.

WATER SHUT-OFF VALVE (SHOWN CLOSED) 620E-003

WATER CONTROL VALVE

Refer also to FIRE PREVENTION in SECTION 1.

10. Slowly unscrew fill plug two full turns. Any remaining air in the tank will be heard expelling from the special fill plug. Do not 3.70

Tigercat 602 Carrier

Lubrication and Maintenance

remove fill plug until all air has been expelled.

4. Turn OFF the engine.

11. Close water shut-off valve.

5. Remove the ignition key.

12. Fill tank with clean water.

6. Turn OFF the battery disconnect switch.

13. When temperatures below 32°F (0°C) are anticipated, use a 60/40 solution of Nontoxic R. V. Antifreeze or other suitable antifreeze.

Antifreeze solution must meet GM 6038M specifications.

7. Block wheels.

8. Install the articulation lock bar.

9. Open water shut-off valve and completely discharge all water and compressed air from the tank via the hose end nozzle.

14. 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.

15. Install fill plug in tank.

16. NOTE: This is a special plug designed to withstand pressurization of the water tank.

Do not substitute.

17. Pressurize the system to 60 psi (4 bar) as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

10. 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.

18. Open the water shut-off valve.

11. Close the water shut-off valve and add 2 US gal (8 L) of CLEAN water to the tank.

19. Discharge about 1/2 US gal (2 L) of fluid into an empty antifreeze jug or other suitable container.

12. Install the fill plug NOTE: This is a special plug designed to withstand pressurization of the water tank.

Do not substitute.

20. There will be significant foaming as the fluid is discharged into the jug. Continue until a very forceful flow is obtained and any contamination that may have been in the tank is flushed from the system.

21. Check fluid in the jug for contamination. If fluid is dirty dispose of it properly.

22. Close the water shut-off valve.

23. Release pressure and fluid from the hose.

24. Pressurize the system to 60 psi (4 bar) as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

13. Pressurize the system to 60 psi (4 bar) as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

14. Open the shut-off valve and completely discharge all the water in the tank via the hose end nozzle.

15. Discharge all the water into an empty antifreeze jug or other suitable container.

There will be significant foaming as the fluid is discharged into the jug. Continue until a very forceful flow is obtained and any contamination that may have been in the tank is flushed from the system.

25. Return the hose to the hose compartment.

PURGING PRESSURIZED WATER SYSTEM Purging should be carried out whenever the flow of water does not forcefully discharge from the end of the hose with the pressure gauge reading 60 psi (4 bar).

16. 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.

1. Park the machine on level ground.

17. After the purging operation, fill and charge the system as described in FILL & CHARGE PRESSURIZED WATER SYSTEM in THIS SECTION.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3. Engage the parking brake.

3.71

Lubrication and Maintenance WINCH MAINTENANCE - CARCO (IF EQUIPPED) WINCH OPERATION The winch is controlled through the winch select switch and the winch control lever. The winch select switch is used to activate/deactivate the winch control lever and to activate the winch freespool function. The winch control lever when activate is used to wind in the winch.

The Carco winch functions differently than other winches operators may be familiar with. The following are notes for Carco winch operators to remember: •

Do not use freespool (mechanical jaw clutch) to drop a suspended load or if there is tension on the cable

•

Use drive away (dynamic brake clutch) to lower a load, drive away from a load, to release tension in a cable.

•

After using freespool or drive away allow the clutches to fully re-engage before winching in. This is especially important when the oil is cold.

•

Use freespool only when pulling cable off the winch by hand

•

Both drive away and freespool clutches are spring applied hydraulic release

•

Read the operator's manual for complete winch operating instructions.

Refer to CAB CONTROLS – WINCH CONTROL LEVER , CAB CONTROLS – WINCH SELECT SWITCH in SECTION 2.

Refer also to OPERATING MACHINE – OPERATING WINCH and SKIDDING – CABLE SKIDDING in SECTION 2.

Refer to SECTION 13 of the SERVICE MANUAL and the winch manufacturer's service manual for additional service information.

Tigercat 602 Carrier WINCH SPECIFICATIONS CARCO STANDARD (GEAR MOTOR) Maximum rated line pull bare drum ............................40000 lbs (18180 kg) full drum................................21700 lbs (9840 kg) Maximum cable size.............1 in (25.4 mm) Drum Size and Capacities Barrel Diameter.................... 9.0 in (228 mm) Barrel Width.......................... 8.31 in (211 mm) Cable Capacity 3/4 in (19.1 mm) ..................275 ft (83.8 m) 7/8 in (22.2 mm) ..................202 ft (61.6 m) 1 in (25mm)..........................169 ft (51 m) Winch Ratio..........................118.65:1 Dry Weight ...........................1430 lbs (649 kg) Maximum pressure to motor................................3300 psi (228 bar) Maximum flow to motor........46 USgpm(176 L/min) WINCH SPECIFICATIONS CARCO HIGH SPEED (PISTON MOTOR) Maximum rated line pull bare drum ............................40000 lbs (18180 kg) full drum................................20000 lbs (9070 kg) Maximum cable size.............1 in (25.4 mm) Drum Size and Capacities Barrel Diameter.................... 9.0 in (228 mm) Barrel Width.......................... 8.31 in (211 mm) Cable Capacity 3/4 in (19.1 mm) ..................275 ft (83.8 m) 7/8 in (22.2 mm) ..................202 ft (61.6 m) 1 in (25mm)..........................169 ft (51 m) Winch Ratio..........................66.98:1 Dry Weight ...........................1475 lbs (669 kg) Maximum pressure to motor................................4500 psi (310 bar) Maximum flow to motor........46 USgpm(176 L/min)

3.72

Tigercat 602 Carrier

Lubrication and Maintenance

LUBRICATION Refer to the manufacturer's maintenance and service manual for information on your winch.

