Tigercat 620 SKIDDER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL Tigercat 620 SKIDDER Issue 4.0, OCTOBER 2003

TABLE OF CONTENTS SECTION INTRODUCTION .............................................................................................................. iii SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ............................. See separate OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ............................................................................... 3 PILOT SYSTEM ................................................................................................................ 5 GAUGES AND ALARM CIRCUIT ...................................................................................... 6 ENGINE START AND STOP ............................................................................................. 7 DRIVE ............................................................................................................................... 8 BRAKES ............................................................................................................................ 9 OIL COOLER/RADIATOR AND FLEXXAIRE® FAN ........................................................ 10 STEERING AND CENTER JOINT .................................................................................. 11 GRAPPLE , ARCH AND BOOM ...................................................................................... 12 WINCH ............................................................................................................................ 13 DOZER BLADE ............................................................................................................... 14

620-SM00

620 Available Literature Operator's Manual, English ............................. Part No. 11581A Manual de Operación, Espanôl ....................... Part No. 17401A Service Manual, English (This Manual) .......... Part No. 11583A Manual de serviçios, Espanôl ......................... Part No. 20468A Parts Catalog, English ..................................... Part No. 11582A Hydraulic Adapters Book, English ..................... Part No. 1472A Hose Assemblies Book, English ....................... Part No. 3707A

Tigercat

®

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

Fax: (519) 442-1855

Tigercat 620 Skidder

Introduction

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Tigercat 620 Skidder

Introduction

Tigercat 620 Skidder INTRODUCTION An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 620 Skidder.

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

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat 620 Skidder

Introduction

S.A.E. STANDARDS ROLL-OVER PROTECTION STRUCTURES (ROPS) FALLING OBJECTS PROTECTION STRUCTURES (FOPS) OPERATOR PROTECTION STRUCTURES (OPS) * MODIFICATIONS AND REPAIRS: The integrity of the ROPS, FOPS, OPS structure and its continued ability to provide the level of protection it was designed for could be seriously affected by any modifications to the structure, its mounting or to the chassis to which it is attached.

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

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

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

ii) Approved modifications officially released by Tigercat.

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

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

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

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

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

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

NOTICE OF CERTIFICATION

Tigercat Industries Inc.

THIS STRUCTURE MEETS THESE REQUIREMENTS OR RECOMMENDED PRACTICES MANUFACTURED BY

Tigercat Industries Inc. Paris, Ont., Canada

ROPS SAE J1040

MAY94

FOPS SAE J231

JAN81

OPS SAE J1084

APR80

Tigercat Model 620/630 MAXIMUM GROSS WEIGHT MANUFACTURERS CERTIFICATION NO.

47,000 lbs.

901099

6958A R03

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Tigercat 620 Skidder

Introduction

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

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes or install options is only as follows: i)

The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat.

ii) Approved options or product changes authorized in writing by the Tigercat Engineering Manager.

Authorization by any other person is unacceptable.

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat 620 Skidder

Introduction

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Tigercat 620 Skidder

SECTION 1 - SAFETY MARCH 2003

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

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 ARTICULATION LOCK ................................................................................ 1.11 BATTERY DISCONNECT SWITCH .............................................................. 1.7 CAB SAFETY CABLE .................................................................................. 1.10 CAB SUPPORT BRACE .............................................................................. 1.10 COOLING SYSTEM ....................................................................................... 1.9 EXHAUST FUMES ....................................................................................... 1.12 FIRE PREVENTION FIRE PREVENTION GUIDELINES ........................................................... 1.13 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE .................... 1.14 WHAT TO DO AFTER A FIRE ................................................................. 1.15 WHAT TO DO IN CASE OF A MACHINE FIRE ........................................ 1.14 FIRST AID ...................................................................................................... 1.4 FLUID LEAKS ................................................................................................ 1.9 HYDRAULIC PRESSURE HAZARD .............................................................. 1.9 LOOSE CLOTHING HAZARD ..................................................................... 1.10 PARKING THE MACHINE ............................................................................. 1.7 PROTECTIVE CLOTHING ............................................................................. 1.3 SAFETY PRECAUTIONS, GENERAL ........................................... 1.3, 1.4, 1.5 SAFETY PRECAUTIONS, OPERATING ....................................... 1.6, 1.7, 1.8 SAFETY PRECAUTIONS, SERVICING ........................... 1.9, 1.10, 1.11, 1.12 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ........................................................................................... 1.2

Tigercat 620 Skidder

Safety

SAFETY SYMBOLS

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

Follow the instructions in the safety message.

Understanding Signal Words DANGER identifies the most serious hazards

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

WARNING denotes a hazard exists which can

WARNING result in serious injury or death if proper precautions are not taken.

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

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

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Tigercat 620 Skidder

Safety 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.

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.

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.

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

Prolonged exposure to loud noise can cause permanent hearing loss.

Follow all instructions from safety inspector and supervisors.

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

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

Do not let an untrained person operate the machine.

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

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

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

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

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

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Tigercat 620 Skidder

Safety 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).

GENERAL SAFETY PRECAUTIONS CONTINUED 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.

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

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

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

•

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.

•

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

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

•

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

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

NOTE:

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.

Check window and door guards for damage.

Check protective windows for cracks, a damaged window has reduced strength to stop flying objects.

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

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.

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

1.4

Tigercat 620 Skidder

Safety

GENERAL SAFETY PRECAUTIONS CONTINUED

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.

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.

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

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

When operating the machine, ensure there is adequate clearance on both sides and above the machine or any of its attachments. Additional clearance may be necessary where the ground is uneven.

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

Maintain a distance of 10 ft. (3m) between any part of the machine or boom and any power line carrying up to 50,000 volts or less plus 1/2 inch (10mm) for each additional 1,000 volts above the 50,000 volt level.

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

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

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

Install articulation lock whenever the machine is to be transported.

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

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

1.5

Tigercat 620 Skidder

Safety Secure loose items in cab.

OPERATING SAFETY PRECAUTIONS

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

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

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

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

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

Sound the machine horn before starting the machine.

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.

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

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

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

Keep the brake properly adjusted at all times.

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

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

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

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

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.

Skidder operations should only be performed from the operator's seat.

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

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Tigercat 620 Skidder

Safety

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

When parking 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, apply the parking brake and lower the grapple and dozer blade onto the ground.

•

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

When reeling in winch cable, make sure all personnel are far enough away in case of rolling logs or whipping cables.

Use only prearranged and approved signalling practices.

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

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

1. Fully apply brake foot pedal 50 times or more.

Do not carry passengers either in the cab or anywhere else on the machine.

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

Use caution when loosening hydraulic connections.

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

Do not work below or behind a skidder 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: •

•

•

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

• • • • •

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

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

If 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.

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.

1.7

Tigercat 620 Skidder

Safety

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

Check for correct tire air pressure. If the pressure is too low it will result in swaying. If the pressure is too high it will result in bouncing.

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.

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 grapple head manufacturer.

1.8

Tigercat 620 Skidder

Safety grounding clamp so current does not pass through bearings, especially the centre joint bearing. Also, turn off the master disconnect switch and disconnect the positive (+) battery cable from both batteries.

SERVICING SAFETY PRECAUTIONS

WARNING Diesel fuel or hydraulic fluid under pressure can penetrate the skin and cause serious personal injury, blindness, or death. If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with treating this type of injury.

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

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

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

Never use bare hand to check for fluid leaks.

Fluid leaks under pressure may not be visible.

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

Wear safety goggles for eye protection.

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

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

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

This machine is optionally equipped with a Flexxaire™ fan. This fan has a clean mode which reverses the flow of air to quickly and effectively remove debris from the heat exchangers and air intake screens. Exercise care when operating this function. Ensure that there are no personnel standing near the machine when performing this operation, as dust and debris will fly out.

Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location. Care must be taken in attaching the welding machine

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

1.9

Tigercat 620 Skidder

Safety

SERVICING SAFETY PRECAUTIONS CONTINUED

SAFETY CABLE

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

•

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

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

311-7

CAB AT FULL TILT SUPPORTED

BY SAFETY CABLE

SUPPORT BRACE

•• 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.

271-22AX

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.

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

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

SAFETY7

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.

1.10

Tigercat 620 Skidder

Safety

SERVICING SAFETY PRECAUTIONS CONTINUED

UPPER DOORS

HAND KNOBS

• • •• •

•• ••

••

LOWER PANELS

• ••

HAND KNOBS

QUICK ACCESS

620-M2

ENGINE COMPARTMENT ACCESS PANELS

ARTICULATION LOCK IN 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.

285-14X

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

CAUTION Do not open cab doors or window screens when machine cab is tilted . The doors and screens are heavy and will swing out with considerable force.

311-1

REMOVE LOWER PANELS

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

Compartment door and panel handles should be hand tight only at all times for easy access to the engine compartment and the pressurized water system in the event of a fire or other emergency.

Refer also to FIRE PREVENTION in THIS SECTION.

20231A R1

1.11

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

Tigercat 620 Skidder

Safety

SERVICING SAFETY PRECAUTIONS CONTINUED

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

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

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

Dispose of fluids properly.

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

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

1.12

Tigercat 620 Skidder

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

FIRE PREVENTION

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

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.

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

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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1.13

Continued on page 14

Tigercat 620 Skidder

Safety WHAT TO DO IN CASE OF A MACHINE FIRE

FIRE PREVENTION continued

•

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

•

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

•

Shut the engine off.

•

Activate the fire suppression system*

•

Radio or call for help (as appropriate).

•

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

•

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

WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE

•

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

•

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

•

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

•

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

•

Use the PASS method with most extinguishers.

•

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

•

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

•

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

•

•

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

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

•

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

•

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

Continued from page 13

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

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

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

•

•

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

You should have a dry chemical extinguisher rated ABC and a pressurized water extinguisher rated A. Prevent the fire from happening by ensuring that the machine is cleaned regularly and all systems are well maintained. *NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some of the Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

1.14

Tigercat 620 Skidder

Safety WHAT TO DO AFTER A FIRE

FIRE PREVENTION continued

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

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

•

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

•

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

•

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

1.15

•

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

•

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

•

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

•

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

Tigercat 620 Skidder

Safety

1.16

Tigercat 620 Skidder

SECTION 3 - LUBRICATION & MAINTENANCE SEPTEMBER 2003

CONTENTS - SECTION 3 AIR CLEANER MAINTENANCE .................................................................. 3.16 APPROVED HYDRAULIC OILS .................................................................... 3.7 CENTER JOINT LUBRICATION .......................................................................................... 3.21 MAINTENANCE ........................................................................................ 3.21 CHARGE PRESSURE FILTER .................................................................... 3.13 FILTER AND LUBRICATION SCHEDULE ..................................................... 3.9 FILTERS AXLE RETURN FILTERS ......................................................................... 3.15 CHARGE PRESSURE FILTER - DRIVE PUMP ...................................... 3.13 FUEL FILTER/WATER SEPARATOR ...................................................... 3.10 FUEL TANK STRAINER ........................................................................... 3.11 HYDRAULIC OIL DOUBLE FILTERS ....................................................... 3.12 HYDRAULIC TANK BREATHER FILTER ................................................. 3.15 FIRE PREVENTION ....................................................................................... 3.3 GENERAL MAINTENANCE ........................................................................... 3.3 GRAPPLE SNUBBER MAINTENANCE ................................... 3.18, 3.19, 3.20 HOUR METER ~ MAINTENANCE ................................................................. 3.2 LUBRICATION AND SERVICE POINTS ....................................................... 3.9 NEW MACHINE MAINTENANCE .................................................................. 3.2 FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................. 3.2 INITIAL PRE-DELIVERY INSPECTION ...................................................... 3.2 OIL LOST FROM LEAKAGE .......................................................................... 3.2 PRESSURIZED WATER SYSTEM MAINTENANCE ................................... 3.22 SCHEDULED MAINTENANCE ...................................................... 3.4, 3.5, 3.6 FREQUENTLY ............................................................................................ 3.4 8 HOURS .................................................................................................... 3.4 125 HOURS ................................................................................................ 3.5 250 HOURS ................................................................................................ 3.5 500 HOURS ................................................................................................ 3.5 1000 HOURS .............................................................................................. 3.6 SEASONAL ................................................................................................ 3.6 SERVICE AND LUBRICATION POINTS ....................................................... 3.9 SPEED CONTROL LEVER ADJUSTMENT ................................................. 3.32 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE ....................... 3.30 TILTING THE CAB ....................................................................................... 3.26 TORQUE CHART ........................................................................................ 3.33 TORQUE CHART, GENERAL ..................................................................... 3.34 WHEELS, INSTALLING ................................................................................. 3.2 WINCH LUBRICATION - LANTEC ONLY .................................................... 3.29 WINCH LUBRICATION - LUFKIN ONLY ..................................................... 3.28

Tigercat 620 Skidder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 620 SKIDDER NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBERS 5281 AND 5283; "PDI AND 50-100 HOUR INSPECTION REPORT"

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

TIGHTENING POINTS FOR:-

IMPORTANT!

THE FIRST 50-100 HOUR INSPECTION REPORT:~

WHEELS: When installing wheels, ensure that all paint has been removed from the mating surfaces of both the wheel disc and the flange of the axle to ensure metal to metal contact.

All hydraulic connections Hose clamps Center joint pin securing bolts

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

Transmission securing bolts Engine mounting bolts Pump drive gearbox securing bolts

HOUR METER ~ MAINTENANCE:

Axle mounting bolts

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

Wheel retaining bolts

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

Cab securing bolts Pin retainers Any other loose nut, bolt or fitting

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

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

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

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

3.2

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

Tigercat 620 Skidder

Lubrication and Maintenance

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

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

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

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

CHECK EMERGENCY EXITS MONTHLY~ Two alternate exit routes are provided: right hand cab door and the sliding windows in the cab doors.

These are only to be used if the left hand cab door cannot be opened.

It is therefore essential that these emergency exits be checked at least once per month to ensure they are fully operational.

FIRE PREVENTION Maintaining your machine properly will greatly extend its life and reduce your operating costs.

Fire can result in a machine loss which can be financially devastating.

1. Pine needles and bark when allowed to accumulate, form a fuel source that when ignited is extremely difficult to extinguish. A thorough program of regular cleaning and washing will reduce the possibility of a fire starting. In the event a fire does start, the regular cleaning program will improve the chances of successfully extinguishing a fire.

2. Pay close attention to wiring and plumbing routings during maintenance, ensure that ALL wiring harnesses or hydraulic hoses are properly restrained and clamped to prevent damage from chaffing.

3. Read the fire suppression system manual and have the system serviced regularly by qualified personnel.

4. In case of fire lower the boom system to the ground and shut off the engine before discharging the fire suppression system.

Also refer to the SAFETY section of this manual for additional information on how to prevent fires from starting on the machine.

Continued on page 4

3.3

Tigercat 620 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE Continued from page 3

determine which axles apply to your machine.

FREQUENTLY:~

• Lubricate mid drive shaft 1-fitting, purge

• Check engine cooling air intake screens for possible restriction

Note: Lubrication of mid drive shaft slip joint should be done with machine fully articulated.

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

EVERY 8 HOURS (EVERY SHIFT):~

• Lubricate center joint bearings, purge

• Perform "frequently" maintenance check, and in addition:~ • Check engine coolant level

• Lubricate steering cylinder ends, 4-fittings, purge

• Check engine oil level

• Lubricate arch cylinders and pivots, 6 or 12fittings, purge

• Drain fuel/water separator • Check air intake precleaner, clean as required

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

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

Clean:~ • Potentially damaging limbs or sticks from machine

• Check hydraulic oil level • Check pump drive gearbox oil level with dipstick

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

• Check transmission oil level with dipstick • Check winch sump oil level • Lubricate front axle pivot, 2-fittings, purge

Check:~ • For leakage around hydraulic components and flexible hoses. See "Oil lost from leakage" chart.

• Lubricate axles - outer bearings ‡ 1-fitting; 4-places; lubricate until grease flows out past outer seals.

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

• For loose nuts, bolts and fittings • Condition and tension of fan belts.

‡ In submerged or snow conditions perform the following every shift (otherwise every 125 hrs)

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

Note: Manual lubrication of outer axle bearings applies only to earlier axles with cartridge lip seals and grease fittings. Later axles have face seals and do not require manual lubrication. Refer to diagram to CARTRIDGE LIP SEAL

GREASE FITTING

•

•

EARLIER AXLES

M724D-15

2-fittings,

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.

FACE SEAL

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

••

LATER AXLES 3.4

Tigercat 620 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE Visually check for damage to:• Arch and pivot linkage

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

• Front and rear frame • Center joint area • Attachment Make repairs immediately Visually inspect for:• Frayed electrical wiring and hydraulic hose • Wear in any other components Clean/replace:• Air conditioner re-circulation filter

EVERY 125 HOURS:~ • Perform "frequently" maintenance

• Cab fresh air filter

• Perform 8 hour maintenance

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

And in addition:~ • Lubricate front drive shaft 1-fitting, purge • Lubricate axles - outer bearings, ‡ 1-fitting; 4-places; lubricate until grease flows out past the outer seals.

EVERY 250 HOURS:~

Note: Do not use power greasers as it will damage the seals. ‡ In submerged or snow conditions perform the following every shift (otherwise every 125 hrs) Note: Manual lubrication of outer axle bearings applies only to earlier axles with cartridge lip seals and grease fittings. Later axles have face seals and do not require manual lubrication. Refer to diagram to determine which axles apply to your machine.

• Perform "frequently" maintenance • Perform 8 hour maintenance • Perform 125 hour maintenance And in addition replace:~ • Replace engine oil and change oil filter • Replace engine fuel filter • Replace fuel/water separator • Replace air intake primary element • Replace oil in pump drive gearbox

Check:~ • Fluid level in batteries unless maintenance free •

Engine rpm.

•

All hydraulic pressures

•

Hydraulic pump and motor securing bolts

•

Check fuel tank filler screen

•

Torque tightening points as per new machine maintenance

•

Proper operation of pressurized water system. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

• Replace oil in transmission • If equipped with an optional Flexxaire® fan visually check the fan for oil leaks. Refer to SECTION 10 of the SERVICE MANUAL for more detailed information.

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

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

3.5

Tigercat 620 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE

EVERY 500 HOURS:~

EVERY 1000 HOURS:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

And in addition : ~ • Replace air intake safety element

• Perform 500 hour maintenance And in addition replace oil in:~ • Replace air cleaner unloader valve

• Drain oil from the hydraulic tank breather filter (later machines only)

• Check center joint preload with a dial indicator.

Refer to CENTER JOINT ~ CHECKING CENTER JOINT PRELOAD in SECTION 11 of the SERVICE MANUAL. If a problem is found corrective action should be taken immediately, refer to CENTER JOINT PRELOAD ADJUSTMENT in SECTION 11 of the SERVICE MANUAL.

• Replace charge pressure filter, drive pump † • Replace hydraulic oil double element filters (2 elements) † 1 white, high performance element.

1 blue, water absorbing element.

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

• Replace oil in winch sump.

• If equipped with an optional Flexxaire® fan check oil level, check fan blades and perform a mechanical review. Refer to SECTION 10 of the SERVICE MANUAL for more detailed information and procedures.

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

SEASONAL:~ • Drain and refill hydraulic oil tank and both front and rear axles with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION also see SECTION 8 of the SERVICE MANUAL for axle draining procedure.

• Replace hydraulic hand fill pump filter. † • Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

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

3.6

Tigercat 620 Skidder

Lubrication and Maintenance

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

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

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

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

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

®

TRACTOR HYDRAULIC FLUID (SUMMER) TRACTOR HYDRAULIC FLUID (33-310) (SUMMER) HYDRAUL 56 (SUMMER) HYDRAUL 50 (LOW VISC) WINTER) DONAX TD (SUMMER) DONAX TDL (WINTER) SUNFLEET TH FLUID (SUMMER) TYPE J20C (HYGARD) (SUMMER) 11514A R1 TYPE J20D (HYGARD) WlNTER)

3.7

Tigercat 620 Skidder

Lubrication and Maintenance

OUTER AXLE BEARINGS

2

4 10 3

4 FTG/8

17

12 11

GRAPPLE YOKE

26

4 FTG/8

24 GRAPPLE PINION GEAR 24 1 FTG/250 5 SHOTS

GRAPPLE SNUBBERS 24 9 FTG /8

NOTE: REMOVE PIPEPLUG TO ACCESS

GRAPPLE ROTATOR 24 2 FTG/125 5 SHOTS

AXLE-PIVOT

2 FTG/8

DRIVE SHAFT

2 FTG/8

18

STEER CYLINDERS

4 FTG/8

DOOR HINGES

ARCH

12 FTG/8

21

16

20

8 FTG/500

DOZER

22 25

1

5

7 8

23

6 FTG/8

6

GRAPPLE 24

8 FTG/8

CENTER JOINT

15 19

2 FTG/8

14

FRONT SHAFT DRIVE

1 FTG/125

15

13

9

18

LEGEND *

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

**

LUBRICATE UNTIL GREASE FLOWS OUT PAST OUTER SEALS. DO NOT USE POWER GREASERS AS IT WILL DAMAGE THE SEALS.

CHK REP

HOURS CHECK REPLACE

***

SEVERE CONDITIONS (DEEP MUD, WATER OR SNOW) LUBRICATE EVERY 8 HOURS. NORMAL CONDITIONS LUBRICATE EVERY 125 HRS. STEER MACHINE FULLY BEFORE GREASING MID DRIVE SHAFT SLIP YOKE.

DRN D/R

DRAIN DRAIN AND REFILL

LUB

LUBRICATE

****

2 FTG/125

†

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2FTG) AND HOURS BETWEEN SERVICING (125 ). JOINT TO BE PURGED. USE LITHIUM BASED GREASE CONTAINING MOLYBDENUM DISULFIDE Use only Genuine T igercat replacement Hydraulic oil filters.

11372B.R1

3.8

Tigercat 620 Skidder

Lubrication and Maintenance

Tigercat® Model 620 SERVICE AND LUBRICATION POINTS

CHK

2

ENGINE OIL/FILTER CUMMINS B SERIES

CHK

32

8.4

QTY

1000

500

250

CHANGE COOLANT EVERY 2 YEARS REP

USG

COOLING SYSTEM

125

8

ITEM

1

FUEL FILTER (ENGINE)

4

FUEL/WATER SEPARATOR

5

FUEL TANK FILLER SCREEN

6

AIR INTAKE PRECLEANER

DRN

SEE ENGINE MANUFACTURERS MAINTENANCE MANUAL

REP

1

REP

1

CHK

1

CHK

AIR INTAKE PRIMARY ELEMENT

DESCRIPTION

60/40 ANTIFREEZE *

13.2 3.5

3

7

CAPACITY

SERVICE EVERY

LITERS

SERVICE POINT NO.