OIL LEVEL SIGHT GAUGE

The sump holds approximately 3 US gal (12 L).

DYNAMIC BRAKE CLUTCH

The oil supplied is DEXTRON III TYPE transmission fluid. Use this or the equivalent.

WINCH FREESPOOL WINCH FREESPOOL TANK

Oil should be changed every 1000 hrs, depending on use.

The oil level should be checked every day (if the winch is being used) before starting the machine.

DRAIN PLUG

The oil level should be up to the centre of oil level sight gauge on the left side of the winch. Check oil when the oil is cool and has been allowed to settle after use. The oil fill plug is on the top of the winch.

602-041

WINCH LUBRICATION TENSION CONTROL BOLT

WARNING Failure to use the recommended type and viscosity of planetary gear oil for operating conditions, particularly in cold weather conditions, may contribute to intermittent brake clutch slippage which could result in death or serious injury.

JAM NUT

Failure to properly warm up the winch, particularly in cold weather conditions, may result in temporary brake clutch slippage which could result in death or serious injury.

WINCH MAINTENANCE Maintenance of the winch is limited to the hydraulic system maintenance of the skidder itself.

620E-095

Periodically check the winch, control valve, and connecting hoses for damage or hydraulic oil leakage. If any problems are found, they should be corrected before operating the winch.

ADJUST THE WINCH FREE-SPOOL TENSION If the winch cable requires too little effort to pull it from the cable drum, the tension can be adjusted as follows: •

Loosen the jam nut.

•

Tighten the tension control bolt to increase the tension and/or loosen it to decrease it.

•

Tighten the jam nut.

Refer to the manufacturer's maintenance and service manual for information on your winch.

3.73

ADJUST THE WINCH FREESPOOL TENSION

Lubrication and Maintenance DEPRESSURIZING SUSPENDED MACHINE ELEMENTS

Tigercat 602 Carrier

When operator controls cannot be used to lower suspended machine elements due to an engine stall or other machine malfunction, suspended elements can be lowered safely using this procedure. This should be done promptly while rear accumulator pressure is available.

When suspended the dozer, arch and boom will tend to extend the hydraulic cylinders supporting them due to gravity.

1. Turn OFF the engine.

2. Turn the ignition key to the RUN position.

3. Using the computer from the main menu navigate to INFORMATION MENU (F3) – More...(F3) – Accumulator (F1) Refer to COMPUTER – INFORMATION MODE MENU in SECTION 2 of the OPERATOR'S or SERVICE MANUAL. 4. Check that all personnel are clear of the machine element to be lowered.

5. Press and hold the F1 button (test functions) and operate the control to lower suspended element until it is on the ground.

6. Repeat step 4 to 6 for all raised implements.

7. Remove the ignition key.

8. Turn OFF the battery disconnect switch

3.74

Tigercat 602 Carrier ARTICULATION LOCK ~ STRAIGHT LOCKED POSITION

Lubrication and Maintenance ARTICULATION LOCK ~ ARTICULATED LOCKED POSITION

1.

1.

Park the machine on level ground and steer machine into a straight ahead position.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3.

Engage the parking brake.

4.

Turn OFF the engine.

5.

Remove the ignition key.

6.

Turn OFF the battery disconnect switch

REAR CHASSIS

Park the machine on level ground and steer machine into a fully articulated position to the right.

2. Lower the dozer blade and grapple or shield to rest firmly on the ground.

3.

Engage the parking brake.

4.

Turn OFF the engine.

5.

Remove the ignition key.

6.

Turn OFF the battery disconnect switch

ARTICULATION LOCK REAR CHASSIS

ARTICULATION LOCK

RETAINING PINS 602-039

ARTICULATION LOCK STORED POSITION

7.

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.

8.

After work is completed, relocate articulation lock into storage position on rear chassis and hold in place with retaining pins.

602-036

RETAINING PINS 602-039

ARTICULATION LOCK STORED POSITION

7.

Remove both retaining pins from the articulation lock. Relocate articulation lock between front and rear chassis. Line up holes on the articulation lock with holes in chassis’ as shown and secure in place with both retaining pins.

8.

After work is completed, relocate articulation lock into storage position on rear chassis and hold in place with retaining pins.

ARTICULATION LOCK IN STRAIGHT LOCKED POSITION

602-063

3.75

ARTICULATION LOCK IN ARTICULATED LOCKED POSITION

Lubrication and Maintenance STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE

Tigercat 602 Carrier •

Prepare the fill pump on the machine to add hydraulic oil. Clean the fill line pipe, remove cap on end of pipe and insert pipe into oil supply drum.

•

Loosen the plug on the top of the left drive motor.

•

Operate the fill pump.

•

Watch for oil leaking from the plug previously loosened and tighten plug when oil leaks out.

•

Continue pumping slowly and watch the oil sight gauge on the reservoir. Continue pumping slowly until the hydraulic tank is full.

This procedure should be followed: •

after major service or a rebuild.

•

whenever the machine has been drained of hydraulic oil.

•

when any major component has been removed, repaired or replaced.

PRE-STARTUP AND FILLING 1. Ensure all filters are in place. Refer to FILTERS in THIS SECTION. 2. Check oil levels in the engine, transmission, main hydraulic tank, winch (if equipped), axles and cab tilt system.

MACHINE STARTUP Before beginning this procedure, perform the PRE-STARTUP AND FILLING steps.

3. Check coolant level in the radiator.

CAUTION

4. Do a final inspection of all fittings and clamps to make sure they are tight and will not leak.

Machine operator must ONLY take directions from the person doing the set-up.

5. Install the articulation lock bar and engage the parking brake.

1. Ensure the articulation lock bar is installed.

6. Turn differential lock switch to OFF. 7. Do not start engine. Purge air from hydraulic system by adding oil as follows: •

Pre-fill the cases of the hydrostatic drive pump, main pump and any other components that have been drained of oil with clean, filtered hydraulic oil.

CASE DRAIN MAKE-UP LINE

DISCONNECT THE TOP PLUG FROM THE ENGINE ECU TEE CONNECTOR

602-027

602-042

ENGINE ECU DISCONNECT - LEFT SIDE

2. Disconnect the top plug from engine ECU (prevents engine starting).

RIGHT DRIVE MOTOR DISCONNECT CASE DRAIN LINE

•

Disconnect the case drain make-up line from the tee connection on the right drive motor and pre-fill the right drive motor with clean, filtered hydraulic oil.

•

Watch for oil leaking from tee connection and reconnect case drain line when oil leaks out.

3.76

Tigercat 602 Carrier

Lubrication and Maintenance

3. Crank engine for 10 seconds, wait for 10 seconds. Repeat 6 times to pump oil into pumps.

4. Check hydraulic oil levels in the main hydraulic tank and add hydraulic oil as required.

5. Reconnect 4 pin engine power connector or injectors on engine as applicable.

NOTE: If the machine was on wheels, the steer and drive functions were not properly purged or flushed. Remove the articulation lock bar and at LOW IDLE, slowly operate the steer function right and left a few times. With the parking brake disengaged and at LOW IDLE, slowly operate the drive function forward and reverse a few times.

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.

6. Start engine.

7. Check for leaks.

8. Bleed brakes (front axle) if required.

Prior to bleeding brakes disconnect the two connectors on the drive pump. This is a DRIVE PUMP

CONNECTORS

620E-134

DISCONNECT TWO CONNECTORS ON DRIVE PUMP PRIOR TO PERFORMING PROCEDURE safety precaution to prevent the machine from travelling while brake bleeding is being performed.

With engine at IDLE, parking brake engaged, hold foot brake down, bleed brakes in front axle (both sides). Refer also to FRONT AXLES – SERVICE BRAKES – BRAKE BLEEDING in SECTION 8 of the SERVICE MANUAL. Reconnect two connectors on drive pump.

9. Set throttle to IDLE and run each function for 2 minutes to purge air from circuit.

10. Set throttle to FULL and run each function again for 2 minutes to flush circuit.

11. Top up the radiator with clean coolant.

12. With cylinders fully retracted, top up the main hydraulic oil tank with clean hydraulic oil.

3.77

Lubrication and Maintenance

Tigercat 602 Carrier

CARE OF POLYCARBONATE WINDOWS IN CAB

INSPECTION AND MAINTENANCE

Most windows used in the cab are made from a polycarbonate resin thermoplastic. This material is a replacement for glass when improved strength, durability and safety is required.

Daily inspection and maintenance is essential to confirm that the window’s ability to protect the operator has not been compromised.

Polycarbonate material is expected to resist heavy impact from large branches and falling tree tops and to absorb high levels of energy when contacted by high velocity thrown objects such as wood chips, disc saw blade teeth or broken harvester head saw chain.

•

Inspect all windows daily and immediately after any impacts.

•

Check for any damage to the window material or steel structure in the area of the window mounting.

•

The edges of the polycarbonate window must be evenly and fully supported on a flat surface around the entire window opening at all times.

Bent or dented skylight structures must be replaced immediately. Bent or dented cab structures must be evaluated immediately for possible repair or replacement.

•

The edges of the polycarbonate window must be free from cracks, chips, notches or scarring and must not be pinched or stressed. These defects will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

•

Cracks, chips, notches or scarring anywhere on the viewing surface of the window will decrease ability to resist heavy impacts.

Windows with these defects must be replaced immediately.