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

REP

AIR INTAKE SAFETY ELEMENT

REP

1

CLEAN AS REQUIRED

1

CHECK FILTER RESTRICTION INDICATOR WITH ENGINE RUNNING

1

8

AIR CLEANER UNLOADER VALVE

CHK

9

HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10 11

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

DRN REP †

12

CHARGE PRESSURE FILTER (DRIVE PUMP)

REP †

13

PUMP DRIVE GEARBOX CHECK LEVEL WITH DIPSTICK

CHK

D/R

3

0.8

1

14

TRANSMISSION

CHK

D/R

6

1.6

1

15

AXLES-DIFFERENTIAL FRONT 1200 (EARLIER)‡ FRONT 1400 (EARLIER)‡ REAR (EARLIER)‡ FRONT 1200 (LATER) FRONT 1400 (LATER) REAR (LATER)

19 5 28 7.4 52 13.7 22 5.8 31 8.2 55 14.5

2

16

AXLE-PIVOT (FRONT ONLY)

PURGE

2

17

AXLES-OUTER BEARINGS LUB LUB ‡ NOTE: MANUAL OUTER AXLE BEARING *** *** LUBRICATION APPLIES ONLY TO EARLIER AXLES WITH CARTRIDGE LIP SEAL AND GREASE FITTINGS. LATER AXLES HAVE FACE SEALS AND DO NOT REQUIRE MANUAL LUBRICATION.

** SEE NOTE

4

LITHIUM BASE EP2 GREASE LITHIUM BASE EP2 GREASE

DRIVE SHAFT, MID:SHAFT

PURGE

1

LITHIUM BASE EP2 GREASE LITHIUM BASE EP2 GREASE LITHIUM BASE EP2 GREASE

18

CAST

1 95

25

1

REFER TO SECTION 3 IN MANUAL FOR DETAILS DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE (SEE HYDRAULIC OIL CHART)

2

REMOVE FILTER, DRAIN AND REINSTALL * NOTE: MUST USE 1 OF EACH TYPE OF FILTER ELEMENT

1

LUB

LUB ****

DRIVE SHAFT, FRONT:SHAFT DRIVE SHAFT, REAR:BEARING

REP

LUB LUB

PURGE

1

PURGE

1

PURGE

2

CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10Fº(-23ºC) USE 75W-90 UP TO 100ºF(38ºC) USE 80W-90 ABOVE 100ºF(38ºC) USE 85W-140 D/R WITH SEASONAL OIL CHANGE

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

CENTER JOINT

LUB

19

CENTER JOINT BEARING PRELOAD

20

STEERING CYLINDERS

CHK 48 LUB

PURGE

4

21

SINGLE ARCH CYLINDER & PIVOTS

LUB

PURGE

22

DOUBLE ARCH CYLINDER & PIVOTS

LUB

PURGE

23

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

LITHIUM BASE EP2 GREASE 12 LITHIUM BASE EP2 GREASE 6 LITHIUM BASE EP2 GREASE

24

GRAPPLE, Tigercat

26

WINCH

LANTEC LUFKIN PRESSURIZED WATER SYSTEM

620LUBMODIFIED.XLS

6

SEE LUBRICATION POINTS DIAGRAM

GRAPPLE, OTHER MANUFACTURER 25

CHK

SEE GRAPPLE MANUFACTURER'S MAINTENANCE SCHEDULE CHK

D/R

18 4.7 20.8 5.5 D/R 52.0 13.7

CHK TEST

3.9

SEE WINCH MANUFACTURER'S MAINTENANCE MANUAL SEASONAL DRAIN AND REFILL

Tigercat 620 Skidder

Lubrication and Maintenance Changing the filter:

FILTERS

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

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.

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

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

4. Wearing face protection (in case of a fuel spray) unscrew the old filter.

FUEL FILTER/WATER SEPARATOR This is a combination unit, with a replaceable fuel filter and a removable water sediment bowl on the bottom of the unit. The water sediment bowl is only replaced if it becomes damaged or non-functional. For service and replacement intervals see SERVICE AND LUBRICATION POINTS in THIS SECTION.

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

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

7. Clean the water sediment bowl.

FUEL WATER SEPARATOR

••

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

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

•• PRIMER PUMP

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

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

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

WATER SEPARATOR BOWL

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

• DRAIN TAP

•• 270-9A

FUEL WATER SEPARATOR

3.10

Tigercat 620 Skidder

Lubrication and Maintenance

FUEL TANK STRAINER This is a stainless steel fuel strainer, screwed on to the inlet pipe of the engine fuel feed line inside at the bottom of the fuel tank.

Changing or cleaning the strainer: NOTE: This should only be required if excessive quantities of foreign material has built up inside the tank.

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

2. Drain the fuel tank. (plug in bottom) 3. Remove the round fuel tank cover plate and “O” ring from the access hole.

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

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

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

7. Reinstall the strainer using the hex on end.

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

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

IMPORTANT Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced according to the engine manufacturer's manual.

3.11

Tigercat 620 Skidder

Lubrication and Maintenance

HYDRAULIC OIL DOUBLE ELEMENT FILTERS The hydraulic oil cooling circuit contains a double filter head with a built in restriction indicator and a 25 psi bypass valve. In the event of a clogged filter element or thicker oil on cold starts, this bypass filter will open and redirect oil around the filter element. When the filter elements become restricted, the Red pop-up indicator will show RED, indicating that the elements must be changed. It is recommended that all machines use two different filter elements:

•

FILTER HEAD

• GASKET

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS 2

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.

Pre-fill filter with clean oil before installation. Screw on new filter until gasket makes contact.

Tighten filter an additional 3/4 turn.

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

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

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

DOUBLE ELEMENT FILTER

•

•

•

FILTER HEAD

• • BLUE ELEMENT

620-07

•

DRIVE PUMP CHARGE PRESSURE FILTER

HYDRAULIC FILTERS

GASKET

• FILTR_SEALS 2

z

Changing the filters:

'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.

Pre-fill filter with clean oil before installation. Screw on new filter until gasket makes contact.

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

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

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

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

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

5. The new Tigercat filter is supplied with two gaskets enclosed, examine the filter head closely to determine which gasket should be used and follow the instructions to ensure proper installation.

FILTER ELEMENT

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

6. Start the engine and check for leaks.

3.12

Tigercat 620 Skidder

Lubrication and Maintenance CHARGE PRESSURE FILTER - DRIVE PUMP

IMPORTANT HYDRAULIC FILTER SERVICING GUIDELINES NEVER PRE-FILL ANY HYDRAULIC FILTERS ON 200, 700, 800 AND 1000 SERIES MACHINES NEVER PRE-FILL CHARGE PRESSURE FILTERS ON 600 SERIES SKIDDERS Tigercat generally 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.

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

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS SECTION. Continued on page 14

DOUBLE ELEMENT FILTER

ALWAYS PRE-FILL DUAL HEAD HYDRAULIC FILTERS ON 600 SERIES SKIDDERS

•

Dual head hydraulic filters on 600 series skidders must always be pre-filled with clean oil as noted specifically in the manuals for each of these machines.

All 600 series hydraulic circuits direct oil from the dual head filters to the main and drive pump inlets. Air must not be allowed to enter the inlets of these pumps. Entry of air directly into pump inlets can cause significant and costly damage to pumps. In this particular case the risk of damage to pumps caused by entry of air into the circuit is considered to be greater than the risk of damage caused by unfiltered oil.

Prefiltering of any hydraulic oil used to pre-fill these filters is strongly recommended to eliminate the risk of damage caused by unfiltered oil.

•

• DRIVE PUMP CHARGE PRESSURE FILTER

620-07

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

3.13

HYDRAULIC FILTERS

Tigercat 620 Skidder

Lubrication and Maintenance

Continued from page 13

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

IMPORTANT HYDRAULIC FILTER SERVICING GUIDELINES NEVER PRE-FILL ANY HYDRAULIC FILTERS ON 200, 700, 800 AND 1000 SERIES MACHINES

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

NEVER PRE-FILL CHARGE PRESSURE FILTERS ON 600 SERIES SKIDDERS

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

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

Tigercat generally 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.

5. Drain filter and dispose of any oil properly.

6. Check the seating area for the gasket on the filter head and wipe it clean.

7. The new filter has an attached gasket. Apply hydraulic oil to the gasket surface.

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

ALWAYS PRE-FILL DUAL HEAD HYDRAULIC FILTERS ON 600 SERIES SKIDDERS

DO NOT PRE-FILL THE NEW PRESSURE FILTER. 9. Turn filter an additional 1/2 turn by hand to tighten.

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

10. Start the engine and check for leaks.

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

3.14

Dual head hydraulic filters on 600 series skidders must always be pre-filled with clean oil as noted specifically in the manuals for each of these machines.

All 600 series hydraulic circuits direct oil from the dual head filters to the main and drive pump inlets. Air must not be allowed to enter the inlets of these pumps. Entry of air directly into pump inlets can cause significant and costly damage to pumps. In this particular case the risk of damage to pumps caused by entry of air into the circuit is considered to be greater than the risk of damage caused by unfiltered oil.

Prefiltering of any hydraulic oil used to pre-fill these filters is strongly recommended to eliminate the risk of damage caused by unfiltered oil.

Tigercat 620 Skidder AXLE RETURN FILTERS (LATER MACHINES)

Lubrication and Maintenance HYDRAULIC TANK BREATHER FILTER (LATER MACHINES)

HYDRAULIC TANK BREATHER FILTER

•

620-34

AXLE RETURN FILTERS 620-35

Later machines are equipped with axle return oil filters in the drain lines of all straight axles.

The axle return oil filters require changing only when repairing a leaking or failed John Deere or Tigercat High Flotation axle.

HYDRAULIC TANK BREATHER (LATER MACHINES)

Later machines are equipped with a hydraulic tank breather filter. Refer to SCHEDULED MAINTENANCE or SERVICE AND LUBRICATION POINTS for correct service interval.

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

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

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

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

5. Drain filter and dispose of any oil properly.

6. Check the seating area for the gasket on the filter head and wipe it clean.

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

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

DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only 9. Start the engine and check for leaks.

3.15

Tigercat 620 Skidder AIR CLEANER MAINTENANCE AIR CLEANER

Lubrication and Maintenance ENGINE AIR CLEANER

ENGINE AIR PRECLEANER

•

••

SENDING UNIT FOR WARNING LIGHT IN CAB

•• ••

FILTER RESTRICTION INDICATOR

•• ENGINE AIR CLEANER

298-1

620-33

AIR CLEANER

EXHAUST PORT AREA

284-25A

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

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

REAR VIEW OF PRECLEANER

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

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

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

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

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

UNLOADER VALVE

• •

AIR CLEANER UNLOADER VALVE AIR CLEANER UNLOADER VALVE This rubber valve on the tube of the air cleaner housing should be checked at the beginning of every shift. (8 hours) If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective. The valve should suck closed at 1/3 throttle.

•

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

•• 310-22

•

TURBO 3

ENGINE AIR CLEANER

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

TURBO II PRECLEANER OPERATION

This valve should be replaced every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. Check and clean the valve. A good valve should be soft and flexible. If it is 3.16

Tigercat 620 Skidder

Lubrication and Maintenance

plugged, be sure to check the filter elements as they may need replacing as well. Reattach the valve to the tube.

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

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

OUTLET TUBE

1. Release the cover latch gently to reduce the amount of dust dislodged.

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

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

4. Always clean the inside of the outlet tube and filter housing.

The most common and damaging servicing problems are: PRIMARY ELEMENT

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS

SAFETY ELEMENT

5. Check your old filter, It can help you detect foreign material on the sealing surface that is causing leakage.

NOTE: Filter elements should never be cleaned and reused. Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media. The dust is then drawn directly into the engine.

• •

•

6. Inspect the new filter for damage.

ENGINE AIR PRECLEANER

171-18A

AIR FILTER ELEMENTS

OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that looks dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond engine manufacturer's guidelines, should a filter be replaced.

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

8. Check connections and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points. Leaks here send dust directly to the engine.

NOTE: This does not apply to oil filters.

IMPROPER SERVICING Engine exposure to dust during servicing is the largest single reason for engine damage due to dust.

Abrasive dust can easily enter the intake system once the air cleaner cover and protective filter element is removed for replacement. The safety element does reduce this risk but it should also be replaced at every third primary element change.

3.17

Tigercat 620 Skidder GRAPPLE SNUBBER MAINTENANCE IMPORTANT All service points on snubbers must be greased every shift (8 hours) to ensure a long service life.

QUADCO MODEL 500 SNUBBER USED ON TIGERCAT GRAPPLES In this model the snubbers are independent of the link. Separate snubbers or pairs of snubbers provide snubbing action in two directions. There are 3 grease fittings on each snubber for daily lubrication of the sleeves and housings. Grapple installations use 2 or 3 model 500 snubbers depending on the type of grapple and yoke. Be sure to lubricate all the grapple snubbers on your machine.

ADJUSTING SNUBBER TENSION

Lubrication and Maintenance QUADCO MODEL 300 SNUBBER USED ON TIGERCAT GRAPPLES In this model the snubbers are independent of the link. Separate snubbers provide snubbing action in two directions. There 1 grease fitting on each snubber for daily lubrication of the sleeves and housings. Grapple installations use 4 model 300 snubbers depending on the type of grapple and yoke used. Be sure to lubricate all the grapple snubbers on your machine.

ADJUSTING SNUBBER TENSION Tension is adjusted by tightening the end cap bolt.

Tighten the end cap bolt only 1/2 turn at a time until the desired tension is achieved.

Note: Overtightening may result in grapple stiffness and reduced friction sleeve life. Applying too much pressure may press the spring washer flat causing all tension to be lost.

Tension is adjusted by tightening the end cap bolt.

Tighten the end cap bolt only 1/2 turn at a time until the desired tension is achieved.

Note: Overtightening may result in grapple stiffness and reduced friction sleeve life. Applying too much pressure may press the spring washer flat causing all tension to be lost.

GREASE FITTINGS (1 PER SNUBBER)

•

LINK

GREASE FITTINGS (3 PER SNUBBER)

LINK

• SPRING WASHER

GREASE FITTINGS (3 PER SNUBBER)

FRICTION SLEEVE

••

•

••

FRICTION SLEEVE SPRING WASHER

•• END CAP BOLT

•

CY045

END CAP BOLT

• CY023

QUADCO MODEL 500 SNUBBER 3.18

QUADCO MODEL 300 SNUBBER

Tigercat 620 Skidder

Lubrication and Maintenance

FRICTION SLEEVE REPLACEMENT QUADCO MODEL 300 AND 500 SNUBBERS

CROSS GROOVE POSITION LINED UP WITH WEAR BLOCK

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

•

•

END CAP

3. Remove the friction sleeve from the core assembly using a pry bar on each side to loosen it. Note: Loctite® is used for friction sleeve installation. Heat may be required to loosen the sleeve for removal.

•

•

••

CORE ASSEMBLY FRICTION SLEEVE

HOUSING BEARING

••

END CAP BOLT

4. Clean the core assembly to remove any Loctite® residue.

QUADCO MODEL 500 SNUBBER

CY044

5. Apply a thin coat of Loctite® 620 retaining compound (or equivalent) to the core assembly and to the inner side of the new friction sleeve.

CROSS GROOVE POSITION LINED UP WITH WEAR BLOCK

WEAR SLOT

END CAP

• •

• ••

•

SPRING WASHER

Check again to be sure the friction sleeve is positioned correctly as shown. Correct positioning of the cross groove is required to ensure proper snubber lubrication and long service life.

7. Apply moly-based grease to the outer friction sleeve surface. Use a generous amount of grease.

•• ••

SPRING WASHER

2. Remove the snubber end cap bolt, end cap, bearing, spring washer and housing.

6. Position the friction sleeve so that the cross groove will be lined up with the wear block (Models 500) or wear slot (Model 300) as shown. Push the friction sleeve onto core assembly.

••

WEAR BLOCK

••

• ••

•

CORE ASSEMBLY FRICTION SLEEVE

HOUSING BEARING

END CAP BOLT CY045

8. Reinstall the housing, spring washer, bearing, end cap and end cap bolt.

9. Allow the Loctite® to cure for at least 30 minutes before operating the machine.

3.19

QUADCO MODEL 300 SNUBBER

Tigercat 620 Skidder

Lubrication and Maintenance

QUADCO MODEL 1500 SNUBBER USED ON ESCO GRAPPLES

FRICTION SLEEVE REPLACEMENT QUADCO MODEL 1500 SNUBBERS

In the model 1500 the snubbers and link are combined and provide snubbing action in two directions. There are a total of 12 grease fittings for daily lubrication of the sleeves and housings.

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

ADJUSTING SNUBBER TENSION

2. In the model 1500 the snubbers and link are combined. It is necessary to remove the pins used to install the grapple to access the snubbers for this procedure.

Tension is adjusted by turning the adjusting bolts.

Each of the two snubber has two adjusting bolts.

Turn adjusting bolts only 1/2 turn at a time until the 3. Remove the snubber pressure plate bolts, desired tension is acheived. Overtightening may pressure plate, bearing, spring washer and result in grapple stiffness and reduced friction sleeve housing. life.

Note: Tightening the acorn nuts which hold link pins in place has no effect on snubber tension. Over tightening of these nuts may damage the link and impair snubber function.

4. Remove the friction sleeve from the core using a pry bar on each side to loosen it.

Note: Loctite® is used for friction sleeve installation. Heat may be required to loosen the sleeve for removal.

5. Clean the core to remove any Loctite® residue.

ACORN NUTS

•

6. Apply a thin coat of Loctite® 620 retaining compound (or equivalent) to the core assembly and to the inner side of the new friction sleeve.

•

7. Position the friction sleeve so that the cross groove will be lined up with the wear slot as shown. Push the friction sleeve onto core.

• •

Check again to be sure the friction sleeve is ADJUSTING BOLTS

FRICTION SLEEVE

••

CROSS GROOVE POSITION LINED UP WITH WEAR BLOCK

ADJUSTING BOLTS

FRICTION SLEEVE WEAR SLOT HOUSING

• •

•

•

SPRING WASHER

••

BEARING

••

CORE

•• PRESSURE PLATE

CY014

•

• ••

BOLTS

•• • •

QUADCO MODEL 1500 SNUBBER

•• •

••

•

•

BEARING SPRING WASHER

HOUSING WEAR SLOT FRICTION SLEEVE

CY014

3.20

QUADCO MODEL 1500 SNUBBER

Tigercat 620 Skidder positioned correctly as shown. Correct positioning of the cross groove is required to ensure proper snubber lubrication and long service life.

8. Apply moly-based grease to the outer friction sleeve surface. Use a generous amount of grease.

9. Reinstall the housing, spring washer, bearing, pressure plate and pressure plate bolts.

10. Allow the Loctite® to cure for at least 30 minutes before operating the machine.

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

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

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

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

Refer SECTION 11 of the SERVICE MANUAL for more information.

REAR CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

DIG-003

3.21

FRONT CHASSIS

CENTER JOINT PRE-LOAD CHECK

Tigercat 620 Skidder PRESSURIZED WATER SYSTEM MAINTENANCE

••

Lubrication and Maintenance SYSTEM TEST This system should be tested once every month by turning the shut-off valve ON and expelling water from the hose end nozzle. A very forceful discharge of water should be obtained. If the water does not come out with force (with pressure gauge reading 60 psi) the system needs to be PURGED. Refer to PURGING PRESSURIZED WATER SYSTEM in THIS SECTION.

DOZER BLADE

••

WATER TANK

WATER CONTROL VALVE

••

After testing, the tank must be refilled and pressurized to 60 psi. Refer to the following FILL AND CHARGE procedure. This FILL AND CHARGE procedure should be carried out yearly.

••

FILL & CHARGE PRESSURIZED WATER SYSTEM

HOSE STORAGE COMPARTMENT

311-15

1. Open water shut off valve and completely discharge all water and compressed air from the tank via the hose end nozzle.

PRESSURIZED WATER SYSTEM

CAUTION

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

Tank capacity is 13.7 US gallons (52 litres).

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

Never remove fill plug before depressurizing tank or injury may result. This fill plug incorporates a vent hole to release air pressure from the tank before the threads disengage. Do not replace this fill plug with any substitute.

2. Slowly unscrew fill plug two full turns. Any remaining air in the tank will be heard expelling from the special fill plug. Do not remove fill plug until all air has been expelled.

The pressure gauge on the valve should read 60 psi check system pressure daily.

••

PRESSURE GAUGE

• ••

••

•

OUTLET CONNECTION

•

AIR CHARGE VALVE 150-1A

WATER TANK

FILL PLUG

WATER SHUT-OFF VALVE (SHOWN OFF)

••

DOZER BLADE

WATER CONTROL VALVE

311-1

PRESSURIZED WATER SYSTEM

3. Close water shut off valve.

4. Fill tank with clean water. Tank capacity is approximately 11 US gallons (42 litres).

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

When temperatures below 32°F are anticipated, use a 60/40 solution of Nontoxic R. V. Antifreeze or other suitable antifreeze.

Antifreeze solution must meet GM 6038M specifications.

3.22

Tigercat 620 Skidder NOTE: Most Nontoxic R.V. Anti freeze solutions contain corrosion and algae inhibitors, it is therefore suggested that this solution be added to the water on a continual basis regardless of temperature conditions.

5. Install fill plug in tank.

NOTE: This is a special plug designed to withstand pressurization of the water tank.

Do not substitute.

Lubrication and Maintenance PURGING PRESSURIZED WATER SYSTEM Purging should be carried out whenever the flow of water does not forcefully discharge from the end of the hose with the pressure gauge reading 60 psi.

1. Open water shut off valve and completely discharge all water and compressed air from the tank via the hose end nozzle.

CAUTION

6. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

Never remove fill plug before depressurizing tank or injury may result. This fill plug incorporates a vent hole to release air pressure from the tank before the threads disengage. Do not replace this fill plug with any substitute.

7. Open the water shut off valve.

8. Discharge about 1/2 gallon (2 litres) of fluid into an empty antifreeze jug or other suitable container.

There will be significant foaming as the fluid is discharged into the jug. Continue until a very forceful flow is obtained and any contamination that may have been in the tank is flushed from the system.

9. Check fluid in the jug for contamination. If fluid is dirty dispose of it properly.

2. Slowly unscrew fill plug two full turns. Any remaining air in the tank will be heard expelling from the special fill plug. Do not remove fill plug until all air has been expelled.