•

Bent, dented or missing window retaining parts must be replaced immediately.

•

Rubber materials used in mounting the window must be maintained in good condition.

•

Identification of the polycarbonate originally used by Tigercat is hot stamped in a corner of the window to identify its composition. Do not use any replacement window without proof of its material composition. Do not substitute with any other materials.

•

Skylights, cab structures, windows and window retaining parts must not be modified or replaced with components that are not approved by Tigercat.

The extreme operating environment seen in logging applications heightens the need to regularly inspect and properly maintain polycarbonate cab windows.

Polycarbonate windows are an essential piece of operator protective equipment and should be maintained as such. It is important to note that cracks, chips, notches or scarring anywhere on the viewing surface or edges of the window will decrease ability to resist heavy impacts and therefore compromise effectiveness as operator safety protective equipment. Windows with these defects must be replaced immediately.

Refer to the next section for detailed information regarding inspection and maintenance of polycarbonate windows.

IMPORTANT !

When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the aftertreatment system and the engine.

3.78

Tigercat 602 Carrier

Lubrication and Maintenance

RESISTANCE TO CHEMICALS

RESISTANCE TO WATER

The resistance of polycarbonate material to chemical exposure varies widely. Fortunately, polycarbonate materials have good resistance to diesel fuel, grease, hydraulic oil, kerosene and engine oil.

Polycarbonate material has good resistance to water up to approximately 65°C (150°F). Above this temperature the effect of water is timetemperature related. This means that the higher the water temperature, the shorter the time before the polycarbonate is adversely affected.

Other chemicals however can seriously weaken the polycarbonate.

DO NOT permit any of the following chemicals to come into contact with polycarbonate windows: • • • • • • • • • • • • •

acetone air conditioning refrigerant ammonia anti-freeze benzene brake fluid carbon tetrachloride cutting oils gasoline lacquer thinner toluene turpentine xylene

Exposing polycarbonate to repeated steam cleanings or high temperature pressure washing may result in crazing, a phenomenon that causes clouding of the surface. Crazing can ultimately result in a loss of physical strength and may precede a fracture.

3.79

Lubrication and Maintenance

Tigercat 602 Carrier

CLEANING INSTRUCTIONS

CAUTIONS

The viewing surfaces of polycarbonate cab windows are specially treated with a hard coating to provide enhanced resistance to abrasion and ultra-violet (UV) radiation.

•

DO NOT use abusive cleaning procedures either by hand or pressure washing on polycarbonate windows.

•

DO NOT use brushes, razor blades, scrapers, squeegees or other sharp tools on polycarbonate windows.

•

DO NOT clean polycarbonate windows when the daytime temperature is high or in direct sunlight.

•

DO NOT use abrasive or highly alkaline cleaners on polycarbonate windows.

•

DO NOT use glass cleaners in either aerosol or non-aerosol containers to clean polycarbonate windows.

•

Failure to follow these cleaning instructions will shorten the service life of polycarbonate and may cause visual hazing, loss of light transmission and delamination of the polycarbonate hard surface coating.

The following instructions are provided to prolong the life of this protective hard coating.

1. Rinse the window thoroughly with lukewarm water 2. Using a soft cloth, cellulose sponge or chamois, gently wash the window with a mild solution of soap or detergent in lukewarm water. Do not scrub or use brushes or squeegees.

Brand name soaps and detergents recommended for cleaning polycarbonate are: • Fantastik • Formula 409 • Hexcel F.O. 554 • Joy • Lysol • Mr. Clean • Neleco-Placer • Pine-Sol • Top Job 3. Rinse the window thoroughly with lukewarm water.

4. Dry the window with a moist soft cloth, cellulose sponge or chamois to prevent water spotting.

5. To remove grease or oil, first rub lightly with a good grade of VM&P Naphtha or isopropyl alcohol followed by the same rinse, wash, rinse and dry procedure described in steps 1 to 4.

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

3.80

Tigercat 602 Carrier

Lubrication and Maintenance

CONCEALING HAIRLINE SCRATCHES The appearance of scratches and minor abrasions on the surfaces of polycarbonate windows can be minimized by using a mild automotive polish such as: • • •

WINDOW SCREEN HANDKNOB

Johnson’s Paste Wax Novus Plastic Polish #1 and #2 Mirror Glaze Plastic Polish

Be certain to clean the polycarbonate window as outlined prior to application of an automotive polish. Refer to CLEANING INSTRUCTIONS. GRAFFITI REMOVAL •

For removal of paints, marking pen inks, etc., the use of Butyl Cellosolve is generally effective. The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

•

To remove labels, stickers, etc., the use of kerosene, VM&P Naphtha, or petroleum spirits is generally effective. When the solvent will not penetrate sticker material, apply heat (hair dryer) to soften the adhesive and promote removal.

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

SIDE WINDOW SCREEN SIDE WINDOW SCREENS 620E-031

The side window screens can be removed to clean the windows. Screens are provided for the personal protection of the operator and must be reinstalled immediately after cleaning the windows.

A handknob is provided on both the inside and the outside. By unscrewing either (not both) of these knobs, the screen will be free to swing out on the hinges. Be aware that the screen will swing outwards with considerable force, if the door is open.