3. Close the water shut off valve and add 2 gallons (8 litres) of CLEAN water to the tank.

4. Install the fill plug NOTE: This is a special plug designed to withstand pressurization of the water tank.

Do not substitute.

10. Close the water shut-off valve.

11. Release pressure and fluid from the hose.

12. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

5. Pressurize the system to 60 psi as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

13. Return the hose to the hose compartment.

6. Open the shut off valve and completely discharge all the water in the tank via the hose end nozzle.

7. Discharge all the water into an empty antifreeze jug or other suitable container.

There will be significant foaming as the fluid is discharged into the jug. Continue until a very forceful flow is obtained and any contamination that may have been in the tank is flushed from the system.

8. If a forceful discharge was not achieved, repeat the purging procedure. If a second purging does not work, remove lines and check for an obstruction.

9. After the purging operation, fill and charge the system as described in FILL & CHARGE PRESSURIZED WATER SYSTEM in THIS SECTION.

3.23

Tigercat 620 Skidder

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

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.

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant only. PAG (polyalkeylene glycol) oil should be present in the system and must be used on 'O' ring fittings during assembly.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

3 LBS. 0 OZ.

7 OZ.

The compressor and charge valves are accessed from the right side engine compartment. The receiver drier is accessed from the compartment behind the right door, on the outside. The evaporator core is accessed on the right hand side of the machine just inside the cab door.

Use this checklist to maintain system between service intervals. a. Check and adjust compressor drive belt tension. b. Check air intake filters and clean as required. c.

Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR'S MANUAL.

311-17

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

d. Check the evaporator core and the inside of the A/C housing for dirt and debris. Clean as required. e. Run air conditioning system for 3 - 5 minutes. f.

CHECK A/C CONDENSER CORE

Check to see that compressor clutch will engage.

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.

3.24

Tigercat 620 Skidder

Lubrication and Maintenance FRESH AIR FILTER

ENGINE

•

•

SHUT-OFF VALVE

• ••

HOSE TO A/C HEATER UNIT 303-20

310-23

HOT WATER SHUT OFF VALVE

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

RECIRCULATING AIR FILTER

•

FRESH AIR FILTER

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

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

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

151-9

HEAT CONTROL DIAL

VENTS BEHIND SEAT - 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 every 125 hours. This is done by removing two thumb screws in the filter box cover.

•• 271-24AC

A/C-HEATER CONTROL PANEL (6200111 TO 6200192)

••

350-4A

TEMPERATURE CONTROL

A/C-HEATER CONTROL PANEL (6200193 AND UP)

HEAT - VARIABLE/TEMPERATURE CONTROL This is a variable, rotary dial to adjust the amount of heated air for the cab. Make sure this control is off or at the coolest setting (full counterclockwise), when using the air conditioning. Refer also to HOT WATER SHUT OFF VALVE. 3.25

Tigercat 620 Skidder TILTING THE CAB

Lubrication and Maintenance 5. Remove the left side Cab Locking Pins (2 pins). This is done by first removing the locking bolts. (2 bolts)

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

Engage the parking brake and turn the ignition switch off.

6. Open the lower compartment door in left hand step below the cab door to access the cab tilt hand pump.

PUMP HANDLE

RAISING THE CAB

•

1. Position the Skidder on level ground.

2. Lower the Grapple and Dozer to the ground.

3. Apply parking brake and turn ignition off.

•

4. Remove the sweep mounting bolts at the cab.

(4 bolts) CAB SWEEP BOLTS

PUMP

HAND PUMP FOR CAB TILT

311-5

7. Turn the lever on the pump manifold to RAISE (pointing in).

••

•• PUMP HANDLE

• PUMP LEVER SHOWN IN "LOWER" POSITION

PUMP LEVER SHOWN IN "RAISE" POSITION 303-14

••

• 138-8AX

PUMP CONTROL LEVER

8. Insert handle into pump and pump in a steady manner to raise the cab to the tilt position.

The pump handle is stored in brackets just inside right cab door.

620-M1

CAUTION

•

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.

•• CAB LOCKING PINS

311-12

311-2

3.26

PUMP HANDLE STORAGE

Tigercat 620 Skidder

Lubrication and Maintenance

9. Insert CAB SUPPORT BRACE for partial tilt.

Secure brace at each end with the cab locking pins. Full tilt is limited to the length of the safety cable and is beyond centre of gravity.

The cab will stay at this limit provided Skidder is on level ground.

•• CAB LOCKING PINS

LOWERING THE CAB 1. Clear the area under the cab of obstructions and secure all lines and wires.

••

2. If the Cab Support Brace was used, you may have to take the weight off of it by slightly raising the cab before removing it.

CAB SUPPORT BRACE (3291B).

MUST USE CAB & CHASSIS LUGS SHOWN

•• SAFETY CABLE

•

3. Turn the lever on the pump manifold to LOWER (pointing out)

271-22AX

PARTIAL TILT WITH CAB SUPPORT BRACE

4. Pump the handle on the pump to lower the cab.

5. Watch closely for pinching of hydraulic lines and wires.

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

6. When fully lowered, insert Cab Locking Pins and tighten locking bolts (2 pins) (2 bolts) 7. Turn the lever on the pump manifold inwards and store the pump handle on the lower door.

•

8. Close and lock the lower door.

9. Replace the Cab Sweep Bolts. (4 bolts)

WARNING

CAB SAFETY CABLE (3361B)

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.

311-7

CAB AT FULL TILT SUPPORTED SUPPORTED BY SAFETY CABLE

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

WARNING

311-13

CAB SUPPORT BRACE STORED UNDER SEAT

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.

3.27

Tigercat 620 Skidder

Lubrication and Maintenance

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

The sump holds 5.5 U.S. Gal. (20.8 litres). The oil supplied is 80-W-90.

Below -10°F(-23°C) use synthetic sae 5W, multipurpose ATF or synthetic ATF, which are good to -40°F. Oil should be changed every 1000 hrs, depending on use.

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

AIR BREATHER/FILLER CAP

•

1726

WINCH LUBRICATION

•

OIL LEVEL PLUG 172-8

The oil level should be up to the oil level check plug (remove with allen wrench) on the left side of the winch. Keep the winch sump filled to the correct level by adding oil through the air breather check valve assembly on the left side of the winch.

3.28

Tigercat 620 Skidder

Lubrication and Maintenance

WINCH LUBRICATION - LANTEC ONLY MAIN FILLER/BREATHER PLUG

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

•

The sump holds 4.7 U.S. Gal. (18 litres). Tigercat recommends the use of tractor hydraulic fluid for the lantec winch. Refer to approved hydraulic oils in this section.

348-21

•

Oil should be changed 1000 hours, depending on use.

OIL LEVEL SIGHT GAUGE

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

The oil level should be up to the oil level sight glass on the left side of the winch.

348-22

LANTEC WINCH - LEFT SIDE

ADDING OIL-LANTEC MODEL 40 WINCH 1. To avoid underfilling the lantec model 40 winch it is necessary to fill first the right side of the winch and then the left side.

2. Remove the auxiliary level plug located on the right side of the winch. Fill the right side of the winch until the oil level reaches the auxiliary level plug. Replace the auxiliary level plug.

•

3. Remove the main filler/breather plug, the top plug on the left side of the winch. Fill the left side of the winch until the oil level reaches the oil level sight glass. Replace the main filler/ breather plug.

AUXILIARY LEVEL PLUG

348-23

3.29

LANTEC WINCH - RIGHT SIDE

Tigercat 620 Skidder STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE This procedure should be followed: •

after major service or a rebuild.

•

whenever the machine has been drained of hydraulic oil.

•

when any major component has been removed, repaired or replaced.

Lubrication and Maintenance

•

Loosen plug on the outside of the main pump.

•

PRE-STARTUP AND FILLING LOOSEN PLUG OUTSIDE OF MAIN PUMP

1. Ensure all filters are in place.

Pre-fill only the hydraulic oil double element filters.

630-D30

Do not pre-fill the charge pressure filter.

•

Refer to FILTERS in THIS SECTION.

Loosen plugs on both motors.

2. Check oil levels in the engine, the pump drive gearbox and the transmission.

•

3. Check coolant level in the radiator.

LOOSEN PLUGS ON BOTH MOTORS

4. Do a final inspection of all fittings and clamps to make sure they are tight and will not leak.

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

• 630-D31

6. Turn both differential lock switches to OFF. 7. Do not start engine. Purge air from hydraulic system by adding oil as follows;

•

Operate the hand fill pump at medium speed, using a steady motion.

•

Prepare the hand fill pump on the machine to add hydraulic oil. Clean the fill line pipe, remove cap on end of pipe and insert pipe into oil supply drum.

•

Watch for oil leaking from each plug previously loosened and tighten each plug when oil leaks out.

•

Pre-fill the cases of the hydrostatic pump and any other components that have been drained of oil.

•

Continue pumping slowly and watch the oil sight gauge on the reservoir. Continue pumping slowly until the hydraulic tank is full.

•

Loosen plug on the top centre of hydrostatic drive pump servo

NOTE: If the axles were drained of oil, refer to FILLING THE AXLES in SECTION 8 of THE SERVICE MANUAL.

LOOSEN PLUG ON TOP CENTER OF HYDROSTATIC DRIVE PUMP SERVO

••

620-D29

3.30

Tigercat 620 Skidder MACHINE STARTUP

Lubrication and Maintenance 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.

Before beginning this procedure, perform the PRE-STARTUP AND FILLING steps.

1. Ensure the articulation lock bar is installed.

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

2. Disconnect red and white wires on injector pump solenoid (prevents engine starting).

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

4. Reconnect wires on injector pump solenoid.

Do not start engine.

5. Install a 0-1000 psi. gauge on drive pump to check charge pressure at ‘G’ ( TEE fitting).

Watch gauge closely during startup.

6. Start engine. If charge pressure does not rise within 5 to 10 seconds, TURN ENGINE OFF. If charge pressure is between 260 and 450 psi., run engine at IDLE for 20 minutes.

Check engine oil pressure in cab. Do not operate any functions. Remove gauge from 'G'.

7. With engine at IDLE, parking brake ON, hold foot brake down, bleed brakes in front axle.

8. Turn both differential locks ON and run engine at IDLE for 30 minutes to purge air and fill axles with oil (axles fill with leakage from diff. locks). If wheels have been removed, operate forward and reverse pedals very slowly to fill axles with oil.

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

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

11. Top up the radiator with clean coolant. With cylinders fully retracted, top up the hydraulic oil reservoir with clean hydraulic oil.

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

3.31

Tigercat 620 Skidder

Lubrication and Maintenance

SPEED CONTROL LEVER ADJUSTMENT

••

The friction setting on the speed control lever is variable and can be adjusted to allow proper operation.

8

350-8A

1. Park machine on level ground, apply park brake, lower dozer blade and grapple to ground, shut off engine.

2. Position the speed control lever in the neutral position (pointing straight up).

3. Raise the protective rubber ‘boot’ from the speed control valve body, located on the side instrument panel.

4. Locate the adjustable friction set screw.

5. Tighten the adjustable friction set screw as required (2.5mm hex key) 6. Replace the protective rubber ‘boot’ over the speed control valve body.

SPEED CONTROL LEVER

•• RIGHT HAND SIDE OF MACHINE

ADJUSTABLE FRICTION SET SCREW CONTROL PANEL

•

630B-31

12

•• •• ••

Before starting work, read and follow all servicing safety precautions in SECTION 1 of THIS MANUAL.

•

11

7

PROCEDURE

•

10

•

••

The friction setting on the speed control lever may reduce over time, during normal operation, and not maintain the set position of the lever, especially at maximum throw.

PROTECTIVE RUBBER BOOT

9

SPEED CONTROL LEVER FRICTION SET SCREW LOCATION 3.32

SIDE INSTRUMENT PANEL (6200151 AND UP)

Tigercat 620 Skidder TORQUE CHART LOCATION

Cylinders Pin bolts Piston nut, steer cylinder Piston nut, arc/boom cylinder Piston nut, dozer cylinder Gland, steer cylinder Keeper plate bolts Keeper plate bolts

Lubrication and Maintenance

THREAD DIAMETER

TORQUE (LUBRICATED) lbf-ft Nm

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

282-310 1100 1750 1260 550 282-310 159-175

393-420 1491 2372 1708 745 393-420 216-237

Cab pin keeper plate bolts

3/4" UNC

282-310

393-420

Center joint bearing Bearing retaining bolts Pin retaining bolts

1/2" UNC 3/4" UNC

80-88 282-310

109-119 393-420

Engine mounting Bolts Bolts, brkt. to bell hsg.

7/8" UNC M12

450 80

610 108

Pump drive gearbox Drive plate to flywheel Bell housing to engine Engine mounting bracket

3/8" UNC 10 x 1.5 5/8" UNC

33-36 32 159-175

45-49 43 216-237

1 1/4" x 18 UNEF 3/4" UNC

475-525 282-310

640-711 393-420

1/2" UNF

120-132

163-179

1/2" UNF

120-132

163-179

1/2" UNF

120-132

163-179

Axle mounting bolts Front Rear

3/4" UNC 7/8" UNC

300 450

406 610

Wheel bolts

7/8" UNF

501-550

679-745

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

5/8"UNC 7/8" UNC

159-175 450

216-237 610

Drive shafts Yoke retaining nut, rear shaft Pillow block retaining bolts Rear drive shaft universal joint bolts Mid. drive shaft universal joint bolts Front drive shaft universal joint bolts

REV 1 05/2000

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

3.33

Tigercat 620 Skidder

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS The torque values listed below are for general use only.

DO NOT use these values if a different torque value or tightening procedure is shown for a specific application.

IMPERIAL

GRADE 5 BOLTS

GRADE 8 BOLTS COARSE THREADS 1/4" - 20 5/16" - 18 3/8" - 16 7/16" - 14 1/2" - 13 9/16" - 12 5/8" - 11 3/4" - 10 7/8" - 9 1" - 8 1 1/8" - 7 1 1/4" - 7 FINE THREADS 1/4" - 28 5/16" - 24 3/8" - 24 7/16" - 20 1/2" - 20 9/16" - 18 5/8" - 18 3/4" - 16 7/8" - 14 1" - 12 1 1/8" - 12 1 1/4" - 12

DRY lbf-ft Nm 11 - 12 15 - 16 20 - 28 27 - 38 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 26 - 30 35 - 40 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250

COARSE DRY THREADS lbf-ft Nm 1/4" - 20 7- 8 10 - 11 5/16" - 18 14 - 18 19 - 24 3/8" - 16 31 - 34 42 - 46 7/16" - 14 49 - 54 66 - 73 1/2" - 13 75 - 83 102 - 112 9/16" - 12 109 - 120 148 - 162 5/8" - 11 150 - 165 204 - 223 3/4" - 10 266 - 293 360 - 397 7/8" - 9 394 - 433 535 - 586 1" - 8 591 - 649 802 - 879 1 1/8" - 7 794 - 873 1077 - 1183 1 1/4" - 7 1120 - 1232 1519 - 1670 FINE DRY THREADS lbf-ft Nm 1/4" - 28 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 3/8" - 24 35 - 39 48 - 53 7/16" - 20 55 - 61 75 - 83 1/2" - 20 85 - 94 116 - 127 9/16" - 18 121 - 133 164 - 180 5/8" - 18 170 - 187 231 - 253 3/4" - 16 297 - 327 403 - 443 7/8" - 14 434 - 477 589 - 646 1" - 12 646 - 711 876 - 965 1 1/8" - 12 891 - 980 1208 - 1328 1 1/4" - 12 1240 - 1364 1682 - 1849

LUBRICATED lbf-ft Nm 8 - 10 11 - 13 10 - 15 13 - 20 23 - 25 31 - 34 37 - 41 50 - 55 57 - 63 77 - 85 82 - 90 111 - 122 113 - 124 152 - 168 200 - 220 271 - 298 296 - 326 402 - 441 443 - 489 601 - 663 596 - 656 808 - 889 840 - 924 1139 - 1252 LUBRICATED lbf-ft Nm 9 - 10 12 - 13 16 - 20 21 - 27 26 - 29 35 - 39 41 - 45 56 - 61 64 - 70 87 - 95 91 - 100 124 - 135 128 - 141 174 - 191 223 - 245 303 - 332 326 - 359 442 - 486 484 - 534 657 - 724 668 - 735 906 - 996 931 - 1024 1262 - 1387

METRIC

SIZE

CLASS 4.8 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

CLASS 8.8 OR 9.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

M6 M8 M10

4.8 12 23

3.5 8.5 17

6 15 29

4.5 11 21

9 22 43

6.5 16 32

11 28 55

8.5 20 40

13 32 63

9.5 24 47

17 40 80

12 30 60

15 37 75

11.5 28 55

19 47 95

14.5 35 70

M12 M14 M16

40 63 100

29 47 73

50 80 125

37 60 92

75 120 190

55 88 140

95 150 240

70 110 175

110 175 275

80 130 200

140 225 350

105 165 225

130 205 320

95 150 240

165 260 400

120 190 300

M18 M20 M22

135 190 260

100 140 190

175 240 330

125 180 250

260 375 510

195 275 375

330 475 650

250 350 475

375 530 725

275 400 540

475 675 925

350 500 675

440 625 850

325 460 625

560 800 1075

410 580 800

M24 M27 M30

330 490 675

250 360 490

425 625 850

310 450 625

650 950 1300

475 700 950

825 1200 1650

600 875 1200

925 1350 1850

675 100 1350

1150 1700 2300

850 1250 1700

1075 1600 2150

800 1150 1600

1350 2000 2700

1000 1500 2000

M33 M36

900 1150

675 850

1150 1450

850 1075

1750 2250

1300 1650

2200 2850

1650 2100

2500 3200

1850 2350

3150 4050

2350 3000

2900 3750

2150 2750

3700 4750

2750 3500

3.34

CLASS 10.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

Tigercat 620 Skidder SECTION 5 - PILOT SYSTEM SEPTEMBER 2003

CONTENTS - SECTION 5 CHARGE PRESSURE FILTER ...................................................................... 5.3 CHARGE PUMP ............................................................................................. 5.2 CIRCUIT DESCRIPTION (6200111 TO 6200150) ......................................... 5.4 CIRCUIT DESCRIPTION (6200151 TO 6200196) ......................................... 5.6 CIRCUIT DESCRIPTION (6200197 TO 6200232) ......................................... 5.8 CIRCUIT DESCRIPTION (6200233 AND UP) ............................................. 5.10 CIRCUIT DIAGRAM (6200111 TO 6200150) ................................................. 5.5 CIRCUIT DIAGRAM (6200151 TO 6200196) ................................................. 5.7 CIRCUIT DIAGRAM (6200197 TO 6200232) ................................................. 5.9 CIRCUIT DIAGRAM (6200233 AND UP) ..................................................... 5.11 PILOT MANIFOLD ......................................................................................... 5.3 PRESSURE SETTINGS .................................................................... 5.12, 5.13

Tigercat 620 Skidder

Pilot system

CHARGE PUMP

The charge pump is the source of pilot pressure to the following components: pilot manifold, drive pedals, speed control valve (if equipped), joystick control valve, dozer valve, and the boom valve.

The charge pump is a secondary pump mounted in the hydrostatic drive pump case. For a more detailed description of charge pump operation refer to HYDROSTATIC DRIVE PUMP in SECTION 8 of THIS MANUAL. CHARGE PRESSURE RELIEF VALVE

Excess charge pump oil is relieved by the charge pump relief valve back into the case of the piston pump. The charge pressure filter ensures that only clean charge pump oil is introduced into the closed loop hydrostatic circuit and the swashplate control system. Should this pressure filter become clogged with debris, charge pump flow is diverted to tank thus preventing the entry of unfiltered charge pump oil into the closed loop.

CHARGE PUMP

• • •• DRIVE PUMP 298-3

REXROTH DRIVE PUMP/CHARGE PUMP

CHARGE PUMP

•• • DRIVE PUMP

620-09

SAUER DRIVE PUMP/CHARGE PUMP

The charge pump is a fixed displacement internal gear pump that is fed from the hydraulic oil reservoir. Charge oil is used by the swashplate control system and as makeup oil for the closed loop drive circuit. The make up oil replaces the oil that leaves the closed loop circuit due to leakage in the drive pump and motors. This make up oil increases the performance and lives of these drive hydrostatic components by acting as a cooling fluid.

5.2

Tigercat 620 Skidder

Pilot system

PILOT MANIFOLD

When the solenoid is de-energized, a spring forces the spool back to the neutral position, blocking the pressure side and opening the pilot line back to tank. There are no adjustments on the solenoid valves.

The pilot manifold is mounted on the valve bench under the cab and supplies pilot oil to the following functions: • • • • • • • • • •

Drive Pedal Pilot Valve (P1) End port Arch/Boom Joystick (P1) End port Dozer Control Lever (P1) End port Winch Control Lever (P1) End port Winch Freespool(EARLY) (C1) Sol. valve Winch Speed Range(LATER) (C1) Sol. valve Grapple Open (C2) Sol. valve Grapple Close (C3) Sol. valve Grapple Rotate CW (C4) Sol. valve Grapple Rotate CCW (C5) Sol. valve

CHARGE PRESSURE FILTER

••

DOUBLE ELEMENT FILTERS

••

WINCH FREESPOOL OR WINCH SPEED RANGE GRAPPLE 'OPEN' GRAPPLE CLOSE GRAPPLE ROTATE 'CW' GRAPPLE ROTATE 'CCW'

DRIVE PUMP

•• •• •• • ••

•

MAIN PUMP DOZER, STEER & GRAPPLE

•• •• PUMPS AND FILTERS

303-24

PILOT MANIFOLD The pilot manifold consists of a one piece manifold block into which, five solenoid operated control valves are installed at outlet ports C1, C2, C3, C4 and C5. Plugs are installed in ports P2,P3, P5, P6, T2 and T3.

COOLING PUMP

298-15

CAB PILOT RETURN MANIFOLD DRIVE PREVENT VALVE

•• •

Pilot oil is supplied to the pilot manifold (port P4) from the charge pump. Pilot oil is further distributed to the drive pedal valve, arch/boom joystick, dozer control lever and winch control lever through port P1. Unused pilot oil in the pilot manifold returns to tank (port T1) via the front chassis pilot return manifold.

FRONT CHASSIS PILOT RETURN MANIFOLD

The solenoid valves installed in the pilot manifold control the position of the spool valves or pistons to which they are hydraulically connected. When a solenoid valve is energized, usually by a switch in the cab, its spool is shifted and pilot oil is directed to one end of a spool valve or piston to operate the function connected to the control valve.