All handles should be hand tight only at all times.

FIRE PRECAUTIONS Polycarbonate window material will ignite when exposed to an ignition source in excess of 427°C (800°F). When working around polycarbonate windows, observe similar fire precautions to those in place for wood.

3.81

Lubrication and Maintenance

Tigercat 602 Carrier

CLEANING A/C CONDENSER AND COOLER PACKAGE The side by side A/C condenser, radiator, charge air cooler (CAC) and hydraulic oil cooler is mounted at the front of the machine. For machines equipped with EHS transmissions an EHS transmission cooler is mounted in front of the hydraulic oil cooler.

A/C CONDENSER

CHARGE AIR HYDRAULIC COOLER (CAC) OIL COOLER

RADIATOR

The engine fan draws air from the engine compartment, through the A/C condenser and cooler package and blows it out through the front door screen. The screened access panels on each side of the engine compartment act as debris screens to prevent debris from being drawn into the engine compartment.

EHS TRANSMISSION COOLER (IF EQUIPPED)

The A/C condenser and cooler package should be checked every 8 hours (every shift) for accumulation of twigs, leaves, pine needles and dust.

This cooler package must be checked daily for debris and may have to be thoroughly cleaned on a weekly or monthly basis, depending on operating conditions. Compressed air or water may be used for cleaning. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

602-015

A/C CONDENSER AND COOLER PACKAGE

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine. For more information on fire prevention refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL. If an oil leak has occurred in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed.

CAUTION Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

If using compressed air for cleaning, use at 30psi or less.

Always use personal protective equipment to guard against flying debris.

602-051

CLEAN SCREENED ACCESS PANELS BOTH SIDES

CAUTION Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

3.82

Tigercat 602 Carrier

Lubrication and Maintenance

USING THE FAN CLEAN FUNCTION TO REMOVE DEBRIS DURING OPERATION (IF EQUIPPED-VARIABLE PITCH FAN OPTION) The Flexxaire® cooling fan has a CLEAN function for use in cleaning debris from the machines engine enclosure. The pitch of the fan blades is changed and the direction of airflow through the engine enclosure is reversed. This change in airflow blows debris from the machine's engine enclosure to eliminate potential overheating and poor machine performance caused by overheating. Ensure that there are no personnel standing directly to the sides of the machine when performing this operation, as dust and debris will fly out.

When the fan control switch is in the AUTOMATIC position, the system will automatically cycle through an auto clean cycle. The frequency and duration of the auto clean cycle is adjustable through the computer control system menu.

Refer to FAN CONTROL SWITCH in THIS SECTION for more information.

USING THE FAN CONTROL SWITCH IN THE EVENT OF AN ENGINE COOLANT TEMPERATURE AND/OR HYDRAULIC OIL TEMPERATURE ALARM. In the event of an engine temperature and/or hydraulic oil temperature alarm: 1. Stop the machine.

2. Place the fan control switch in the FULL ON position until cooling is achieved.

3. If necessary use the CLEAN function to reverse fan flow and clean debris from the machine's engine enclosure 4. In severe operating conditions manual cleaning of debris may be required.

5. If the problem persists check engine coolant and/or hydraulic oil levels. Refer to OPERATING MACHINE – PRESTART CHECKS in THIS SECTION. 6. Return the fan control switch to the AUTOMATIC position and check for proper operation of the fan. In the event of a problem with the automatic control system the fan control switch should be placed in the FULL ON position while the machine is operating until the fan control can be properly repaired.

3.83

Lubrication and Maintenance

Tigercat 602 Carrier

TORQUE CHART TORQUE (LUBRICATED) lbf-ft Nm

LOCATION

DIAMETER

Cylinders Piston nut, steer cylinder (38087B) Gland, steer cylinder Piston nut, dozer cylinder Piston nut, dozer grapple arm cylinder Piston nut, oscillation lock cylinder Gland, oscillation lock cylinder Keeper plate bolts Keeper plate bolts

1 3/8" UNF 1 3/8" UNF 1 3/8" UNF 1 3/8" UNF 3/4" UNC 5/8" UNC

1260 550 1260 1260 1260 500 282 159

1708 745 1708 1708 1708 745 678 215

Cab pin keeper plate bolts

3/4" UNC

282

393

Center joint bearing Articulation bearing retaining bolts Articlutation pin retaining bolts Centre joint to slew bearing mounting bolts Rear chassis to slew bearing mounting bolts

1/2" UNC 3/4" UNC M20 x 2.5 M18 x 2.5

80 282 394 280

109 382 534 380

M10 M12

70 80

95 109

5/8" UNC M10 M10 M16 M12 -12.9 M12

159 47 47 173 49 73

215 64 64 235 66 99

1 1/4" x 18 UNEF 1/2" UNC

500 80

677 109

1/2" UNF

90

122

1/2" UNF

90

122

1/2" UNF

90

122

1/2" UNF

90

122

M12

70

95

Axle mounting bolts

7/8" UNC

364

493

Wheel bolts

7/8" UNF

501

679

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

M12 7/8" UNC

70 364

95 493

Engine mounting To Chassis To Engine Pump Mounting Drive pump to flywheel adapter plate Flywheel adapter plate to flywheel housing Torsional drive coupler to flywheel Main pump to drive pump Adapter to main pump Gear pump to adapter Drive shafts Yoke retaining nut, rear shaft Bearing mounting bolts Rear drive shaft universal joint bolts Rear axle input universal joint bolts Middle drive shaft universal joint bolts Front drive shaft universal joint bolts Front axle input universal joint bolts

Torque values pertaining to the engine and attachment are provided in the appropriate manuals.