••

311-7X

5.3

DRIVE PREVENT SOLENOID VALVE UNDER CAB

Tigercat 620 Skidder

Pilot system

PILOT CIRCUIT DESCRIPTION (6200111 TO 6200150) The pilot circuit is supplied with oil at pilot pressure from the charge pump, which is a secondary pump located in the hydrostatic drive pump case.

The pilot pressure is controlled by the charge pump pressure relief valve located in the drive pump housing. The charge pressure relief valve adjustments are explained in DRIVE PUMP PRESSURE SETTINGS in SECTION 8 of THIS MANUAL. The oil is filtered by the hydrostatic charge pump pressure filter before entering the pilot circuit.

This cartridge filter is mounted on the front of the hydraulic reservoir. It has a differential pressure relief valve which will bypass oil to tank if the pressure differential exceeds 50 psi. In cases of loss of control or slow response the condition of this filter should be suspected. Refer to CHARGE FILTER BYPASS - YELLOW LIGHT in SECTION 2 of the OPERATOR'S MANUAL. Pilot oil enters the pilot manifold through port P4.

There are five solenoid operated control valves in the pilot manifold which operate the winch freespool, grapple open/close and grapple rotate functions. Pilot oil is further distributed through port P1 to the arch/boom joystick, dozer control lever and winch lever. Port P1 also supplies pilot oil to the drive pedal via the drive prevent valve.

Unused pilot oil is directed back to tank via the T1 port in the pilot manifold and the T ports of the control valves completing the circuit.

The drive prevent valve prevents the machine from being driven either forward or reverse when the parking brake is ON, refer to DRIVE PREVENT VALVE in SECTION 8 of THIS MANUAL.

5.4

Tigercat 620 Skidder

620-02

Pilot system

PILOT SUPPLY CIRCUIT SERIAL NUMBER 6200111 TO 6200150 5.5

Tigercat 620 Skidder

Pilot system

PILOT CIRCUIT DESCRIPTION (6200151 TO 6200196) The pilot circuit is supplied with oil at pilot pressure from the charge pump, which is a secondary pump located in the hydrostatic drive pump case.

The pilot pressure is controlled by the charge pump pressure relief valve located in the drive pump housing. The charge pressure relief valve adjustments are explained in DRIVE PUMP PRESSURE SETTINGS in SECTION 8 of THIS MANUAL. The oil is filtered by the hydrostatic charge pump pressure filter before entering the pilot circuit.

This cartridge filter is mounted on the front of the hydraulic reservoir. It has a differential pressure relief valve which will bypass oil to tank if the pressure differential exceeds 50 psi. In cases of loss of control or slow response the condition of this filter should be suspected. Refer to FILTER BYPASS - YELLOW LIGHT in SECTION 2 of the OPERATOR'S MANUAL. Pilot oil enters the pilot manifold through port P4.

There are five solenoid operated control valves in the pilot manifold which operate the winch freespool, grapple open/close and grapple rotate functions. Pilot oil is further distributed through port P1 to the arch/boom joystick, dozer control lever and winch lever. Port P1 also supplies pilot oil to the drive pedal via the drive prevent valve and the speed control valve. Unused pilot oil is directed back to tank via the T1 port in the pilot manifold and the T ports of the control valves completing the circuit.

The drive prevent valve prevents the machine from being driven either forward or reverse when the parking brake is ON, refer to DRIVE PREVENT VALVE in SECTION 8 of THIS MANUAL. The speed control valve limits the maximum speed of the machine by reducing the flow of pilot oil to the drive pedal, refer to SPEED CONTROL VALVE in SECTION 8 of THIS MANUAL.

5.6

Tigercat 620 Skidder

620-01

Pilot system

PILOT SUPPLY CIRCUIT SERIAL NUMBER 6200151 AND 6200196 5.7

Tigercat 620 Skidder

Pilot system

PILOT CIRCUIT DESCRIPTION (6200197 TO 6200232) The pilot circuit is supplied with oil at pilot pressure from the charge pump, which is a secondary pump located in the hydrostatic drive pump case.

The pilot pressure is controlled by the charge pump pressure relief valve located in the drive pump housing. The charge pressure relief valve adjustments are explained in DRIVE PUMP PRESSURE SETTINGS in SECTION 8 of THIS MANUAL. The oil is filtered by the hydrostatic charge pump pressure filter before entering the pilot circuit.

This cartridge filter is mounted on the front of the hydraulic reservoir. It has a differential pressure relief valve which will bypass oil to tank if the pressure differential exceeds 50 psi. In cases of loss of control or slow response the condition of this filter should be suspected. Refer to FILTER BYPASS - YELLOW LIGHT in SECTION 2 of the OPERATOR'S MANUAL. Pilot oil enters the pilot manifold through port P4.

There are five solenoid operated control valves in the pilot manifold which operate the grapple open/ close, grapple rotate and winch freespool functions. Machines equipped with a Lantec winch also have a remote mounted solenoid operated control valve for the winch speed range function. Pilot oil is further distributed through port P1 to the arch/boom joystick, dozer control lever and winch lever. Port P1 also supplies pilot oil to the drive pedal via the drive prevent valve and the speed control valve. Unused pilot oil is directed back to tank via the T1 port in the pilot manifold and the T ports of the control valves completing the circuit.

The drive prevent valve prevents the machine from being driven either forward or reverse when the parking brake is ON, refer to DRIVE PREVENT VALVE in SECTION 8 of THIS MANUAL. The speed control valve limits the maximum speed of the machine by reducing the flow of pilot oil to the drive pedal, refer to SPEED CONTROL VALVE in SECTION 8 of THIS MANUAL.

5.8

Tigercat 620 Skidder

630B-01

Pilot system

PILOT SUPPLY CIRCUIT SERIAL NUMBER 6200197 TO 6200232 5.9

Tigercat 620 Skidder

Pilot system

PILOT CIRCUIT DESCRIPTION (6200233 AND UP) The pilot circuit is supplied with oil at pilot pressure from the charge pump, which is a secondary pump located in the hydrostatic drive pump case.

The pilot pressure is controlled by the charge pump pressure relief valve located in the drive pump housing. The charge pressure relief valve adjustments are explained in DRIVE PUMP PRESSURE SETTINGS in SECTION 8 of THIS MANUAL. The oil is filtered by the hydrostatic charge pump pressure filter before entering the pilot circuit.

This cartridge filter is mounted on the front of the hydraulic reservoir. It has a differential pressure relief valve which will bypass oil to tank if the pressure differential exceeds 50 psi. In cases of loss of control or slow response the condition of this filter should be suspected. Refer to FILTER BYPASS - YELLOW LIGHT in SECTION 2 of the OPERATOR'S MANUAL. Pilot oil enters the pilot manifold through port P4.

There are five solenoid operated control valves in the pilot manifold which operate the grapple open/ close, grapple rotate and winch speed range functions. There is also a remote mounted solenoid operated control valve for the winch freespool function. Pilot oil is further distributed through port P1 to the arch/boom joystick, dozer control lever and winch lever. Port P1 also supplies pilot oil to the drive pedal via the drive prevent valve and the speed control valve.

Unused pilot oil is directed back to tank via the T1 port in the pilot manifold and the T ports of the control valves completing the circuit.

The drive prevent valve prevents the machine from being driven either forward or reverse when the parking brake is ON, refer to DRIVE PREVENT VALVE in SECTION 8 of THIS MANUAL. The speed control valve limits the maximum speed of the machine by reducing the flow of pilot oil to the drive pedal, refer to SPEED CONTROL VALVE in SECTION 8 of THIS MANUAL.

5.10

Tigercat 620 Skidder

630B-01-1

Pilot system

PILOT SUPPLY CIRCUIT SERIAL NUMBER 6200233 AND UP 5.11

Tigercat 620 Skidder

Pilot system

PRESSURE SETTINGS - REXROTH PUMP AND REXROTH MOTORS Pressure and Speed Settings (120°F-140°F) Engine RPM .............................................................................. 2400-2450 rpm full throttle 900-1000 rpm idle HYDROSTATICS CHARGE PRESSURE Rexroth Pump ............................................................................ 450-460 psi Rexroth Motor ............................................................................ Non-Adjustable

MAIN RELIEFS P.O.R. Forward .......................................................................... 6200-6250 psi P.O.R. Reverse .......................................................................... 6200-6250 psi High Pressure Relief Forward with 135 psi @ ‘X’ ...................................6850-6900 psi High Pressure Relief Reverse with 135 psi @ ‘X’ ...................................6850-6900 psi DRIVE MOTORS Drive Motor P.O.R. ..................................................................... 4150 psi Drive Motor Begin of Displacement Control............................................125-135 psi Minimum Displacement (90mm screw length) ........................................x = 20.6mm

@ full throttle

@ @ @ @

full throttle full throttle full throttle full throttle

@ full throttle @ full throttle

MAIN PUMP Pump P.O.R. .............................................................................. 3000-3100 psi

@ idle

MULTIFUNCTION VALVE Main Relief (with dozer inlet relief) ............................... 3575-3600 psi + 4 flats Main Relief (without dozer inlet relief) ........................................ 3500-3600 psi Pressure Reducing Valve, Diff-Locks ......................................... 625-630 psi Sequence Valve, Diff-Locks ....................................................... 750-755 psi

@ @ @ @

DOZER VALVE Dozer Up Port Relief .................................................................. 3500-3600 psi Dozer Down Port Relief .............................................................. 3500-3600 psi Inlet Relief (if equipped) ............................................................. 3500-3525 psi

@ idle @ idle @ idle

GRAPPLE VALVE Boom Up Port Relief ..................................................................

Boom Down Port Relief ..............................................................

Rotate CW Port Relief (if equipped) ...........................................

Rotate CCW Port Relief (if equipped) ........................................

Grapple Open Port Relief ...........................................................

Grapple Close Port Relief ...........................................................

Arch In Port Relief ......................................................................

Arch Out Port Relief ...................................................................

Winch In Port Relief - Lufkin Winch (if equipped) ......................

Winch In Port Relief - Lantec Winch (if equipped) .....................

BRAKES Brake Maximum Pressure ..........................................................

Brake applications - engine off (5 applications) ..........................

3500-3600 psi 2500-2600 psi 2500-2600 psi 2500-2600 psi 3500-3600 psi 3650-3700 psi 3500-3600 psi 2500-2600 psi 3500-3600 psi 2900-2950 psi

@ @ @ @ @ @ @ @ @ @

1000 psi 800 psi minimum

@ idle

NOTE: The above values are for reference purposes only, SEE SERVICE MANUAL FOR SETTING PROCEDURES.

ISSUE 3 11/02

5.12

idle idle idle idle

idle idle idle idle idle idle idle idle idle idle

Tigercat 620 Skidder

Pilot system

PRESSURE SETTINGS - SAUER PUMP AND REXROTH MOTORS Pressure and Speed Settings (120°F-140°F) Engine RPM .............................................................................. 2400-2450 rpm full throttle 900-1000 rpm idle HYDROSTATICS CHARGE PRESSURE Sauer Pump ............................................................................... 450-460 psi Rexroth Motor ............................................................................ Non-Adjustable

@ full throttle

MAIN RELIEFS P.O.R. Forward .......................................................................... See chart below P.O.R. Reverse .......................................................................... See chart below High Pressure Relief Forward ................................................................. Non-Adjustable High Pressure Relief Reverse ................................................................ Non-Adjustable DRIVE MOTORS Drive Motor P.O.R. ..................................................................... 4150 psi Drive Motor Begin of Displacement Control ............................................125-135 psi Minimum Displacement (90mm screw length) ........................................ x = 19.2 mm

@ full throttle @ full throttle

@ full throttle @ full throttle

MAIN PUMP Pump P.O.R. .............................................................................. 3000-3100 psi

@ idle

MULTIFUNCTION VALVE Main Relief (with dozer inlet relief) .............................. 3575-3600 psi + 4 flats Main Relief (without dozer inlet relief) ........................................ 3500-3600 psi Pressure Reducing Valve, Diff-Locks ......................................... 625-630 psi Sequence Valve, Diff-Locks ....................................................... 750-755 psi

@ @ @ @

DOZER VALVE Dozer Up Port Relief .................................................................. 3500-3600 psi Dozer Down Port Relief .............................................................. 3500-3600 psi Inlet Relief (if equipped) ............................................................. 3500-3525 psi

@ idle @ idle @ idle

GRAPPLE VALVE Boom Up Port Relief ..................................................................

Boom Down Port Relief ..............................................................

Rotate CW Port Relief (if equipped) ...........................................

Rotate CCW Port Relief (if equipped) ........................................

Grapple Open Port Relief ...........................................................

Grapple Close Port Relief ...........................................................

Arch In Port Relief ......................................................................

Arch Out Port Relief ...................................................................

Winch In Port Relief - Lufkin Winch (if equipped) ......................

Winch In Port Relief - Lantec Winch (if equipped) .....................

BRAKES Brake Maximum Pressure ..........................................................

Brake applications - engine off (5 applications) ..........................

ISSUE 1 11/02

TRANSMISSION PART NUMBER 7956B 9488B 9491B 11020B

3500-3600 psi 2500-2600 psi 2500-2600 psi 2500-2600 psi 3500-3600 psi 3650-3700 psi 3500-3600 psi 2500-2600 psi 3500-3600 psi 2900-2950 psi

@ @ @ @ @ @ @ @ @ @

1000 psi 800 psi minimum

@ idle

NOTE: The above values are for reference purposes only, SEE SERVICE MANUAL FOR SETTING PROCEDURES. DRIVE PUMP P.O.R. FWD & REV (PSI) 6200 - 6250 5200 - 5250 5200 - 5250 5625 - 5675

5.13

idle idle idle idle

idle idle idle idle idle idle idle idle idle idle

Tigercat 620 Skidder

Pilot system

5.14

Tigercat 620 Skidder SECTION 6 - ELECTRICAL, GAUGES AND ALARMS SEPTEMBER 2003

CONTENTS - SECTION 6 FUSE AND RELAY PANEL (6200111 TO 6200238) ................................... 6.10 FUSE AND RELAY PANEL (6200239 AND UP) .......................................... 6.11 GAUGES AND ALARMS .............................................................................. 6.12 SCHEMATIC DIAGRAM (6200111 TO 6200180) .................................. 6.2, 6.3 SCHEMATIC DIAGRAM (6200181 TO 6200238) .......................... 6.4, 6.5, 6.6 SCHEMATIC DIAGRAM (6200239 AND UP) ................................ 6.7, 6.8, 6.9 SENSOR DETAILS ...................................................................................... 6.12 SWITCH AND SENSOR LOCATIONS ........................................................ 6.13 TROUBLESHOOTING AND TESTING ........................................................ 6.12 WIRE COLOUR CODE CHART ................................................................... 6.10

Tigercat 620 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

630-17

MACHINE SCHEMATIC DIAGRAM 6576B REV.4 (SHEET 1) SERIAL NUMBERS 6200111 TO 6200180 6.2

Tigercat 620 Skidder

630-18

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM 6576B REV.4 (SHEET 2) SERIAL NUMBERS 6200111 TO 6200180 6.3

Tigercat 620 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

620-21

MACHINE SCHEMATIC DIAGRAM 11386B REV.2 (SHEET 1 OF 3) SERIAL NUMBERS 6200181 TO 6200238 6.4

Tigercat 620 Skidder

Electrical, gauges and alarms

*NOTE: EARLY MACHINES S/N 6200111 TO 6200196 LATER MACHINESS/N 6300197 & UP

620-22

MACHINE SCHEMATIC DIAGRAM 11386B REV.2 (SHEET 2 OF 3) SERIAL NUMBERS 6200181 TO 6200238 6.5

Tigercat 620 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

620-23

MACHINE SCHEMATIC DIAGRAM 11386B REV.2 (SHEET 3 OF 3) SERIAL NUMBERS 6200181 TO 6200238 6.6

Tigercat 620 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

620-30

MACHINE SCHEMATIC DIAGRAM 14169B REV.2 (SHEET 1 OF 3) SERIAL NUMBERS 6200239 AND UP 6.7

Tigercat 620 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

620-31

MACHINE SCHEMATIC DIAGRAM 14169B REV.2 (SHEET 2 OF 3) SERIAL NUMBERS 6200239 AND UP 6.8

Tigercat 620 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

620-32

MACHINE SCHEMATIC DIAGRAM 14169B REV.2 (SHEET 3 OF 3) SERIAL NUMBERS 6200239 AND UP 6.9

Tigercat 620 Skidder

Electrical, gauges and alarms

Tigercat wire colour code chart applicable to all products manufactured by Tigercat Industries Inc. COLOUR Red Black White Blue Purple Tan Yellow Grey Brown Green Orange

FUNCTION EXAMPLE Power ........................................ (fused and unfused) Ground Engine control ........................... (fuel shut-off, start aid) Propulsion Control .................... (transmission/reverser solenoids) Monitor, electrical and mechanical systems ................. (air cleaner, alternator, wheel speed, engine speed) Electrical and electromechanical control ......... (park brake, alternator excitation) (power door motor, backup alarm) Monitors .................................... (flow, pressure, temperature, level) Standard monitor system .......... (logic module to monitor) Lights Electro-hydraulic control ........... (pilot solenoids) Accessories .............................. (horn, A/C, heater)

9597AR1

FUSE AND RELAY PANEL (6200111 TO 6200238)

301-11

6.10

Tigercat 620 Skidder

Electrical, gauges and alarms

FUSE AND RELAY PANEL (6200239 AND UP)

630-D41

6.11

Tigercat 620 Skidder

Electrical, gauges and alarms

GAUGES AND ALARMS The 620 is monitored for proper operation by sensors located in the hydraulic system and on the engine. These sensors are connected to either gauges, warning lights, alarms or a combination of these devices.

To troubleshoot temperature and pressure type gauges, use an ohmmeter to test between the terminals at the back of the gauge. Refer to illustration 726B07 for reading values. If the resistance readings taken with the ohmmeter are within the range shown, the gauge is functioning properly. Faulty readings will therefore be the result of a poor sending unit.

For operation of the gauges and warning lights listed in the sensor chart below, refer to SECTION 2 of the OPERATOR'S MANUAL. The operator may sound the warning horn at any time. A back-up alarm will also sound when the machine is travelling in reverse.

726B07

•

Engine Oil Pressure

•

Hydraulic Oil Temperature

•

Engine Coolant Temperature OHMETER TEST READINGS

SENSOR DETAILS SENSOR FUNCTION

GAUGE RANGE LIGHT

HORN

TRIGGER OR RANGE INFO.

Engine oil pressure ......................... 0 - 100 psi ......... None ....... None ..................... Stop engine below 15 psi Engine coolant temp. ................... 100°F - 280°F ...... None ....... None ................. Operating range 190°F-210°F (38°C) - (138°C) Hydraulic oil temp. ....................... 100°F - 240°F ...... None ....... None ............. Stop machine above 185°F (85°C) (38°C) - (116°C) Volts .................................................. 8v - 18v ........... None ....... None .......... Normal operating range 12 - 13.5 volts.

Fuel level ............................................ 'E' - 'F' ............ None ....... None ........................ Capacity; 86 gal.(US) Engine hours .................................... 0 - 9999 .......... None ....... None ............................. Engine running Tachometer .................................... 0-3000 rpm ........ None ....... None .. Refer to pressure settings CHART in SECTION 5 Hydraulic oil - low ...................................

Coolant temperature ..............................

Engine oil pressure ................................

Main pump unloading .............................

Parking brake engaged ..........................

Hydraulic oil temp. .................................

Low coolant ............................................

Engine air filter clogged .........................

Charge filter bypass ...............................

Grapple pressure (constant) ..................

Winch free spool engaged .....................

Differential lock front engaged ...............

Differential lock rear engaged ................

- .................. ON - .................. ON - .................. ON - .................. ON - .................. ON - .................. ON - .................. ON - .................. ON - .................. ON - .................. ON - .................. ON - .................. ON - .................. ON

.......... ON ....................... 10 Gal. (38L) below Full .......... ON ............. Coolant temperature exceeds 215°F .......... ON ................. Engine oil pressure below 10psi ............ - ........ "Main pump unloading valve" switch on dash ............ - ....................... Pulling up on brake handle .......... ON ...... Hydraulic oil temperature above 180°F (82°C) ............ - ............................. Coolant level drops ............ - .................. Air inlet vacuum above 25" H2O ............ - .................. Filter restriction, 50 psi or greater ............ - .............. "Constant pressure" switch on joystick ............ - ..... "Winch free" switch side panel (to 6200180 only) ............ - ..... Front differential lock switch joystick control lever ............ - ..... Rear differential lock switch joystick control lever

Back-up alarm ........................................ - .................... - ............. ON .......................... Reverse drive pedal Horn ....................................................... - .................... - ............. ON .................. Push button on steering wheel ISSUE 2 11/02

6.12

Tigercat 620 Skidder

Electrical, gauges and alarms

MAIN PUMP UNLOADING VALVE MAIN PUMP UNLOADING VALVE SWITCH (LIGHT)

FRONT PARKING BRAKE PROXIMITY SENSOR

HYDRAULIC OIL CHARGE FILTER BYPASS SENDER (LIGHT)

HYDRAULIC OIL TEMPERATURE SENDER (GAUGE)

• HYDRAULIC OIL TANK

•• • •

ENGINE AIR FILTER VACUUM SWITCH (LIGHT)

•

• •

ENGINE COOLANT TEMPERATURE SENDER (GAUGE)

• • •

ENGINE COOLANT LEVEL SENDER (LIGHT)

ENGINE HOURS PRESSURE SWITCH (GAUGE) COOLANT TEMPERATURE SWITCH (LIGHT AND HORN) ENGINE OIL PRESSURE SENDER (GAUGE)

• •

•

HYDRAULIC OIL TEMPERATURE SWITCH (LIGHT AND HORN) TACHOMETER PROXIMITY SWITCH (GAUGE)

• •

•

HYDRAULIC OIL LEVEL SENDER (LIGHT AND HORN)

ELECTRIC THROTTLE ACTUATOR

•

•

•

BACK-UP ALARM (DRIVE PEDAL ACTIVATED)

RADIATOR ENGINE OIL PRESSURE SENDER (LIGHT AND HORN)

FUEL SOLENOID RELAY (6200181 AND UP) BATTERIES ENGINE START SOLENOID RELAY (NOTE: 6200111 TO 6200180 ONLY - START SOLENOID RELAY FUNCTIONED AS BOTH A START AND FUEL SOLENOID RELAY)

•

• •

BACK-UP ALARM SENDER (HORN)

• • •

TRANSMISSION

BATTERY DISCONNECT SWITCH

HORN (PUSH BUTTON ON STEERING WHEEL)

FUEL LEVEL SENDER (GAUGE)

• •

•

NOTE: THIS ILLUSTRATION IS INTENDED TO SHOW THE GENERAL LOCATION OF SENSORS. SOME MACHINES MAY NOT BE EQUIPPED WITH ALL SENSORS AS SHOWN.

620-33 ISSUE 2 11/02

SWITCH AND SENSOR LOCATIONS 6.13

FUEL TANKS

Tigercat 620 Skidder

Electrical, gauges and alarms

6.14

Tigercat 620 Skidder SECTION 7 - ENGINE START AND STOP NOVEMBER 2002

CONTENTS - SECTION 7 DRIVE PREVENT VALVE ...................................................................... 7.3, 7.8 FUEL CONTROL VALVE ....................................................................... 7.3, 7.8 MAIN PUMP UNLOADING VALVE ........................................................ 7.3, 7.9 START CIRCUIT DESCRIPTION EARLIER DESIGN (6200111 TO 6200238) ................................................ 7.2 LATER DESIGN - WITH LOW OIL PRESSURE SHUT-DOWN (6200239 AND UP) ................................................................................. 7.7 START CIRCUIT DIAGRAM SERIAL NUMBERS 6200111 TO 6200180 ................................................. 7.4 SERIAL NUMBERS 6200181 TO 6200238 ......................................... 7.5, 7.6 SERIAL NUMBERS 6200239 AND UP ............................................. 7.9, 7.10 START MOTOR AND SOLENOID ......................................................... 7.3, 7.8 START SOLENOID RELAY ................................................................... 7.2, 7.7 TACHOMETER SET-UP .............................................................................. 7.11

Tigercat 620 Skidder

Engine start and stop

ENGINE START CIRCUIT EARLIER DESIGN (6200111 TO 6200238)

CIRCUIT DESCRIPTION Refer to schematic diagrams for your machine serial number, showing the ENGINE START CIRCUIT in THIS SECTION.

For detailed engine information refer to the engine manufacturer's manual.

With the parking brake ON, the park brake switch closed and the drive enable relay coil is energized through wires 6 and 11. When the ignition switch is turned to the START position, voltage is supplied to the start circuit through wire 6 to the drive enable relay and wire 9 to the start relay.

For engine starting and stopping procedures refer to ENGINE STARTING AND STOPPING in SECTION 2 of the OPERATOR’S MANUAL. The engine starting circuit is controlled by the proximity switch located on the parking brake lever which prevents the engine from being started when the parking brake is OFF.

Voltage is supplied through wire 23 to the coil of the start relay, which closes and supplies voltage through wire 16 to the start solenoid relay, which in turn closes and supplies voltage through wire 12 to close the start solenoid contacts and supply battery power to the starter to turn the engine.

The fuel solenoid relay contacts also close and current flows through wire 54 to the fuel solenoid pull in contact. (Early machines, 6200111 to

The engine is started by turning the ignition switch to the START position and then releasing it to the RUN position after the engine starts.

The parking brake must be ON to allow the engine to start.

If the engine stalls during operation of the vehicle, the key must be turned to the OFF position to reset before the engine can be restarted.

START RELAY (#1) DRIVE ENABLE RELAY (#2)

• •

DRIVE SYSTEM RELAYS FRONT VIEW OF CONTROL PANEL

6424BIL1

LOCATED BEHIND CAB LH SIDE ACCESS PANEL

PARKING BRAKE 'OFF' POSITION

320-21

RUN OFF

••

START

• •• 270-22A

630-D39

START SOLENOID RELAY

•

START SOLENOID RELAY (6200111 TO 6200180)

START SOLENOID RELAY

IGNITION SWITCH

317-7A

7.2

••

•

FUEL SOLENOID RELAY

START SOLENOID RELAY AND FUEL SOLENOID RELAY (6200181 TO 6200240)

Tigercat 620 Skidder

Engine start and stop drive prevent pilot valve, making pilot oil available to the drive pedals. Current also flows through wire 20, to wire 13, to the fuel solenoid hold contact.

6200180, did not have a fuel solenoid relay.

Instead, they used the start solenoid relay to supply voltage to both wire 12 and wire 54.)

Current also flows through wire 20 to wire 13 to the fuel solenoid hold contact.

FUEL CONTROL VALVE AND SOLENOID

RIGHT SIDE OF ENGINE

When the parking brake is OFF the drive enable relay coil is de-energized. Voltage is not available in wire 9 and therefore the engine cannot be started. This prevents accidental starting of the engine when the parking brake is OFF.

•

•

When the engine is running and the parking brake is ON the park brake switch is closed and the drive enable relay coil is energized through wires 6 and 11. This de-energizes the drive prevent pilot valve which removes pilot oil from the drive pedals. Once the engine is running pilot oil is immediately available to the dozer, steer, winch and grapple functions. These controls spring return to neutral and will not function unless the operator touches them. Current also flows through wire 20 to wire 13 to the fuel solenoid hold contact.

FUEL CONTROL VALVE

320-11

FUEL CONTROL VALVE There is a fuel control valve on the engine that is activated when the key is turned on. It has a pull in coil that is activated by the solenoid through wire 54 during the start procedure and a holding coil activated through wire 13 during the start procedure and when the engine is running.

When the engine is running and the parking brake is OFF the drive enable relay coil is de-energized.

Current flows through wire 33 and energizes the

••

CAUTION SOLENOID

Do not apply pressure to these controls during the starting procedure as immediate movement of the functions will occur.

••

SOLENOID

••

TO MAIN PUMP

TO MULTIFUNCTION VALVE

••

LOCATED ON RH SIDE OF FRONT CHASSIS

MAIN PUMP UNLOADING VALVE 320-2

MAIN PUMP UNLOADING VALVE To relieve the load on the engine during start-up, the main pump is destroked at a low pressure by the main pump unloading valve. It is energized through wire 35, when the main pump unloading valve switch (on the instrument panel) is in the ON position during engine starting. The main pump unloading valve improves cold weather starting ability. The parking must be engaged to activate the main pump unloading valve with the main pump unloading valve switch. The machine can be operated with this sw itch in the on position and the parking brake disengaged.

START MOTOR

•• 320-10

START MOTOR AND SOLENOID

DRIVE PREVENT PILOT VALVE

•

317-10A

DRIVE PREVENT VALVE UNDER CAB

7.3

Tigercat 620 Skidder

630-21

Engine start and stop

ENGINE START CIRCUIT SERIAL NUMBERS 6200111 TO 6200180

7.4

Tigercat 620 Skidder

Engine start and stop

START CIRCUIT -AT REST

SERIAL NUMBERS 6200181 TO 6200238

620-24

START CIRCUIT BATTERY DISCONNECT ON PARKING BRAKE ON IGNITION KEY - START POSITION

620-25

SERIAL NUMBERS 6200181 TO 6200238 7.5

Tigercat 620 Skidder

Engine start and stop

START CIRCUIT BATTERY DISCONNECT ON PARKING BRAKE ON IGNITION KEY - RUN POSITION

SERIAL NUMBERS 6200181 TO 6200238 620-26

START CIRCUIT BATTERY DISCONNECT ON PARKING BRAKE OFF IGNITION KEY -RUN POSITION

620-27

SERIAL NUMBERS 6200181 TO 6200238 7.6

Tigercat 620 Skidder

Engine start and stop

ENGINE START CIRCUIT

CIRCUIT DESCRIPTION

LATER DESIGN - WITH LOW ENGINE OIL PRESSURE SHUT-DOWN SYSTEM

With the parking brake ON, the park brake proximity switch is closed and the drive enable relay (2) coil is energized through wires 6 and 11.

(6200239 AND UP)

When the key switch is turned to the START position, voltage is supplied to the start circuit through wire 6 to the drive enable relay(2) and wire 9 to the start relay.

For detailed engine information refer to the engine manufacturer's manual.

For engine starting and stopping procedures refer to ENGINE STARTING AND STOPPING in SECTION 2 of the OPERATOR’S MANUAL.

Voltage is supplied through wire 23 to the coil of the start relay(1), which closes and supplies voltage through wire 16 to the start solenoid relay, which in turn closes and supplies voltage through wire 12 to close the start solenoid contacts and supply battery power to the starter to turn the engine. The fuel solenoid relay contacts also close and current flows through wire 54 to the fuel solenoid PULL IN contact.

The engine starting circuit is controlled by the a proximity switch located on the parking brake lever which prevents the engine from being started when the parking brake is OFF. The parking brake must be in the ON position to allow the engine to start. The engine is started by holding the bulb test/engine start switch in the ON position, turning the key to the START position and then releasing it to the RUN position after the engine starts. The the bulb test/engine start switch is also released.

START RELAY (#1) DRIVE ENABLE RELAY (#2)

• •

If the engine stalls during operation of the vehicle, the key must be turned to the OFF position to reset the ignition switch before the engine can be restarted.

Refer to START CIRCUIT DIAGRAMS in THIS SECTION for your machine serial number.

DRIVE SYSTEM RELAYS 14156BIL1

FRONT VIEW OF CONTROL PANEL

••

••

START SOLENOID RELAY

FUEL SOLENOID RELAY

320-21

PARKING BRAKE 'OFF' POSITION 317-7A

RUN OFF

START START SOLENOID RELAY

• •• •

630-D39

START SOLENOID RELAY AND FUEL SOLENOID RELAY (6301241 AND UP)

IGNITION SWITCH

317-7A

7.7

•

••

START SOLENOID RELAY AND FUEL SOLENOID RELAY (6200181 TO 6200240)

FUEL SOLENOID RELAY

Tigercat 620 Skidder

Engine start and stop

During the start procedure the BULB TEST/ ENGINE START switch must be pressed and held to allow current to flow through wires 12C and 13 which activates the HOLDING COIL in the fuel control valve. The switch can be released after engine oil pressure rises above 10 psi. At this point the engine oil pressure switch contacts open and de-energize the oil pressure override relay (14) allowing current to flow through wires13C and 13 to keep the HOLDING COIL activated.

engine oil pressure shut-down system).

When the engine is running and the parking brake is OFF the drive enable relay coil is de-energized.

Current flows through wire 33 and energizes the drive prevent pilot valve, making pilot oil available to the drive pedals. Current also flows through wire 20 to wires 13C and 13 to the fuel solenoid hold contact (unless engine oil pressure falls below 10 psi activating the low engine oil pressure shut-down system).

When the parking brake is OFF the drive enable relay (2) is de-energized. Voltage is not available in wire 9 and therefore the engine cannot be started. This prevents accidental starting of the engine when the parking brake is OFF.

RIGHT SIDE OF ENGINE

•

When the engine is running and the parking brake is ON the park brake switch is closed and the drive enable relay coil is energized through wires 6 and 11. This de-energizes the drive prevent pilot valve which removes pilot oil from the drive pedals. Once the engine is running pilot oil is immediately available to the dozer, steer, winch and grapple functions. These controls spring return to neutral and will not function unless the operator touches them. Current also flows through wire 20 to wires 13C and 13 to the fuel solenoid hold contact (unless engine oil pressure falls below 10 psi activating the low

FUEL CONTROL VALVE There is a fuel control valve on the engine that is activated when the key is turned on. It has a pull in coil that is activated by the solenoid through wire 54 during the start procedure and a holding coil activated through wire 13 during the start procedure and when the engine is running.

SOLENOID

••

Do not apply pressure to these controls during the starting procedure as immediate movement of the functions will occur.

•

SOLENOID

•

TO MAIN PUMP

TO MULTIFUNCTION VALVE

•• 320-2

START MOTOR

LOCATED ON RH SIDE OF FRONT CHASSIS

MAIN PUMP UNLOADING VALVE

MAIN PUMP UNLOADING VALVE

••

To relieve the load on the engine during start-up, the main pump is destroked at a low pressure by the main pump unloading valve. It is energized through wire 35, when the main pump unloading valve switch (on the instrument panel) is in the ON position during engine starting. The main pump unloading valve improves cold weather starting ability. The parking brake must be engaged to activate the main pump unloading valve with the main pump unloading valve switch.

The machine can be operated with main pump unloading valve switch in the ON position and the parking brake OFF.

START MOTOR AND SOLENOID

DRIVE PREVENT PILOT VALVE

••

DRIVE PREVENT VALVE 317-10A

••

FUEL CONTROL VALVE

320-11

CAUTION

320-10

FUEL CONTROL VALVE AND SOLENOID

UNDER CAB

7.8

Tigercat 620 Skidder

Engine start and stop

START CIRCUIT -AT REST

630B-12

SERIAL NUMBERS 6200239 AND UP

START CIRCUIT BATTERY DISCONNECT - ON PARKING BRAKE - ON BULB TEST/ENGINE START SWITCH - ON IGNITION KEY - START POSITION

630B-13

SERIAL NUMBERS 6200239 AND UP 7.9

Tigercat 620 Skidder

Engine start and stop

START CIRCUIT BATTERY DISCONNECT ON PARKING BRAKE ON BULB TEST/ENGINE START SWITCH - OFF IGNITION KEY - RUN POSITION

630B-14

SERIAL NUMBERS 6200239 AND UP

START CIRCUIT BATTERY DISCONNECT ON PARKING BRAKE OFF BULB TEST/ENGINE START SWITCH - OFF IGNITION KEY -RUN POSITION

630B-15

SERIAL NUMBERS 6200239 AND UP 7.10

Tigercat 620 Skidder

Engine start and stop

TACHOMETER SET-UP: NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1. Set the parking brake ON, lower the grapple and dozer to the ground and turn off the engine.

2. Remove the instrument panel to provide access to the back of the tachometer on the machine.

3. The BLACK knob (screw driver slot) on the back of the tachometer should be set to 6. (the choice are 4-6-8) 4. Place a piece of reflecting tape on the damper pulley. (on the front of the engine by the fan) 5. Using an electronic photo tachometer on the damper pulley, adjust the throttle control to give an engine speed of 2200 rpm on the photo tachometer.

6. Set the tachometer on the instrument panel to 2200 rpm using an allen key in the hole on the back of the tachometer.

7. Reduce the engine rpm to IDLE and then back to 2200 rpm, using the photo tachometer.

8. Check the instrument panel tachometer for 2200 rpm. Readjust if necessary.

9. Turn off the engine and replace the instrument panel, being careful not to pinch the wiring on the back of the panel.

7.11

Tigercat 620 Skidder

Engine start and stop

7.12

Tigercat 620 Skidder SECTION 8 - DRIVE OCTOBER 2003

CONTENTS - SECTION 8 AXLES .......................................................................................................... 8.46 CAPACITIES ............................................................................................ 8.49 DIFFERENTIAL AND DIFFERENTIAL LOCKS ........................................ 8.47 DRAINING THE AXLES ............................................................................ 8.48 FILLING THE AXLES ................................................................................ 8.48 FILLING THE AXLES, ALTERNATE METHOD ........................................ 8.49 LUBRICATION .......................................................................................... 8.48 OIL CAPACITIES ...................................................................................... 8.49 OSCILLATION SHIM CHECK AND ADJUSTMENT (FRONT AXLE) ....... 8.51 SERVICE BRAKES (FRONT AXLE ONLY) BRAKE BLEEDING ............................................................................... 8.48 BRAKE LINING INSPECTION .............................................................. 8.48 SERVICING BRAKES ........................................................................... 8.47 CIRCUIT DESCRIPTION ............................................................................... 8.3 DRIVE SYSTEM CHECK VALVE ......................................................................................... 8.15 DRIVE CIRCUIT DIAGRAM REXROTH PUMP AND MOTORS (6200111 TO 6200150) ................... 8.16 REXROTH PUMP AND MOTORS (6200151 TO 6200230) .................. 8.17 SAUER PUMP AND REXROTH MOTORS ........................................... 8.31 DRIVE FOOT CONTROL VALVE ............................................................. 8.12 DRIVE MOTOR DESCRIPTION ............................................................... 8.10 DRIVE MOTOR SCREW ADJUSTMENTS ............................................... 8.25 DRIVE PREVENT VALVE ......................................................................... 8.13 DRIVE PUMP DESCRIPTION - REXROTH ................................................ 8.4 DRIVE PUMP DESCRIPTION - SAUER PUMP .......................................... 8.7 DRIVE PUMP PRESSURE SETTINGS .................................................... 8.21 DRIVE SPEED CONTROL VALVE ........................................................... 8.14 HYDRAULIC SET-UP - REXROTH PUMP / REXROTH MOTORS DRIVE MOTOR PRESSURE ADJUSTMENT ....................................... 8.23 DRIVE PUMP PRESSURE ADJUSTMENT ................................ 8.20, 8.23 MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ........... 8.24 MOTOR MINIMUM DISPLACEMENT ADJUSTMENT .......................... 8.23 MOTOR PRESSURE OVERRIDE ADJUSTMENT (P.O.R.) .................. 8.27 HYDRAULIC SET-UP - SAUER PUMP/ REXROTH MOTORS DRIVE MOTOR PRESSURE ADJUSTMENT ....................................... 8.38 DRIVE PUMP PRESSURE ADJUSTMENT .......................................... 8.35 MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ........... 8.39 MOTOR MINIMUM DISPLACEMENT ADJUSTMENT .......................... 8.38 MOTOR PRESSURE OVERRIDE ADJUSTMENT (P.O.R.) .................. 8.42 HYDRAULIC OIL HEATING PROCEDURE ................................................. 8.15

continued ...

Tigercat 620 Skidder

Drive

SECTION 8 - DRIVE TEST DRIVE - REXROTH PUMP AND REXROTH MOTORS BEGIN OF DISPLACEMENT CONTROL PRESSURE ............................. 8.18 DIFFERENTIAL LOCKS ........................................................................... 8.19 HORSEPOWER ....................................................................................... 8.19 MOTOR PRESSURE OVERRIDE (POR) ................................................. 8.18 STEERING OPERATION ......................................................................... 8.19 TEST DRIVE - SAUER PUMP AND REXROTH MOTORS BEGIN OF DISPLACEMENT CONTROL PRESSURE ............................. 8.32 DIFFERENTIAL LOCKS ........................................................................... 8.33 GROUND SPEED ..................................................................................... 8.34 HORSEPOWER ....................................................................................... 8.33 MOTOR PRESSURE OVERRIDE (POR) ................................................. 8.32 STEERING OPERATION ......................................................................... 8.33 TRANSMISSION .......................................................................................... 8.45 TRANSMISSION IDENTIFICATION .................................................. 8.34, 8.35 WHEEL INSTALLATION .............................................................................. 8.50 TAPERED ASSEMBLY STUD .................................................................. 8.51

8.2

Tigercat 620 Skidder

Drive

HYDROSTATIC DRIVE SYSTEM

A hydraulic system is termed closed loop when the hydraulic oil returning from the motor is fed straight back to the pump without first returning to tank. When the machine is travelling forward, one side of the closed loop is a high pressure supply while the other side is a low pressure return. The supply and return will alternate from side to side of the closed loop as the direction of travel of the vehicle goes from forward to reverse.

The primary components of the 620 hydrostatic drive system are a hydraulic pump and two hydraulic motors connected together by two hydrostatic hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This high pressure flow of hydraulic oil is then transmitted to the hydraulic motor through the first connecting hose. The motor then reconverts the hydraulic power back into the mechanical power used to propel the machine. Low pressure hydraulic oil flow then returns from the motor to the pump through the other connecting hose thereby completing a continuous closed loop hydraulic circuit.

Hydrostatic drives are used because they offer enhanced operator control of vehicle speed and tractive effort. As well hydrostatic drive systems give flexibility in the positioning of components within the machine when compared to mechanical drive systems.

BENT AXIS PISTON MOTOR

TO VEHICLE DRIVE

HIGH PRESSURE SUPPLY

SWASHPLATE, AXIAL PISTON PUMP

FROM DIESEL ENGINE

BENT AXIS PISTON MOTOR LOW PRESSURE RETURN

620-03

TO VEHICLE DRIVE

CONTINUOUS CLOSED LOOP HYDRAULIC CIRCUIT

8.3

Tigercat 620 Skidder

Drive

REXROTH DRIVE PUMP

DOUBLE ELEMENT FILTERS

(6200111 TO 620230) The hydrostatic drive pump is mounted at the top right of the pump drive gearbox. A spline adapter connects the input driveshaft of the pump directly to the output of the gearbox. The gearbox is driven directly by the diesel engine through a flexible plate coupling.

DRIVE PUMP MAIN PUMP DOZER, STEER & GRAPPLE

•

•• •

620-07

COOLING PUMP

PUMPS AND FILTERS

The drive footpedal control valve directs oil from the charge pump and sends a pressure signal to shift the spool in the swashplate control valve.

This changes the position of the control cylinder which is directly connected to the swashplate of the piston pump. The angle and direction that the swashplate moves determines the speed and direction of travel of the vehicle. The angle and direction that the swashplate moves is directly proportional to the position of the drive footpedal

The secondary pump is a fixed displacement, internal gear type which provides charge oil (make-up oil) for the hydrostatic pump and motors in the closed loop system. The charge pump also provides pilot oil to the pilot manifold, drive pedals and speed control (if equipped), joystick control valve, dozer control valve and winch control valve.

SWASHPLATE CONTROL VALVE

DRIVE PUMP CHARGE PRESSURE FILTER

BLUE ELEMENT

The primary pump is a variable displacement, swashplate, axial piston type. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume and direction of oil flow from the piston pump is determined by the angle of this swashplate. When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow in one direction in the closed loop.

As the swashplate is de-stroked the flow smoothly decreases until there is no flow at an angle of zero (0o). Continuing to angle the swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

CONTROL CYLINDER

•

•

The hydrostatic drive pump is actually two separate hydraulic pumps mounted in a common case and driven by the same input driveshaft.

DRIVE SHAFT

•

•

CHARGE PUMP

'B' PORT RELIEF

PORT 'B'

PORT 'B' CHARGE PUMP RELIEF

A

AP024-F AP024-G

'A' PORT RELIEF SWASHPLATE

SPLINED SHAFT

PORT 'A'

VIEW A

PORT 'A'

DRIVE PUMP SECTION(REXROTH) 8.4

PRESSURE OVERRIDE VALVE (P.O.R.)