602TORQUECHARTR0.XLS 04/17

3.84

Tigercat 602 Carrier

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS

The torque values listed below are for general use only. DO NOT use these values if a different torque value or tightening procedure is shown for a specific application.

IMPERIAL GRADE 8 BOLTS

GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 8 BOLTS GRADE 5 BOLTS DRY LUBRICATED COARSE THREAD lbf-ft Nm lbf-ft Nm 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED lbf-ft Nm lbf-ft Nm THREAD 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

8.8

10.9

8.8

10.9

8.8

10.9

10

10

10

METRIC

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 20 - 28 27 - 38 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

10

12.9

12.9

10

12.9

12.9

12.9

12

12

DRY lbf-ft Nm 11 - 12 15 - 16 26 - 30 35 - 40 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

10

COARSE THREAD 1/4" - 20 5/16" - 18 3/8" - 16 7/16" - 14 1/2" - 13 9/16" - 12 5/8" - 11 3/4" - 10 7/8" - 9 1" - 8 1 1/8" - 7 1 1/4" - 7 FINE THREAD 1/4" - 28 5/16" - 24 3/8" - 24 7/16" - 20 1/2" - 20 9/16" - 18 5/8" - 18 3/4" - 16 7/8" - 14 1" - 14 1 1/8" - 12 1 1/4" - 12

12

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

SIZE PITCH LUBRICATED mm Nm lbf-ft M6 1 8-9 6-7 M8 1.25 20 - 22 15 - 16 M10 1.5 39 - 43 29 - 32 M12 1.75 68 - 75 50 - 55 M14 2 109 - 120 80 - 89 M16 2 169 - 186 125 - 137 M18 2.5 234 - 257 172 - 190 M20 2.5 330 - 364 244 - 268 M22 2.5 451 - 496 332 - 366 M24 3 571 - 628 421 - 463 M27 3 837 - 921 618 - 679 M30 3.5 1135 - 1249 837 - 921 M33 3.5 1545 - 1699 1139 - 1253 M36 4 1985 - 2183 1464 - 1610

CLASS 10.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft Nm lbf-ft 11 - 12 8-9 11 - 12 8-9 15 - 17 11 - 12 26 - 29 19 - 21 27 - 30 20 - 22 36 - 40 27 - 30 52 - 57 38 - 42 54 - 60 40 - 44 72 - 79 53 - 59 91 - 100 67 - 74 94 - 104 70 - 77 126 - 138 93 - 102 145 - 160 107 - 118 151 - 166 111 - 122 201 - 221 148 - 163 226 - 248 166 - 183 234 - 257 173 - 190 312 - 343 230 - 253 312 - 343 230 - 253 324 - 356 239 - 262 431 - 474 318 - 350 441 - 485 325 - 357 457 - 503 337 - 371 610 - 670 450 - 495 601 - 661 443 - 487 623 - 686 460 - 506 831 - 914 613 - 674 761 - 838 562 - 618 790 - 869 583 - 641 1053 - 1159 777 - 855 1116 - 1228 823 - 906 1158 - 1274 854 - 940 1544 - 1699 1139 - 1253 1514 - 1665 1116 - 1228 1570 - 1727 1158 - 1274 2094 - 2303 1544 - 1699 2060 - 2266 1519 - 1671 2137 - 2351 1576 - 1734 2849 - 3134 2102 - 2312 2646 - 2911 1952 - 2147 2745 - 3020 2025 - 2227 3661 - 4027 2700 - 2970 DRY

3.85

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft 13 - 14 10 - 11 18 - 19 13 - 14 32 - 35 24 - 26 43 - 47 31 - 35 63 - 70 47 - 51 84 - 93 62 - 68 110 - 121 81 - 90 147 - 162 109 - 119 176 - 194 130 - 143 235 - 259 173 - 191 274 - 301 202 - 222 365 - 401 269 - 296 378 - 416 279 - 307 504 - 554 372 - 409 534 - 588 394 - 433 712 - 784 525 - 578 728 - 801 537 - 591 971 - 1068 716 - 788 923 - 1016 681 - 749 1231 - 1354 908 - 999 1354 - 1489 998 - 1098 1805 - 1985 1331 - 1464 1835 - 2019 1354 - 1489 2447 - 2692 1805 - 1985 2498 - 2747 1842 - 2026 3330 - 3663 2456 - 2702 3208 - 3529 2366 - 2603 4278 - 4706 3155 - 3471

Lubrication and Maintenance

Tigercat 602 Carrier

Parker

Assembly Torque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts. The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head on to the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

The 4-Bolt Split Flange consists of four main components: • A body (flange head) • An O-ring • One “captive” or two “split” flange clamps

• Four bolts and washer

WASHERS BOLTS FLANGE CLAMP

Flange Port Assembly

FLANGE HEAD

The steps to properly assemble the flange port clamping bolts are: 1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

2. Lubricate the O-ring.

3. Position flange and clamp halves.

4. Place lock washers on bolts and insert through clamp halves.

5. Hand tighten bolts.

6. Torque bolts in diagonal sequence (see Fig. T9) in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

O-RING TAPPED HOLES

FLANGE.JPG

Fig. T8 - 4 Bolt Split Flange Components

FLANGE2.JPG

Fig. T9 - Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque Nm

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

17 +/- 2 25 +/- 3.5 31 +/- 4.5 41 +/- 5 52 +/- 6 60 +/- 6 85 +/- 9 144 +/- 15 125 +/- 8 125 +/- 8 125 +/- 8

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

8 12 16 20 24 32

1/2 3/4 1 1 1/4 1 1/2 2

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

17 +/- 2 30 +/- 4.5 46 +/- 4.5 69 +/- 6 125 +/- 8 208 +/- 20

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

* Does not meet ISO 6162 specification.

Table T7 - Code 62 Flange Recommended Bolt Torque

* Does not meet ISO 6162 specification.

Table T6 - Code 61 Flange Recommended Bolt Torque

3.86

Tigercat 602 Carrier

Lubrication and Maintenance

Parker

Assembly Torque

JIC 37 Degree Flare SAE Dash Size

Thread Size

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 3-12

NA NA 2 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 1 1 1

SAE Dash Size

NA NA 2 2 1 1/4 1 1 1 1 1 1 1 1 1

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

Thread Size

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok SAE Dash Size

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

SAE Dash Size

NA NA 1/2 TO 3/4 NA 1/2 TO 3/4 1/2 TO 3/4 1/2 TO 3/4 1/3 TO 1/2 NA 1/3 TO 1/2 1/3 TO 1/2 1/3 TO 1/2 NA NA

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

Thread Size

Tube Connection Swivel or Hose Connection TFFT TFFT

1/8-28 NA 1/4-19 NA 3/8-19 1/2-14 NA 3/4-14 NA 1-11 1 1/4-11 1 1/2-11 2-11 NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE = 10 % -0 SAE DASH SIZE

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (85) 10 (155) 18 (260) 29 (280) 32 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

PLUGS

ADJUSTABLE

NON-ADJUSTABLE THREAD SIZE

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.87

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (60) 7 (100) 11 (180) 20 (250) 28 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

HOLLOW HEX HP5ON-S lbf-ft (lbf-in) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

Nm 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

HEX HEAD P5ON-S lbf-ft (lbf-in) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

Nm 10 18 29 32 40 70 115 183 237 271 339 414 509

Lubrication and Maintenance

Tigercat 602 Carrier

EATON Aeroquip

Assembly Torque

Recommended Parallel Connection Assembly torque

Eaton recommends that a Torque wrench be used to assure proper fitting assembly of these connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514)

Straight Thread O-Ring Boss High Pressure with ORS (J1453)

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32

The values listed are for steel connections. Contact Teaton for torque values for other materials.

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-9 12-13 13-15 18-20 14-15 19-21 23-24 32-33 40-43 55-57 43-48 59-64 68-75 93-101 83-90 113-122 112-123 152-166 146-161 198-218 154-170 209-230 218-240 296-325

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24

ORS

Dash Size -04 -06 -08 -10 -12 -16 -20 -24

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-10 11-16 14-16 20-22 18-20 24-27 24-26 33-35 50-60 68-78 72-80 98-110 125-135 170-183 160-180 215-245 200-220 270-300 210-280 285-380 270-360 370-490

SAE 37º (JIC) Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

10-12 18-20 32-35 46-50 65-70 92-100 125-140 150-165

Swivel Nut Torque Newton Meters 14-16 24-27 43-47 62-68 88-95 125-136 170-190 204-224

Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -32

Metric Thread Size mm M10x1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2

Thread Size (inches) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Swivel Nut Torque lb.-ft.

11-12 15-16 18-20 38-42 57-62 79-87 108-113 127-133 158-167 245-258

Swivel Nut Torque Newton Meters 15-16 20-22 24-28 52-58 77-85 108-119 148-154 173-182 216-227 334-352

BSPP Straight Adapter or Locknut Torque lb.-ft.

Newton Meters 13-15 18-20 15-19 20-25 19-23 25-30 33-40 45-55 37-44 50-60 52-66 70-90 55-70 75-95 81-96 110-130 96-111 130-150 162-184 220-250 170-192 230-260 258-347 350-470

Nominal Thread Size Straight Adapter or Locknut Torque inches** lb.-ft.