Tigercat 620 Skidder 'B' PORT RELIEF 5 MM ALLEN KEY 17 MM WRENCH

Drive

•

GAUGE TEST PORT 'M B' • PORT SIZE - 04 ORB 'TEE' GAUGE TEST PORT (G) • PORT SIZE - 04 JIC

•• •

CHARGE PRESS. RELIEF • 5 MM ALLEN KEY • 17 MM WRENCH

• •• GAUGE TEST PORT 'M A' • PORT SIZE - 04 ORB 'A' PORT RELIEF 5 MM ALLEN KEY 17 MM WRENCH

••

REXROTH - DRIVE PUMP

320-4X

TO DRIVE PEDAL CONTROL VALVE

TO MOTOR (A)

TO MOTOR (B) P.O.R. VALVE

R F P

CHARGE PUMP RELIEF HIGH PRESSURE RELIEF VALVE 'B'

SWASHPLATE CONTROL VALVE

HIGH PRESSURE RELIEF VALVE 'A'

CONTROL CYLINDER HYDROSTATIC PUMP (PISTON) CHARGE PRESSURE FILTER

CHARGE PUMP (GEAR)

MA TEST PORT

726B05

MB TEST PORT

DRIVE PUMP SCHEMATIC (REXROTH) 8.5

Tigercat 620 Skidder

Drive

and may be limited by the use of the speed control valve. When neither of the drive footpedals are depressed, pilot oil is not supplied to the swashplate. The swashplate therefore remains in the neutral position and no oil is pumped by the piston pump.

closed loop.

The charge pump continuously introduces oil from the hydraulic tank back into the hydrostatic drive system. The charge pump relief valve maintains a constant pilot pressure for use by the swashplate control system. In addition, the charge pump oil is used as make up oil to the low pressure side of the closed loop to replenish losses due to internal leakage in the hydrostatic pump and motor. This same flow acts as a cooling fluid for the piston pump and motors to ensure peak hydrostatic drive performance and long service life.

The speed control valve limits the maximum speed of the vehicle by reducing the flow of pilot oil to the drive pedal, allowing the operator to maintain a given speed without the need to feather the footpedals. Note that some early machines are not equipped with the speed control valve.

Excess charge pump oil is relieved by the charge pump relief valve back into the case of the piston pump. The charge pump pressure filter ensures that only clean charge pump oil is introduced into the closed loop hydrostatic circuit and the swashplate control system. Should this pressure filter become clogged with debris, charge pump flow is diverted to tank thus preventing the entry of unfiltered charge pump oil.

The drive footpedal control valve only functions when the parking brake lever is in the OFF position. This prevents driving the machine when the parking brake is applied. A proximity switch is attached to the parking brake lever. When this lever is in the OFF position, the proximity switch contacts are open, de-energizing the drive enable relay and energizing the drive prevent valve. With the drive prevent valve energized, drive footpedal oil can be directed to either the forward or reverse side of the pump swashplate control valve as required. With the drive prevent valve deenergized, drive footpedal oil is directed to tank the drive pump displacement control valve does not move and the pump swashplate angle remains at zero (0o).

The hydrostatic piston pump is equipped with a pressure override (P.O.R.) valve to protect the closed loop hydrostatic drive components from excessive pressure. When the tractive effort requirements of the vehicle are demanding then pressure on the high side of the closed loop can reach maximum. At this pressure the P.O.R. valve signals the swashplate control valve to destroke the swashplate, reducing piston pump flow and maintaining system pressure at the P.O.R. setting.

The P.O.R. prevents continuous dumping of high pressure oil across the piston pump high pressure relief valves. This eliminates unnecessary heating of the oil and protects the pump and motors during rapid acceleration and deceleration or when the drive system stalls.

The two high pressure relief valves at ‘A’ and ‘B’ ports are intended only to act as pressure limiting safety devices in the event that the P.O.R. valve malfunctions or does not respond quickly enough to high pressure surges. For this reason the high pressure relief valves are always adjusted higher than the P.O.R. valve setting. The high pressure relief valves always dump oil from the high pressure to the low pressure side of the closed loop thereby keeping the hydraulic oil within the 8.6

Tigercat 620 Skidder

Drive

SAUER DRIVE PUMP

swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

(6200231 AND UP) The hydrostatic drive pump is mounted at the top right of the pump drive gearbox. A spline adapter connects the input driveshaft of the pump directly to the output of the gearbox. The gearbox is driven directly by the diesel engine through a flexible plate coupling. The drive pump provides high pressure flow of hydraulic oil to the two drive motors.

The hydrostatic piston pump is equipped with two pressure override (POR) valves at ports A and B to protect the closed loop hydrostatic drive components from excessive pressure. When the tractive effort requirements of the vehicle are demanding, pressure on the high side of the closed loop can reach maximum. At this pressure the POR. valve signals the swashplate control valve to destroke the swashplate, reducing piston pump flow and maintaining system pressure at the POR. valve setting. Each P.O.R. valve incorporates an internal nonadjustable high pressure relief valve. The two high pressure relief valves at ‘A’ and ‘B’ ports are intended only to act as pressure limiting safety devices in the event that the P.O.R. valve malfunctions or does not respond quickly enough to high pressure surges.

The P.O.R. valve prevents continuous dumping of high pressure oil across the piston pump high pressure relief valves. This eliminates unnecessary heating of the oil and protects the

The Sauer hydrostatic drive pump is actually two separate hydraulic pumps mounted in a common case and driven by the same input driveshaft.

The primary pump is a variable displacement, swashplate, inline axial piston type pump. The volume and direction of oil flow from the piston pump is determined by the angle of the tiltable swashplate. When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow in one direction in the closed loop. As the swashplate is de-stroked, the flow smoothly decreases until there is no flow at an angle of zero (0°). Continuing to angle the

'A' P.O.R.VALVE

'TEE' GAUGE TEST PORT (M3) • PORT SIZE - 04 JIC

••

5/16" ALLEN KEY 15/16" WRENCH

'B' P.O.R. VALVE

••

5/16" ALLEN KEY 15/16" WRENCH

•

CHARGE PRESS. RELIEF • 13MM WRENCH • 1 1/4" WRENCH

••

GAUGE TEST PORT 'M1' • PORT SIZE - 06 JIC

••

GAUGE TEST PORT 'M2' • PORT SIZE - 06 JIC

•• 333-9

SAUER - DRIVE PUMP 8.7

Tigercat 620 Skidder

Drive

pump and motors during rapid acceleration or deceleration and drive system stalls. For this reason the high pressure relief valves are automatically set to a higher pressure than the P.O.R. valve setting and are nonadjustable. The high pressure relief valves always dump oil from the high pressure to the low pressure side of the closed loop, keeping the hydraulic oil within the closed loop.

SWASHPLATE CONTROL VALVE

M2 TEST PORT

•

DRIVE SHAFT

• •

•

The secondary pump is a fixed displacement, internal gear type that provides charge oil (makeup oil) for the hydrostatic pump and motors in the closed loop system. The charge pump also provides pilot oil to the pilot manifold, drive foot controls and speed control (if equipped), joystick control valve, dozer control valve and winch control valve.

• M1 TEST PORT

SWASHPLATE

DRIVE PUMP (SAUER)

AP105-1

foot controls are depressed, pilot oil is not supplied to the swashplate. The swashplate therefore remains in the neutral position and no oil is pumped by the piston pump.

OPERATING DESCRIPTION The drive foot control valve directs oil from the charge pump and sends a pressure signal to shift the spool in the swashplate control valve. This changes the position of the control cylinder, which is directly connected to the swashplate of the piston pump. The angle and direction that the swashplate moves determines the speed and direction of travel of the vehicle. The angle and direction that the swashplate moves is directly proportional to the position of the drive foot control and may be limited by the use of the speed control valve. When neither of the drive

The speed control valve limits the maximum speed of the vehicle by reducing the flow of pilot oil to the drive pedal, allowing the operator to maintain a given speed without the need to feather the foot controls. Note that some early machines are not equipped with the speed control valve.

The drive foot control valve only functions when the parking brake lever is in the OFF position.

This drive prevent circuit will not allow the machine to be driven with the parking brake ON.

CHARGE PRESSURE FILTER

TO PILOT MANIFOLD (P4) CHARGE PUMP FROM DRIVE FOOT CONTROL VALVE

REVERSE

SWASHPLATE CONTROL VALVE

FORWARD

CHARGE PUMP RELIEF

TO MOTORS GAUGE TEST PORT 'A'

CHARGE PUMP

GAUGE TEST PORT 'B'

TO MOTORS HIGH PRESSURE RELIEFS 'A' AND 'B'

AP105-2

CHARGE PUMP

CONTROL CYLINDER

P.O.R VALVES 'A' AND 'B'

CONTROL CYLINDER

DRIVE PUMP SCHEMATIC (SAUER) 8.8

Tigercat 620 Skidder

Drive

A proximity switch is attached to the parking brake lever. When this lever is in the OFF position, the proximity switch contacts are open, de-energizing the drive enable relay and energizing the drive prevent valve. With the drive prevent valve energized, drive foot control oil can be directed to either the forward or reverse side of the pump swashplate control valve as required. With the drive prevent valve de-energized, drive foot control oil is directed to tank the drive pump displacement control valve does not move and the pump swashplate angle remains at zero (0o).

The charge pump continuously introduces oil from the hydraulic tank back into the hydrostatic drive system via a charge pressure filter. The charge pump relief valve maintains a constant pilot pressure for use by the swashplate control system. Excess charge pump oil is relieved by the charge pump relief valve back into the case of the piston pump and used as make up oil. Make up oil goes to the low pressure side of the closed loop to replenish losses due to internal leakage in the hydrostatic pump and motor. The flow of make-up oil acts as a cooling fluid for the piston pump and motors to ensure peak hydrostatic drive performance and long service life. The charge pressure filter ensures that only clean charge pump oil is introduced into the closed loop hydrostatic circuit and swashplate control system.

Should the charge pressure filter become clogged with debris, charge pump flow is diverted to tank thus preventing the entry of unfiltered charge pump oil.

For pressure setting procedures see DRIVE SYSTEM PRESSURE SETTINGS - SAUER PUMP AND REXROTH MOTORS in THIS SECTION.

8.9

Tigercat 620 Skidder HYDROSTATIC DRIVE MOTOR

Drive displacement control cylinder thus increasing displacement to maximum.

Two motors are used to drive the skidder. They are mounted to the input side of the transmission.

A splined coupling connects the motor shaft to the transmission input shaft.

The spool in the P.O.R. valve is moved by system pressure from the high pressure side of the loop.

When the P.O.R. spool moves as a result of high pressures it reduces the pressure directed to the displacement control cylinder. The reduced pressure will cause the displacement control piston to move. The point at which the displacement control spool begins to move is known as "begin of displacement regulation set point".

The motor is an axial piston, variable displacement type. It forms a closed loop circuit with the pump.

High pressure oil from the pump enters the motor via port 'A' or port 'B', depending on the direction of travel. The oil is directed to the back of a set of pistons in the motor's rotary group. The pistons push against the back of the drive shaft at an angle causing it to rotate.

The MOTOR P.O.R. must be correctly set for the system to function properly. SEE REXROTH

The angle of the pistons relative to the drive shaft determine the speed of the motor and the available torque. Reducing the angle provides increased speed with less torque. Increasing the angle will reduce the speed and provide more torque.

The angle of the pistons is variable and is changed by an internal control cylinder that receives high pressure oil via the MOTORS' pressure override valve (P.O.R.) and a displacement control spool.

The displacement control spool is operated by pilot pressure from the forward and reverse foot pedals. When sufficient pressure from the pedals is directed to the spool, it shifts against a spring and directs oil past the P.O.R. valve to the displacement control cylinder thus decreasing the displacement of the motor. Removal of the pressure signal from the foot pedals will cause the displacement control spool to return to the neutral position, shutting off the pressure to the MINIMUM DISPLACEMENT ADJUSTING SCREW

•

DRIVE SHAFT

FROM PUMP AQ010-2

DRIVE MOTOR SCHEMATIC

P.O.R. ADJUSTING SCREW

•

•

FROM PUMP

• PORT 'X'

BEGIN OF DISPLACEMENT ADJUSTING SCREW

•

PORT 'B'

•

PORT 'A'

'A'

AQ010-5Y

AQ010-1

PORT 'M1'

ROTATING GROUP

•

•

FLUSHING VALVE

DRIVE MOTOR ~ REXROTH (160CC SIZE) 8.10

VIEW 'A'

Tigercat 620 Skidder

Drive

HYDROSTATIC DRIVE MOTOR PRESSURE SETTINGS in this section.

A minimum displacement adjusting screw on the outside of the motor housing limits the maximum speed of the motor.

WARNING: Improper adjustment of minimum displacement adjusting screw can result in motor and transmission failure due to overspeeding.

When installing a new motor always ensure stroke limiting screw is set correctly. Refer to SET MOTOR MINIMUM DISPLACEMENT, in this section.

A flushing valve is incorporated into the motor.

This valve provides a regulated flow of oil from the low pressure side of the loop in the motor case. This action reduces the possibility of particle build up in the loop by providing a continuous change of oil, it also assists with cooling. This valve is factory set and requires no adjusting.

8.11

Tigercat 620 Skidder

Drive

DRIVE PEDAL PILOT VALVE •

5

• •

4

•

2

3

•

1

•

• • •

•

8

'P' PORT

AU013-1

SPOOL ARRANGEMENT

AU013-2

OPERATING DESCRIPTION

2

1

WORK PORTS 1, OR 2

In the neutral position the foot pedal is held centered by return spring (4).

P AU004

T

When the pedal (1) is operated, the plunger (5) is pushed against the return spring (4).

DRIVE PILOT VALVE

At the same time the regulating spool (2) is moved through the regulating spring (3).

This pilot valve is a manually operated directional valve and operates on the same principal as a direct operating pressure reducing valve. The footpedal, control lever and joystick valves use similar spool arrangements

When the regulating stroke begins, there is a connection from port 'P' via hole (8) in the spool and work ports 1 and 2 in the base of the valve, to the swashplate control valve on the drive pump.

Operated by foot, this valve directs pilot pressure to the swashplate control valve on the drive pump to drive the machine either forward or reverse

Flow is directly proportional to the operator position of the foot pedal and the regulating spring characteristic.

8.12

Tigercat 620 Skidder DRIVE PREVENT VALVE

Drive

DRIVE PREVENT VALVE

317-10A

The drive prevent valve is located under the cab.

This solenoid operated spool valve prevents the machine from being driven either forward or reverse when the parking brake is ON. OPERATING DESCRIPTION When the solenoid valve is de-energized (parking brake ON) the spool connects the pilot pressure line on the foot control to tank. This prevents the foot pedal from supplying pilot pressure to the drive pump displacement controller.

When the solenoid valve is energized (parking brake OFF), the spool shifts and connects pilot pressure to the foot control. This allows the foot control (forward or reverse) to send pilot pressure to the drive pump displacement controller, causing the hydrostatic drive pump to provide flow to the drive motors.

SOLENOID AND CONNECTOR

90016-2

• • C B SPOOL SECTION

A

•

PORT 'A' PILOT PRESSURE PORT 'C' TO FOOT PEDAL

• AT022

TANK PORT 'B'

DRIVE PREVENT VALVE

8.13

Tigercat 620 Skidder

Drive

SPEED CONTROL LEVER VALVE •

5

• •

4

•

2

3

•

1

•

• • •

•

8

'P' PORT WORK PORTS 1, 2 AU013-1

SPOOL ARRANGEMENT

AU013-2

OPERATING DESCRIPTION When the lever (1) is operated, plunger (5) is pushed against the return spring (4). The friction clutch makes the lever infinitely adjustable.

At the same time, control spool (2) is moved by control spring (3).

AW020

As the spool moves down, the control chamber to tank connection is closed. As the spool continues to move, the connection between input pressure (P) and the control chamber is opened and the pressure is then able to build up in the control chamber.

SPEED CONTROL LEVER VALVE

This pilot valve is a manually operated directional control valve and operates on the same principal as a direct operating pressure reducing valve.

The control lever, the joystick and foot control valves use similar spool arrangements.

Once the pressure equals the value set by control spring (3), the control spool closes the loop and there is a connection to work port 2.

Oil flow is directly proportional to the position of the control lever setting by the operator and the control spring (3) characteristics.

This control valve is used to control the amount of pilot oil supplied to the drive pedal control valve, limiting the maximum speed of the vehicle and allowing the operator to maintain a given speed without having to feather the drive pedals. When the lever is pushed fully forward oil is supplied to the drive pedal at pilot pressure (450 psi). When pulled all the way back no pilot pressure is supplied to the foot pedals. The speed control lever has a friction clutch which is infinitely adjustable and can be used while the machine is in motion.

8.14

Tigercat 620 Skidder

Drive HYDRAULIC OIL HEATING PROCEDURE

CHECK VALVE

There is a specific procedure to heat up the hydraulic oil in the machine in preparation for setting up Hydraulic pressures.

CHECK VALVE

1. Set the parking brake ON, grapple/dozer down and the engine off.

2. Connect a 0-5000 psi gauge to the 'P3' test port.

3. Start the engine (full throttle). Place a sheet of cardboard in front of the oil cooler side of the heat exchanger. The radiator must remain uncovered to prevent engine overheating.

••

4. Adjust the port relief valve to 1500 psi, on EITHER the dozer blade up or the grapple open.

WARNING 317-17A

Do not exceed 1500 psi, or overheating and damage of the valve will result.

CHECK VALVE

An inline check valve is located between the X port of the motors and the P port in the drive pedal control valve. This check valve has a 5 psi cracking pressure and corrects for pressure differences caused when the speed control valve is used to stop the flow of pilot oil while the machine is in motion. It directs oil from the motor X port back to the drive pedal control valve when there is a pressure difference of more than 5 psi.

5. Operate EITHER the dozer blade up or grapple open function (which ever you selected) and HOLD in the operating position, while monitoring the ENGINE coolant temperature and the HYDRAULIC oil temperature on the panel gauges. This should be done at full throttle and will take 3 to 9 minutes.

WARNING DO NOT leave the machine while heating the oil, as overheating of engine or oil can cause serious damage.

6. Ensure that the hydraulic oil temperature is between 120F and 140F. 7. Once the hydraulic oil is up to temperature, proceed to required hydraulic set-up procedure.

WARNING The temperature rises quickly when setting relief valves. Remove the cardboard blocking the oil cooler if necessary to maintain the proper temperature. Do not pass oil over relief valves for longer than 5 seconds at a time during set-up procedures. Damage to valves can occur from excessive heat.

8.15

Tigercat 620 Skidder

620-19

Drive

DRIVE CIRCUIT - REXROTH PUMP AND REXROTH MOTORS WITHOUT SPEED CONTROL SERIAL NUMBERS 6200111 TO 6200150 8.16

Tigercat 620 Skidder

620-04

Drive

DRIVE CIRCUIT - REXROTH PUMP AND REXROTH MOTORS WITH SPEED CONTROL SERIAL NUMBERS 6200151 TO 6200230 8.17

Tigercat 620 Skidder

Drive

TEST DRIVE

LM1

REXROTH PUMP AND REXROTH MOTORS

RM1

X

The test drive will verify the following:

••

1. Motor begin of displacement control pressure: 125-135 psi.

•• ••

2. Motor pressure override (P.O.R.): 4150 psi and (half of ‘Ma’) - 2075 psi.

3. Steering check; slow and fast.

TEST PORT COMPARTMENT

620-M6

4. Front and rear differential lock functions.

5. Horsepower/engine stall test.

Install three 0-10,000 psi gauges on ‘LM1’ and 'RM1' test ports in the TEST PORT COMPARTMENT and ‘Ma’ on the HYDROSTATIC PUMP. Install a 0-1,000 psi gauge on ‘X’ test port in the TEST PORT COMPARTMENT.

GAUGE TEST PORT 'M A' • PORT SIZE - 04 ORB

NOTE: Fasten these four gauges so they can be easily viewed from the operator’s seat in the cab.

Fasten your seat belt and move the machine to a suitable test area, where it can be safely driven at full speed for approximately 150 feet. Grapple UP, CLOSED and ROTATED TO CENTER. Dozer blade UP.

• 320-4

IMPORTANT: Foot brake must only be applied for 5-10 seconds followed each time by a minimum 20 second cool down period. Failure to do so will result in 'burn out' of front axle brake.

1.

REXROTH DRIVE PUMP

BEGIN OF DISPLACEMENT CONTROL PRESSURE

A. Turn ON both front and rear differential locks.

Set throttle control to FULL. B. Drive the machine FORWARD, using the foot pedal, to get 130 psi at ‘X’.

The foot brakes may have to be applied to create approximately 2000 psi at ‘Ma’ on the PUMP.

308-2

C. While doing the above, observe the TWO ‘M1’ gauges and adjust forward foot pedal, up or down until a reading of 1000 psi (half of ‘Ma’) just starts to appear on both the ‘LM1’ and 'RM1' gauges. Read the ‘X’ pressure gauge which is showing the begin of displacement pressure and it should be 125135 psi. Both motors (‘LM1’ and 'RM1' gauges) should rise to 1000 psi within the 125-135 psi range on the ‘X’ gauge, if the set-up is correct.

2.

FASTEN GAUGES FOR VIEWING FROM THE OPERATOR'S SEAT MOTOR PRESSURE OVERRIDE (P.O.R.):

A. Turn ON both front and rear differential locks.

Set throttle control to FULL. B. Drive the machine FORWARD in a straight line with FULL DRIVE PEDAL. The ‘X’ gauge should show 450 psi (charge pressure).

Apply foot brake to slow machine down to approximately half maximum speed but NO SLOWER than half speed.

C. While doing the above, observe the pressure at ‘Ma’. It should read the P.O.R. setting of 4150 psi. Also read the pressure at both 'LM1' and 'RM1' gauges, it should be

Note: This test may have to be done a few times to get a proper reading.

8.18

Tigercat 620 Skidder approximately half of ‘Ma’ 2075 psi. The engine should lug down to 2150-2200 rpm during this test. If the rpm stays above 2200 rpm during the test, check the hydrostatic pump.

Note: This test may have to be done a few times to get a proper reading.

3.

STEERING OPERATION

A. Disengage the parking brake, turn OFF both front and rear differential locks, NO foot brake applied and set throttle control to FULL. Turn the steering wheel completely one way until it hits the stop.

B. Turn the steering wheel the opposite way, as SLOWLY as possible, until it hits the end stop. This should take 7 1/2 to 8 turns of the wheel.

C. Turn the wheel back SLOWLY to the other end stop, very slowly to verify the 7 1/2 to 8 turns.

D. Turn the wheel back to the other end stop, as FAST as possible. Resistance to turning the wheel will be felt during this operation. This should take 3 1/2 to 4 turns of the wheel.

E. Turn the wheel back to the other end stop, as FAST as possible to verify the 3 1/2 to 4 turns from one stop to the other.

F.

5.

DIFFERENTIAL LOCKS

A. Bring the machine to a full stop, set throttle to IDLE, ensure that both front and rear differential locks are turned OFF. Steer the machine without depressing the drive pedal.

HORSEPOWER

A. To check engine horsepower it is necessary to temporarily reset dozer pressure to 1500 psi.

B. Park machine on level ground, set parking brake ON, grapple DOWN, dozer DOWN and shut off the engine.

C.

Connect a 0-5000 psi gauge to the ‘P3’ port.

D. Ensure that the hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in this SECTION. E. Start the engine, hold down the brake pedal and set the throttle control to FULL. F.

With the aid of an assistant operate the dozer UP control and hold pressure.

G. Adjust the dozer UP, port relief valve to give a reading of 1500 psi on the gauge.

H. Turn off engine, remove gauges, reinstall plugs on the test ports.

I.

Start the engine, set throttle control to FULL. Set parking brake OFF, grapple UP and dozer UP.

J.

Drive the machine FORWARD in a straight line with FULL DRIVE PEDAL. Apply service brakes to slow machine down to 2200 RPM and hold. While driving, pull the dozer blade control lever FULLY BACK to raise and hold the dozer blade.

If these values are not obtained, check the priority valve and/or steering control unit.

For additional information on the steering system refer to SECTION 11 of THIS MANUAL.

4.

Drive

K. While doing the above, observe the engine rpm. The engine should lug down to between 1500 rpm and 1700 rpm and should not stall.

L. IMPORTANT: Dozer pressures must be reset to normal levels after this test. See PRESSURE SETTINGS PROCEDURE in SECTION 14 of the SERVICE MANUAL. Note: This test may have to be done a few times to get a proper reading.

All wheels should rotate as machine is being steered. Steer several times, check all wheels.

B. Turn only the front differential lock switch ON. While steering the machine, both front wheels should slide instead of rotating. Rear wheels should still rotate.

C. Turn front differential lock switch OFF. D. Turn only the rear differential lock switch ON. While steering the machine, both rear wheels should slide.

8.19

Tigercat 620 Skidder DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS

Drive LM1

RM1

X

REXROTH PUMP AND REXROTH MOTORS

••

IMPORTANT The adjustment or set-up procedure is a series of steps that must be done in a proper sequence to achieve optimum performance from the machine. Any deviation from the procedures could present a safety hazard, damage components and/or affect the operation of the machine.

TEST PORT COMPARTMENT 3. Connect a 0-10,000 psi gauge to port ‘Ma’ and ‘Mb’ on the HYDROSTATIC DRIVE PUMP, and a 0-1000 psi gauge to the tee connection from port ‘G’ on the HYDROSTATIC DRIVE PUMP. Also connect a 0-1000 psi gauge on the ‘X’ port in the TEST PORT COMPARTMENT. 620-M6

Also refer to Chart 1 - DRIVE PUMP PRESSURE SETTINGS in THIS SECTION. NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

4. Disconnect parking brake switch power wire from the switch.

NOTE: Relief valves are set by loosening the locknut and turning the adjusting screw OUT (counter-clockwise) to reduce the pressure setting and IN (clockwise) to increase the pressure setting.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected from the parking brake. Also, avoid the risk of unintentionally driving the machine with the auxiliary brake set-up caliper engaged.

Driving the machine with either brake engaged will result in overheating of the brakes which could cause a fire in the machine.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock pin is held securely in place by the lynch pins provided.

5. Start the engine, set throttle control to FULL and set the charge pressure relief valve on the pump to 450 - 460 psi (0 - 1000 psi gauge at ‘G’ port).

1. Set parking brake ON, adjust speed control (if equipped) to the fully forward position, lower grapple and dozer and shut off the engine.

6. Turn both of the high pressure relief valve adjusting screws (A) and (B) on the PUMP to an ‘X’ dimension of 3/32” to 1/8” (0.094" 0.125") (2.38mm - 3.18mm) above the locknut and lock down.

2. Adjust auxiliary brake set-up caliper to 50 lbf/ft, to lock the rotating Brake disc.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF/FT.

'X'

•

TYPICAL 'X' DIMENSION FOR MAIN RELIEF AND P.O.R. VALVES 7. Turn the PUMP P.O.R. to an ‘X’ dimension of 5/8" to 21/32”(.625-.656”) (15.88-16.67mm) above the locknut and lock down.

DIM X

336-3AX

•• •

AUXILIARY BRAKE SET-UP CALIPER 8.20

Tigercat 620 Skidder

Drive reading at the ‘X’ port in the TEST PORT COMPARTMENT using both the REVERSE drive and FORWARD drive pedals.

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

•• •• • REVERSE LIMITING SCREW

FORWARD LIMITING SCREW

FORWARD AND REVERSE DRIVE PEDALS 189-10

DRIVE MOTORS

296-9

8. With the aid of an assistant, hold down the brake pedal, and while fully depressing the REVERSE foot pedal, set the PUMP P.O.R. to 4150 psi. @ full throttle on the ‘Mb’ gauge.

9. To set the drive pump port reliefs (forward, ‘Ma’ and reverse, ‘Mb’), it is ALSO necessary to temporarily achieve a 135 psi pressure

10. Adjust the REVERSE drive pedal stroke limiting screw (located under pedal) UPWARDS to limit the stroke of the pedal.

With the aid of an assistant, hold down the brake pedal and while fully depressing the REVERSE foot pedal, observe the pressure reading at the ‘X’ test port. It must read

Chart 1 - DRIVE PUMP PRESSURE SETTINGS MACHINE

PUMP

P.O.R. (FOR. AND REV.)

MAIN RELIEFS (FOR. AND REV.)

CHARGE PRESSURE

MOTOR

620

AP024 (90CC)

6200 - 6250 PSI @ FULL THROTTLE

6850-6900 PSI @ FULL THROTTLE

450-460 PSI @ FULL THROTTLE

AQ010 (160 CC)

'B' PORT RELIEF 5 MM ALLEN KEY 17 MM WRENCH ‘X’ DIMENSION = Î 3/32” - 1/8” OR: Î (0.094" - 0.125") Î (2.38MM - 3.18MM)

P.O.R. VALVE ‘X’ DIMENSION = Î 5/8"- 21/32” OR: Î (.625-.656”) Î (15.88-16.67MM) • 4 MM ALLEN KEY • 13 MM WRENCH

•

••

GAUGE TEST PORT 'MB' • PORT SIZE - 04 ORB

'TEE' GAUGE TEST PORT (G) • PORT SIZE - 04 JIC

•

320-1

••

PUMP P.O.R. VALVE

CHARGE PRESS. RELIEF • 5 MM ALLEN KEY • 17 MM WRENCH

• • GAUGE TEST PORT 'M A' • PORT SIZE - 04 ORB

•• 320-4X

DRIVE PUMP- REXROTH 8.21

'A' PORT RELIEF ‘X’ DIMENSION = Î 3/32” - 1/8” OR: Î (0.094" - 0.125") Î (2.38mm - 3.18mm) 5 MM ALLEN KEY 17 MM WRENCH

Tigercat 620 Skidder

Drive

135 psi @full throttle for 15 seconds, to ensure that the reading is correct. If it is not correct, repeat the procedure until it is correct. Repeat for forward drive pedal.

pressure) for 15 seconds, to ensure that the reading is correct. If it is not correct, repeat the procedure until it is correct. Repeat for forward drive pedal stroke limiting screw.

CAUTION

CAUTION

The machine should not be able to move while the brake pedal is depressed.

Do NOT adjust the drive pedal stroke limiting screw IN any further than the minimum required to achieve 450-460 psi (the same value as charge pressure). Damage to the foot pedal can occur if the pedal is allowed to stroke more than is required.

For machines equipped with speed control valves the speed control must be in the fully forward position to acheive 450-460 psi.

WARNING Do not permit high pressure relief valves to operate for periods longer than 5 - 10 seconds as this will cause excessive heating of the hydraulic fluid and damage to the valve.

NOTE: Monitor oil temperature closely, if cardboard is being used to block the oil cooler it should be removed if the temperature starts to rise above normal. The operator should be instructed to press the pedal for 5 seconds and then to release the pedal for 5 seconds to prevent overheating of the valve by the hydraulic oil as it passes over the relief valve in the next procedures.

Adjustments are made during the time the pedal is pressed.

16. Set the parking brake ON, and shut off the engine.

17. Remove all pressure gauges and reinstall all plugs and caps.

18. Reconnect the PARK BRAKE SWITCH POWER WIRE to the switch.

19. Re-adjust the auxiliary set-up caliper to its ORIGINAL POSITION (loose and locked with a cotter pin) using a wrench to back-off the screw adjustment. Friction between the brake caliper and the rotating brake disc can cause a fire.

11. Turn the pump P.O.R. adjusting screw in exactly 2 1/2 turns.

SUMMARY:

12. With the aid of an assistant, hold down the brake pedal, and while fully depressing the REVERSE foot pedal, set the port ‘B’ relief valve (‘Mb’) to 6850 - 6900 psi @ full throttle.

The settings must be made in the order shown.

1. Adjust charge pressure to 450-460 @ full throttle. (Note that speed control must be in the fully forward position to achieve this.)

13. With the aid of an assistant, hold down the brake pedal, and while fully depressing the FORWARD foot pedal, set the port ‘A’ relief valve (‘Ma’) to 6850 - 6900 psi @ full throttle.

2. Turn BOTH pump mains screws to ‘X’ dimension above locknut.

3. Turn pump P.O.R. to ‘X’ dimension above locknut.

14. With the aid of an assistant, hold down the brake pedal, and while fully depressing the REVERSE foot pedal, reset the pump pressure override adjustment (P.O.R.) to 6200 - 6250 psi @ full throttle on the ‘Mb’ gauge.

4. Set pump P.O.R. to 4150 @ full throttle.

5. Adjust forward and reverse pedals to 135 @ full throttle.

6. Turn P.O.R. screw IN exactly 2 1/2 turns.

7. Adjust BOTH main relief valves to 6850-6900 @ full throttle.

15. Re-adjust the reverse drive pedal stroke limiting screw to change the stroke of the pedal and the pressure at test port ‘X’ . With the aid of an assistant, hold down the brake pedal and while fully depressing the reverse foot pedal, observe the pressure reading at test port ‘X’ . It must read 450-460 psi @full throttle (the same value as charge

8. Adjust pump P.O.R. to 6200-6250 @ full throttle.

9. Adjust forward and reverse pedals to 450-460 @ full throttle.

8.22

Tigercat 620 Skidder

Drive

DRIVE MOTOR PRESSURE SETTINGS AND ADJUSTMENTS

A. MOTOR MINIMUM DISPLACEMENT ADJUSTMENT

REXROTH PUMP AND REXROTH MOTORS DO NOT adjust drive motor pressure settings without first confirming the need to do so. Drive motor pressure settings are checked as part of the test drive procedure. Refer to TEST DRIVE REXROTH PUMP AND REXROTH MOTORS in THIS SECTION. To set the hydrostatic drive motor pressures and speeds, the following procedure must be performed in the order shown.

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

Perform this procedure on BOTH MOTORS..

1. Park machine on level ground, lower grapple and dozer and set parking brake ON. Install articulation lock pin and stop engine

A. Set the motor minimum displacement.

B. Set the motor begin of displacement control pressure.

C. Set the motor pressure override.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock pin is held securely in place by the lynch pins provided.

IMPORTANT The adjustment or set-up procedure is a series of steps that must be done in a proper sequence to achieve optimum performance from the machine. Any deviation from the procedures could present a safety hazard, damage components and/or affect the operation of the machine. All adjustments must be performed on BOTH MOTORS.

2. Remove the minimum displacement adjusting screw (largest screw) from the top of motor housing and measure its length.

MOTOR BEGIN OF DISPLACMENT ADJUSTING SCREW MINIMUM DISPLACEMENT ADJUSTING SCREW

••

IMPORTANT • When installing a new or rebuilt motor, ensure minimum displacement screw is set correctly.

• Improper adjustment of min. displacement adjusting screw can result in motor failure due to overspeeding.

• It may be necessary to verify the length of adjusting screw used by removing and measuring the screw.

LM1

RM1

X

• • •• TEST PORT COMPARTMENT

620-M6

•• •• (SOME HOSES REMOVED FOR CLARITY)

320-23

NOTE: Repeat for the other motor.

•• MAIN DRIVE PUMP

DRIVE MOTOR (R.H. SHOWN)

3. Reinstall the minimum displacement adjusting screw and locknut into the motor housing. For a 90mm long screw, it should be adjusted such that the dimension from the top of the locknut to the end of the exposed screw is 20.6mm. (For different length screws, measure the length and subtract 69.4mm from this total length. This is the amount of screw that should be exposed above the locknut.) (For example: 100mm screw, minus 69.4mm will leave 30.6mm above locknut).

GAUGE TEST PORT 'MA' • PORT SIZE - 04 ORB

320-4

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

8.23

Tigercat 620 Skidder

Drive

B. MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ADJUSTMENT

PREPARATION FOR ADJUSTMENT 1. Set parking brake ON, lower grapple and dozer to the ground, place the speed control (if equipped) lever in the fully forward position, and shut off the engine.

IMPORTANT NOTES: The goal of this procedure is to set motor control pressures 'RM1' and 'LM1' at 2075 psi (50 % of work port pressure, 4150 psi) when a pilot pressure from the foot pedal of 130 psi is applied at the 'X' port. It is not possible to make this adjustment directly.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF/FT.

The procedure used to make this adjustment is based on the assumption that: If applying a pressure of 135 psi at 'X' results in a reading at 'RM1' and 'LM1' of 2125 psi or more.

•

And applying a pressure of 125 psi at 'X' results in a reading at 'RM1' and 'LM1' of 2025 psi or less.

Then the goal of approximately 2075 psi (50 % of work port pressure, 4150 psi) at 'RM1' and 'LM1' when a pilot pressure of 130 psi is applied at the 'X' port will have been achieved. (The test drive procedure will confirm these settings.)

336-3AX

AUXILIARY BRAKE SET-UP CALIPER 2. Adjust auxiliary brake set-up caliper to 50 lbf/ft, to lock the rotating brake disc.

3. Connect a 0-1000 psi gauge to the ‘X’ test port , two 0-10,000 psi gauges to the ‘LM1’ and 'RM1' testports a 0-10,000 psi gauge to the ‘Ma’ port on the main drive pump.

It is important to understand that there is no "correct" pressure for 'RM1' and 'LM1'. The reading must simply be 'or less' and 'or more' as described above (and in the steps of this procedure).

4. To set the motor begin of displacement control pressure, it is necessary to temporarily adjust the hydrostatic PUMP pressure override to 4150 psi.

It is not necessary for both motors to have the same reading at 'M1'. Motors may perform differently from one machine to another or even from one motor to another on the same machine.

5. Disconnect power wire from the parking brake switch terminal.

This procedure describes adjusting both motors at the same time. However, it may be simpler and less time consuming in the long run to perform this procedure on one motor at a time. This is a personal preference and will not affect the end result of the procedure.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected from the parking brake. Also, avoid the risk of unintentionally driving the machine with the auxiliary brake set-up caliper engaged.

Driving the machine with either brake engaged will result in overheating of the brakes which could cause a fire in the machine.

Two procedures will be described.

• • •

Either procedure can be used.

If one procedure proves difficult then try the other.

Both procedures require 2 people to perform.

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

6. Start the engine, set throttle control to FULL.

8.24

Tigercat 620 Skidder

Drive MOTOR BEGIN OF DISPLACMENT ADJUSTING SCREW

PUMP PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.) • 4 MM ALLEN KEY • 13 MM WRENCH

MINIMUM DISPLACEMENT ADJUSTING SCREW

••

• (SOME HOSES REMOVED FOR CLARITY)

DRIVE PUMP P.O.R. VALVE

320-1

••

320-23

7. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the hydrostatic drive PUMP pressure override (POR) to achieve a pressure at ‘Ma’ of 4150 psi @full throttle.

•

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

DRIVE MOTOR (R.H. SHOWN)

CAUTION The machine should not be able to move while the brake pedal is depressed.

9. With the aid of an assistant, hold down the brake pedal and while fully depressing the REVERSE foot pedal, adjust the reverse drive pedal stroke limiting screw (located under pedal) upwards to limit the stroke of the reverse pedal to give a pressure reading at

8. Adjust the MOTOR pressure override screw (POR) IN until it lightly seats. This screw points backwards and is located on top of the motor. Do not over tighten. Do this for BOTH motors.

Chart 2 - DRIVE MOTOR SCREW ADJUSTMENTS MACHINE

MOTOR

BEGIN OF DISPLACEMENT

620

AQ010 (160 CC)

2075 PSI @ FULL THROTTLE

"X" DIMENSION** *LENGTH OF TOP OF SCREW TO TOP OF NUT ADJUSTING SCREW 10.6 MM (0.42") ***20.6 MM (0.81") 30.6 MM (1.20")

PUMP

M12 X 80 MM (3.1") M12 X 90 MM (3.5") M12 X 100 MM (3.9")

AP024 (90 CC)

* NOTE: ALWAYS CHECK OVERALL LENGTH OF ADJUSTING SCREW BEFORE SETTING THE "X" DIMENSION ON A NEW DRIVE MOTOR **NOTE: THIS IS A SENSITIVE ADJUSTMENT, SIGNIFICANT CHANGES IN SPEED WILL OCCUR WITH ONLY A SMALL MOVEMENT OF THE ADJUSTING SCREW. IT IS IMPORTANT THAT THIS DIMENSION BE WITHIN THE SPECIFIED TOLERANCE: "X" = +0MM/-1MM (+0"/-0.031") *** INDICATES THE ADJUSTING SCREW CUSTOMARILY INSTALLED IN A NEW UNIT

MINIMUM DISPLACEMENT ADJUSTING SCREW - 6MM ALLEN KEY - 19MM WRENCH DIM. 'X' = 13/16" (20.6 MM) FOR A 90MM LONG SCREW

•• ••

P.O.R. ADJUSTING SCREW

••

PORT 'X'

• AQ010-1

BEGIN OF DISPLACEMENT ADJUSTING SCREW - 3MM ALLEN KEY - 10MM WRENCH PORT 'B'

'A'

AQ010-5Y

MAXIMUM DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 5/8" (16MM) FOR A 50MM LONG SCREW

PORT 'A'

••

VIEW 'A'

•• DRIVE MOTOR (160CC SIZE) 8.25

PORT 'M1' • 6 ORB 1/4" ALLEN KEY

Tigercat 620 Skidder

Drive no "correct" pressure for 'RM1' and 'LM1'.

The reading must simply be 'or more' as described above. It is NOT NECESSARY for both motors to have the same settings.

Motors may perform differently from one machine to another or even from one motor to another on the same machine.

•• • REVERSE LIMITING SCREW

FORWARD LIMITING SCREW

CAUTION

FORWARD AND REVERSE DRIVE PEDALS 189-10

The machine should not be able to move while the brake pedal is depressed.

the ‘X’ test port of 125 psi @full throttle for 15 seconds.

11. With the aid of an assistant, hold down the brake pedal, full throttle and while fully depressing the REVERSE foot pedal (125 psi at 'X') check for a reading of 2025 psi or less @full throttle at ‘RM1’ and 'LM1' test ports.

Repeat this until it is correct. Repeat this procedure again with the FORWARD foot pedal to get a reading at the ‘X’ test port of 135 psi @full throttle for 15 seconds.

NOTICE the difference in the pressure settings for forward and reverse pedals.

These settings are important.

12. Alternately apply 135 psi and 125 psi at 'X'.

Confirm that at 135 psi 'RM1' and 'LM1' ports read 2125 psi or more and at 125 psi 'RM1' and 'LM1' ports read 2025 psi or less. Repeat several times to ensure that the setting does not change.

NOTE: Alternatively, it is possible to adjust the speed control lever (if equipped) to give pressure readings at the 'X' test port of 125 psi and 135 psi. The lever must be readjusted for each step in the procedure to give a reading at 'X' of either 125 psi or 135 psi as required.

13. If these readings are obtained, then the motor begin of displacement control setpoint is now between 125 and 135 psi.

If not, readjust begin of displacement screw on failing motor and check again for 125 psi (low pressure and 135 psi (high pressure).

PROCEDURE ONE This is the first of two alternative procedures for motor begin of displacement control adjustment.

Perform steps 1 to 9 (PREPARATION FOR ADJUSTMENT) before proceeding to step 10.

When properly set, this means that the motors will begin to stroke in the pressure range 125135 psi. This is a critical setting for the smooth and efficient drive operation of the machine.

10. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal (135 psi at 'X'), adjust the motor begin of displacement screw (small screw in pocket, points upwards) to give a reading of 2125 psi or more @full throttle at 'RM1' and 'LM1' test ports with the locknut tightened. Use TWO gauges and set BOTH MOTORS, moving back and forth between the two motors.

14. The motor pressure override (POR) must be re-adjusted to complete this procedure. Refer to MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR) below.

PROCEDURE TWO This is the second of two alternative procedures for motor begin of displacement control adjustment.

Perform steps 1 to 9 (PREPARATION FOR ADJUSTMENT) before proceeding to step 10.

If the reading is HIGH; turn the motor begin of displacement control adjusting screw OUT (counter-clockwise). Release the FORWARD foot pedal and re-apply several times to ensure that both gauges read 2125 psi or more. If not ,re-adjust the motor begin of displacement control adjusting screw on the motor that is incorrect.

10. With the aid of an assistant, hold down the brake pedal and while fully depressing the REVERSE foot pedal (125 psi at 'X'), adjust the motor begin of displacement screw (small screw in pocket, points upwards) to give a reading of 800-1000 psi @full throttle at 'RM1' and 'LM1' test ports with the locknut tightened.

Use TWO gauges and set BOTH MOTORS, moving back and forth between the two motors.

If the reading is LOW; turn the motor begin of displacement control adjusting screw IN (clockwise)

If the reading is HIGH; turn the motor begin of displacement control adjusting screw OUT

It is important to understand that there is 8.26

Tigercat 620 Skidder (counter-clockwise). Release the REVERSE foot pedal and re-apply several times to ensure that both gauges read 800-1000 psi.

If not, re-adjust the motor begin of displacement control adjusting screw on the motor that is incorrect.

If the reading is LOW; turn the motor begin of displacement control adjusting screw IN (clockwise).

It is NOT NECESSARY for both motors to have the same settings. Motors may perform differently from one machine to another or even from one motor to another on the same machine.