Newton Meters G1/8-28 13-15 18-20 G1/4-19 19-23 25-30 G3/8-19 33-40 45-55 G1/2-14 55-70 75-95 G3/4-14 103-118 140-160 G1-11 162-184 220-250 G1 1/4-11 170-192 230-260 G1 1/2-11 258-347 350-470 ** "G" denotes parallel threads, other than ISO 6149 (Port connection only)

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.88

Tigercat 602 Carrier WEIGHTS OF COMMERCIAL WOOD

Alder, Red

SPECIES

Ash, White Aspen, Quaking Bald Cypress Basswood, American Beech, American Birch, Paper Birch, Yellow Cedar, Alaska Cedar, Incense Cedar, Northern White Cedar, Port-Orford Cedar, Western Red Cherry, Black Cottonwood, Eastern Douglas Fir, Coast Douglas Fir, Inland North Elm, American Fir, Alpine Fir, Balsam Fir, Nobel Fir, Red Fir, Silver Fir, White Gum, Black Gum, Blue Gum, Red Gum, Tupelo Hemlock, Eastern Hemlock, Western Hickory, Pecan Hickory, True Larch, Western Locust, Black Magnolia, Cucumber

Lubrication and Maintenance

KG/M3 LB/FT3 737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

SPECIES

Maple, Big Leaf Maple, Black Maple, Red Maple, Silver Maple, Sugar Oak, Black Oak, Chestnut Oak, Red Oak, Red, Swamp Oak, Swamp Chestnut Oak, White Oak, White, Swamp Pine, Jack Pine, Loblolly Pine, Lodgepole Pine, Long Leaf Pine, Norway, Red Pine, Short Leaf Pine, Slash Pine, Sugar Pine, Western Yellow Pine, White-Western Pine, White-Eastern Poplar, Yellow Redwood Spruce, Black Spruce, Engleman Spruce, Red Spruce, Sitka Spruce, White Sweetgum Sycamore, American Tamarack Walnut, Black Willow, Black

46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

NOTE: The values shown here are green weights.

3.89

KG/M3 LB/FT3 753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Lubrication and Maintenance TIRE PRESSURES Tigercat Part # BP012 BP021 BP056 BP111 BP112 BP013 BP022 BP113 BP114 BP139 BP137 BP145 BP100 BP193 BP190 BP066 BP039 BP175 BP143 BP174 BP167 BP180 BP182

Tigercat 602 Carrier

Manufacturer

Inflation Pressure

Size

Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Goodyear Goodyear Goodyear GPX Tire (Primex) GPX Tire (Primex) Nokian Nokian Nokian Nokian Nokian Nokian Nokian Nokian Nokian

23.1-26 14PR LS2 24.5-32 16 PR LS2 28L-26 16PR LS2 DW (FS) 30.5L-32 20PR LS2 (FS) 30.5L-32 26PR SS LS2 DH (FS) 67x34-26 14PR HF4 73x44-32 16PR HF3 DH (FS) 35.5L-32 20PR LS2 DH (FS) 35.5L-32 24PR LS2 DH (FS) 30.5L-32 20 PR LOGLUGIII LS2 TL 30.5L-32 26 PLY CRC SS TUBELESS 35.5L-32 26PR LOGLUGIII TLL S2 66/4300-26 20PR HF4 DW (GPX) 67x34-26 20PR HF4 PRIMEX TL 710/45-26.5 20PR FOREST KING TRS2 SF 750/55-26.5 20PR F (N) 750/55-26.5 20PR TRS (N) 750/55 26.5 24 PR FOREST KING F2 780/55-26.5 20PR F 780/50 28.5 24PR FOREST KING TRS2 780-50-28.5 24PR FOREST KING F2 SF 30.5L-32 26PR FOREST KING TRS LS-2 TL 35.5L-32 26PR FOREST KING TRS LS-2 TL

psi 35 35 35 35 45 40 40 30 35 35 45 40 50 55 80 87 87 87 87 87 87 45 40

kPa 240 240 240 240 310 275 275 205 240 240 310 275 345 380 550 600 600 600 600 600 600 310 275

SKIDDER TIRE PRESSURES R5 04/16

Common Conversions To Convert...

Into...

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To Convert...

Into...

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BAR ��������������������

PSI ����������������������

14.5

in3 ������������������������

cm3 ����������������������

16.39

cm ����������������������

in ������������������������

0.06102

°F ������������������������

°C �����������������������

(°F - 32) / 1.8

°C �����������������������

°F ������������������������

(°C x 9/5) + 32

US Gal ����������������

L ��������������������������

3.785

kg ������������������������

lb �������������������������

2.205

hp �����������������������

kW ����������������������

0.7457

kW ����������������������

hp �����������������������

1.341

in �������������������������

mm ����������������������

25.4

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US Gal ����������������

0.2642

lb �������������������������

kg ������������������������

0.4535

mm ����������������������

in �������������������������

0.03937

lbf•ft ��������������������

Nm ����������������������

1.356

Nm ����������������������

lbf•ft ��������������������

0.7375

psi �����������������������

par ����������������������

0.06896

N �������������������������

lbf ������������������������

0.22481

in Hg �������������������

psi �����������������������

0.4912

in H2O ����������������

psi �����������������������

0.03613

lb �������������������������

N �������������������������

4.4482

3

3

3.90