CAUTION The machine should not be able to move while the brake pedal is depressed.

11. With the aid of an assistant, hold down the brake pedal, full throttle and while fully depressing the FORWARD foot pedal (135 psi at 'X') check for a reading of 2125 psi or more @full throttle at ‘RM1’ and 'LM1' test ports.

Drive 14. The motor pressure override (POR) must be re-adjusted to complete this procedure.

Refer to MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR) below.

C. MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR) NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

Perform this procedure on BOTH MOTORS. Note: Steps 1 to 7 were completed in BEGIN OF DISPLACEMENT. If this procedure was just finished move to step 8.

1. Set parking brake ON, adjust speed control (if equipped) to the fully forward position, lower grapple and dozer and shut off the engine.

2. Adjust auxiliary set-up caliper to 50 lbf/ft, to lock the rotating brake disc.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF/FT.

It is important to understand that there is no "correct" pressure for 'RM1' and 'LM1'.

The reading must simply be 'or more' as described above. It is NOT NECESSARY for both motors to have the same readings. Motors may perform differently from one machine to another or even from one motor to another on the same machine.

12. Alternately apply 125 psi and 135 psi at 'X'.

Confirm that at 125 psi 'RM1' and 'LM1' ports read 800-1000 psi and at 135 psi 'RM1' and 'LM1' ports read 2125 psi or more. Repeat several times to ensure that the setting does not change.

13. If these readings are obtained, then the motor begin of displacement control setpoint is now between 125 and 135 psi.

If not, readjust begin of displacement screw on failing motor and check again for 125 psi (low pressure) and 135 psi (high pressure).

••

336-3AX

AUXILIARY BRAKE SET-UP CALIPER

3. Connect a 0-1000 psi gauge to the ‘X’ test port, two 0-10,000 psi gauges to 'LM1’ and 'RM1' test ports a 0-10,000 psi gauge to the ‘Ma’ port on the main drive pump.

4. To set the motor pressure override adjustment (POR), it is necessary to temporarily adjust the hydrostatic PUMP pressure override to 4150 psi.

When properly set, this means that the motors will begin to stroke in the pressure range of 125-135 psi. This is a critical setting for the smooth and efficient drive operation of the machine.

8.27

Tigercat 620 Skidder LM1

Drive RM1

MOTOR BEGIN OF DISPLACMENT ADJUSTING SCREW

X

MINIMUM DISPLACEMENT ADJUSTING SCREW

••

•• ••

•

TEST PORT COMPARTMENT

620-M6

(SOME HOSES REMOVED FOR CLARITY)

GAUGE TEST PORT 'M A' • PORT SIZE - 04 ORB

••

320-23

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

DRIVE MOTOR (R.H. SHOWN)

The machine should not be able to move while the brake pedal is depressed.

5. Disconnect power wire from the parking brake switch terminal.

8. To set the motor pressure override adjustment (POR), it is ALSO necessary to achieve a 450-460 psi pressure reading at the ‘X’ test port in order to reset correct foot pedal travel.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected from the parking brake. Also, avoid the risk of unintentionally driving the machine with the auxiliary brake set-up caliper engaged.

Driving the machine with either brake engaged will result in overheating of the brakes which could cause a fire in the machine.

9. With the aid of an assistant, hold down the brake pedal and adjust the FORWARD and the REVERSE foot pedal stroke limiting screws (located under pedals) to give a pressure reading of 450-460 psi @full throttle (the same value as charge pressure) at the ‘X’ test port. It must read this for 15 seconds, to ensure that the reading is correct. If it is not correct, repeat the procedure until it is correct for both pedals.

6. Start the engine, set throttle control to FULL.

PUMP PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

CAUTION

• 4 MM ALLEN KEY • 13 MM WRENCH

Do NOT adjust the drive pedal stroke limiting screw IN any further than the minimum required to achieve 450-460 psi (the same value as charge pressure). Damage to the foot pedal can occur if the pedal is allowed to stroke more than is required.

For machines equipped with speed control valves the speed control must be in the fully forward position to acheive 450-460 psi.

•

320-1

•

CAUTION

MAIN DRIVE PUMP

320-4

••

DRIVE PUMP P.O.R. VALVE

10. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, observe the pressure at ‘LM1’ and 'RM1'. A reading of 2075 psi (half of ‘Ma’) @ full throttle should register if the motor pressure override adjustment is set correctly. Check both motors.

7. With the aid of an assistant, hold down the brake pedal, and while depressing the FORWARD foot pedal adjust the hydrostatic drive PUMP pressure override (POR) to achieve a pressure at the PUMP ‘Ma’ port of 4150 psi @full throttle.

If the reading is LOW; turn the motor pressure override adjusting screw IN 8.28

Tigercat 620 Skidder

Drive

(clockwise) until a correct reading at the ‘LM1’ and 'RM1' test ports (2075 psi @full throttle, half of ‘Ma’) is obtained with the locknut tightened. Release the FORWARD foot pedal and re-apply to ensure that the gauge reading at ‘RM1’ and 'LM1' is 2075 psi. If it is not correct re-adjust the motor pressure override adjusting screw.

SUMMARY:

If the reading is HIGH; turn the motor pressure override adjusting screw OUT (counter-clockwise) until a correct gauge reading at ‘LM1’ and 'RM1' port (2075 psi @full throttle, half of ‘Ma’) is obtained with the locknut tightened. Release the FORWARD foot pedal and re-apply to ensure that the gauge reading at ‘RM1’ and 'LM1' is 2075 psi. If it is not correct re-adjust the motor pressure override adjusting screw.

1. Adjust pump POR to 4150 @ full throttle.

This adjustment must be done on both motors. When properly set the motor pressure override adjustment setpoint will be 4150 psi. Re-check frequently while adjusting by having assistant release and depress pedals.

6. Apply 125 psi at 'X' (reverse pedal).

11. With the aid of an assistant, hold down the brake pedal, full throttle and while depressing the FORWARD foot pedal, reset the POR on the drive PUMP to 6200 - 6250 psi @full throttle at ‘Ma’.

12. Set the parking brake ON, and shut off the engine.

13. Remove all pressure gauges and reinstall all plugs and caps.

14. Reconnect the PARK BRAKE SWITCH POWER WIRE to the switch.

15. Re-adjust the auxiliary set-up caliper to its ORIGINAL POSITION (loose and locked with a cotter pin) using a wrench to back-off the screw adjustment. Friction between the brake caliper and the rotating brake disc can cause a fire.

The settings must be made in the order shown.

MOTOR MINIMUM DISPLACEMENT ADJUSTMENT: 1. Check adjusting screw for proper length BEGIN OF DISPLACEMENT ADJUSTMENT:

2. Turn both motor POR IN carefully until lightly seated.

3. Adjust reverse pedal to 125 psi and forward pedal to 135 psi @ full throttle at 'X'.

4. Apply 135 psi at 'X' (forward pedal).

5. Adjust both motor begin of displacement to 2125 psi or more @ full throttle.

7. Check for a reading of 2025 psi or less @ full throttle.

8. Apply 135 psi at 'X' (forward pedal).

9. Check for a reading of 2125 psi or more @full throttle at 'RM1' and 'LM1'.

10. Motor POR must be reset. See below.

POR ADJUSTMENT: 1. Adjust pump POR to 4150 @ full throttle.

(Done in step 1 above) 2. Adjust forward and reverse pedals to give 450-460 @ full throttle. (Note that speed control must be in the fully forward position to achieve this.)

3. Adjust both motor POR to 2075 @ full throttle.

4. Adjust pump POR to 6200-6250 @ full throttle.

8.29

Tigercat 620 Skidder

Drive

8.30

Tigercat 620 Skidder

630B-02

Drive

DRIVE CIRCUIT - SAUER PUMP AND REXROTH MOTORS SERIAL NUMBERS 6200231 AND UP 8.31

Tigercat 620 Skidder DRIVE TEST:

Drive LM1

SAUER PUMP & REXROTH MOTORS

RM1

X

The test drive will verify the following: 1. Motor begin of displacement control pressure: 125-135 psi.

••

•• ••

2. Motor pressure override (P.O.R.): 4150 psi and (half of ‘M2’) - 2075 psi.

3. Steering check; slow and fast.

620-M6

TEST PORT COMPARTMENT

4. Front and rear differential lock functions.

5. Horsepower/engine stall test.

6. Ground speed test.

Install three 0-10,000 psi gauges on: • 'LM1’ , 'RM1' (test port compartment) and 'M2' (drive pump)

GAUGE TEST PORT 'M2' • PORT SIZE - 06 JIC

Install one 0-1,000 psi gauge on: • ‘X’ (test port compartment) NOTE: Fasten these four gauges so they can be easily viewed from the operator’s seat in the cab.

Fasten your seat belt and move the machine to a suitable test area, where it can be safely driven at full speed for approximately 150 feet. Grapple UP, CLOSED and ROTATED TO CENTER. Dozer blade UP.

• 233-9

IMPORTANT: Foot brake must only be applied for 5-10 seconds followed each time by a minimum 20 second cool down period. Failure to do so will result in 'burn out' of front axle brake.

1.

MAIN DRIVE PUMP-SAUER

GAUGES

•

BEGIN OF DISPLACEMENT CONTROL PRESSURE

A. Turn ON both front and rear differential locks.

Set throttle control to FULL..

B. Drive the machine FORWARD, using the foot pedal, to get 130 psi at ‘X’.

308-2X

FASTEN GAUGES FOR VIEWING FROM THE OPERATOR'S SEAT

2. MOTOR PRESSURE OVERRIDE (P.O.R.):

The foot brakes may have to be applied to create approximately 2000 psi at ‘M2’ on the PUMP.

A. Turn ON both front and rear differential locks.

Set throttle control to FULL.

C. While doing the above, observe the TWO ‘M1’ gauges and adjust forward foot pedal, up or down until a reading of 1000 psi (half of ‘M2’) just starts to appear on both the ‘LM1’ and 'RM1' gauges. Read the ‘X’ pressure gauge which is showing the begin of displacement pressure and it should be 125135 psi. Both motors (‘LM1’ and 'RM1' gauges) should rise to 1000 psi within the 125-135 psi range on the ‘X’ gauge, if the setup is correct.

B. Drive the machine FORWARD in a straight line with FULL DRIVE PEDAL. The ‘X’ gauge should show no lower than 380 psi while the machine is in motion. (NOTE: Charge pressure drops from its set value of 450-460 psi to 380 psi while driving forward during this test. This is normal.) Apply foot brake to slow machine down to approximately half maximum speed but NO SLOWER than half speed. (Note: When the machine is stationary the 'X' gauge will show 0 psi charge pressure.)

Note: This test may have to be done a few times to get a proper reading.

8.32

Tigercat 620 Skidder C. While doing the above, observe the pressure at ‘M2’. It should read the P.O.R. setting of 4150 psi. Also read the pressure at both 'LM1' and 'RM1' gauges, it should be approximately half of ‘M2’ 2075 psi. The engine should lug down to 2150-2200 rpm during this test. If the rpm stays above 2200 rpm during the test, check the hydrostatic pump.

Drive D. Turn only the rear differential lock switch ON. While steering the machine, both rear wheels should slide.

PUMP PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.) • 5/16" ALLEN KEY • 15/16" WRENCH

••

Note: This test may have to be done a few times to get a proper reading.

3.

STEERING OPERATION

A. Disengage the parking brake, turn OFF both front and rear differential locks, NO foot brake applied and set throttle control to FULL. Turn the steering wheel completely one way until it hits the stop.

•• GAUGE TEST PORT 'M2' • PORT SIZE - 06 JIC

B. Turn the steering wheel the opposite way, as SLOWLY as possible, until it hits the end stop. This should take 7 1/2 to 8 turns of the wheel.

5. HORSEPOWER

C. Turn the wheel back SLOWLY to the other end stop, very slowly to verify the 7 1/2 to 8 turns.

A. Park machine on level ground, set parking brake ON, grapple DOWN, dozer DOWN and shut off the engine.

D. Turn the wheel back to the other end stop, as QUICKLY as possible. Resistance to turning the wheel will be felt during this operation.

This should take 3 1/2 to 4 turns of the wheel.

B. Connect a 0-5000 psi gauge to the ‘P3’ port.

E. Turn the wheel back to the other end stop, as QUICKLY as possible to verify the 3 1/2 to 4 turns from one stop to the other.

F.

If these values are not obtained, check the priority valve and/or steering control unit.

For additional information on the steering system refer to SECTION 11 of THIS MANUAL.

4.

DIFFERENTIAL LOCKS

A. Bring the machine to a full stop, set throttle to IDLE, ensure that both front and rear differential locks are turned OFF. Steer the machine without depressing the drive pedal.

All wheels should rotate as machine is being steered. Steer several times, check all wheels.

B. Turn only the front differential lock switch ON. While steering the machine, both front wheels should slide instead of rotating. Rear wheels should still rotate.

333-9

SAUER DRIVE PUMP P.O.R. VALVE

C. Ensure that the hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in this SECTION. D. To check engine horsepower it is necessary to temporarily reset the main pump POR to 3500 psi.

E. Start the engine, hold down the brake pedal and set the throttle control to IDLE. F.

Turn the main pump POR valve adjusting screw all the way in. The main pump POR should now read 3500 psi on the 'P3 gauge.

G. Turn off engine, remove gauges, reinstall plugs on the test ports.

H. Start the engine, set throttle control to FULL. Set parking brake OFF, grapple UP and dozer UP. I.

Drive the machine FORWARD in a straight line with FULL DRIVE PEDAL. Apply service brakes agressively.

K. While doing the above, observe the engine rpm. The engine should lug down to between 1500 rpm and 1700 rpm and should not stall.

C. Turn front differential lock switch OFF. 8.33

Tigercat 620 Skidder

Drive

L. IMPORTANT: Main pump POR must be reset to normal levels after this test is complete. Reset main pump POR to 3000-3100 psi on 'P3' gauge, using the adjusting screw on the side of the pump.

EXAMPLE: Transmission identified as 9491B by: Hole punched on the transmission identification label next to transmission part number 9491B.

Note: This test may have to be done a few times to get a proper reading.

OR Transmission part number 9491B indicated on transmission at the assembly part number stamp location.

6. GROUND SPEED A. Turn ON both front and rear differential locks, set throttle to FULL and push the speed control lever fully forward to allow travel at FULL SPEED.

Recorded time: Time recorded as 15.25 seconds.

Test Result: Acceptable time within the range 14.33 16.50 seconds. Machine passes the ground speed test.

B. Drive machine FORWARD with the FULL DRIVE PEDAL. Allow the machine to reach top speed.

C. With the aid of an assistant drive the machine forward at top speed and record the time to complete 10 tire revolutions. Refer to chart below for correct time for the transmission installed on your machine.

Transmission

Time range for

Part Number

10 tire revolutions

HOLE PUNCHED TO INDICATE FACTORY INSTALLED TRANSMISSION PART NUMBER

FACTORY INSTALLED TRANSMISSION PART NUMBER

(seconds) 7956B

n/a - 9.89

9488B

11.81 - 13.83

9491B

14.33 - 16.50

11020B

10.39 - 11.31

7956B 9488B 9491B 11020B REFER TO SERVICE MANUAL FOR CORRECT DRIVE SYSTEM PRESSURE SETTINGS.

To identify the transmission on your machine refer to the label inside the cab of the machine or check the part number stamp on the transmission for your machine.

18287A R0

TRANSMISSION IDENTIFICATION LABEL INSIDE CAB

If the recorded time is outside the time range given either the MOTOR minimum displacement, MOTOR POR or PUMP charge pressure may be incorrectly set. If a time range is not given for your machine's transmission part number contact Tigercat customer service for more information.

ASSEMBLY PART NUMBER STAMP LOCATION

Note: This test may have to be done a few times to get a proper reading.

630B-08

8.34

TRANSMISSION IDENTIFICATION

Tigercat 620 Skidder DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS

Drive IMPORTANT

SAUER PUMP & REXROTH MOTORS The drive pump P.O.R. settings are different depending on the transmission part number used.

Before beginning this procedure, use the illustrations below to help determine the transmission part number that is installed on the machine. Later machines have a label in the cab which indicates the part number of the transmission installed at the factory.

ASSEMBLY PART NUMBER STAMP LOCATION

The adjustment or set-up procedure is a series of steps that must be done in a proper sequence to achieve optimum performance from the machine. Any deviation from the procedures could present a safety hazard, damage components and/or affect the operation of the machine.

1. Set parking brake ON, lower grapple and dozer and shut off the engine.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock pin is held securely in place by the lynch pins provided.

630B-08

TRANSMISSION IDENTIFICATION

2. Adjust auxiliary brake set-up caliper to 50 lbf/ft, to lock the rotating Brake disc.

HOLE PUNCHED TO INDICATE FACTORY INSTALLED TRANSMISSION PART NUMBER

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF/FT.

FACTORY INSTALLED TRANSMISSION PART NUMBER 7956B 9488B 9491B 11020B

••

REFER TO SERVICE MANUAL FOR CORRECT DRIVE SYSTEM PRESSURE SETTINGS. 18287A R0

TRANSMISSION IDENTIFICATION LABEL INSIDE CAB NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

336-3AX

AUXILIARY BRAKE SET-UP CALIPER

3. Connect a 0-10,000 psi gauge to port ‘M1’ and ‘M2’ on the HYDROSTATIC DRIVE PUMP, and a 0-1000 psi gauge to the tee connection from port ‘M3’ on the HYDROSTATIC DRIVE PUMP.

NOTE: Relief valves are set by loosening the locknut and turning the adjusting screw OUT (counter-clockwise) to reduce the pressure setting and IN (clockwise) to increase the pressure setting.

TRANSMISSION DRIVE PUMP P.O.R. PART NUMBER FWD & REV (PSI) 7956B 6200 - 6250 9488B 5200 - 5250 9491B 5200 - 5250 11020B 5625 - 5675

LM1

•

620-M6

8.35

RM1

X

• ••

TEST PORT COMPARTMENT

Tigercat 620 Skidder

Drive

4. Disconnect parking brake switch power wire from the switch.

7. With the aid of an assistant, hold down the brake pedal, and while fully depressing the FORWARD foot pedal, set the 'B' PUMP P.O.R. @ full throttle on the ‘M2’ gauge.

See chart for the correct Drive Pump P.O.R setting.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected from the parking brake. Also, avoid the risk of unintentionally driving the machine with the auxiliary brake set-up caliper engaged.

Driving the machine with either brake engaged will result in overheating of the brakes which could cause a fire in the machine.

WARNING

5. Start the engine, set throttle control to FULL and set the charge pressure relief valve on the pump to 450-460 psi (0 - 1000 psi gauge at ‘M3’ port).

6. With the aid of an assistant, hold down the brake pedal, and while fully depressing the REVERSE foot pedal, set the 'A' PUMP P.O.R. @ full throttle on the ‘M1’ gauge. See chart for the correct Drive Pump P.O.R setting.

Do not permit high pressure relief valves to operate for periods longer than 5 - 10 seconds as this will cause excessive heating of the hydraulic fluid and damage to the valve.

NOTE: Monitor oil temperature closely, if cardboard is being used to block the oil cooler it should be removed if the temperature starts to rise above normal. The operator should be instructed to press the pedal for 5 seconds and then to release the pedal for 5 seconds to prevent overheating of the valve by the hydraulic oil as it passes over the relief valve in the next procedures.

Adjustments are made during the time the pedal is pressed.

CAUTION The machine should not be able to move while the brake pedal is depressed.

'A' P.O.R.VALVE 5/16" ALLEN KEY 15/16" WRENCH

'TEE' GAUGE TEST PORT (M3) • PORT SIZE - 04 JIC

•• ••

'B' P.O.R. VALVE 5/16" ALLEN KEY 15/16" WRENCH

••

CHARGE PRESS. RELIEF • 13MM WRENCH • 1 1/4" WRENCH

•

GAUGE TEST PORT 'M1' • PORT SIZE - 06 JIC

•

GAUGE TEST PORT 'M2' • PORT SIZE - 06 JIC

• 333-9

SAUER - DRIVE PUMP 8.36

Tigercat 620 Skidder

Drive

8. Set the parking brake ON, and shut off the engine.

9. Remove all pressure gauges and reinstall all plugs and caps.

10. Reconnect the PARK BRAKE SWITCH POWER WIRE to the switch.

11. Re-adjust the auxiliary set-up caliper to its ORIGINAL POSITION (loose and locked with a cotter pin) using a wrench to back-off the screw adjustment. Friction between the brake caliper and the rotating brake disc can cause a fire.

SUMMARY: The settings must be made in the order shown.

1. Adjust charge pressure to 450-460 @ full throttle 2. Adjust forward pump P.O.R. 'M2' @ full throttle to the pressure indicated on the chart.

3. Adjust reverse pump P.O.R. 'M1' @ full throttle to the pressure indicated on the chart.

8.37

Tigercat 620 Skidder

Drive

DRIVE MOTOR PRESSURE SETTINGS AND ADJUSTMENTS

A. MOTOR MINIMUM DISPLACEMENT ADJUSTMENT

SAUER PUMP & REXROTH MOTORS

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

DO NOT adjust drive motor pressure settings without first confirming the need to do so.

Drive motor pressure settings are checked as part of the test drive procedure. Refer to TEST DRIVE - SAUER PUMP AND REXROTH MOTORS in THIS SECTION.

Perform this procedure on BOTH MOTORS..

1. Park machine on level ground, lower grapple and dozer and set parking brake ON. Install articulation lock pin and stop engine

To set the hydrostatic drive motor pressures and speeds, the following procedure must be performed in the order shown.

A. Set the motor minimum displacement.

WARNING

B. Set the motor begin of displacement control pressure.

To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock pin is held securely in place by the lynch pins provided.

C. Set the motor pressure override.

IMPORTANT The adjustment or set-up procedure is a series of steps that must be done in a proper sequence to achieve optimum performance from the machine. Any deviation from the procedures could present a safety hazard, damage components and/or affect the operation of the machine. All adjustments must be performed on BOTH MOTORS.

2. Remove the minimum displacement adjusting screw (largest screw) from the top of motor housing and measure its length.

MOTOR BEGIN OF DISPLACMENT ADJUSTING SCREW MINIMUM DISPLACEMENT ADJUSTING SCREW

•

IMPORTANT

••

• When installing a new or rebuilt motor, ensure minimum displacement screw is set correctly.

• Improper adjustment of min. displacement adjusting screw can result in motor failure due to overspeeding.

• It may be necessary to verify the length of adjusting screw used by removing and measuring the screw.

LM1

••

620-M6

RM1

(SOME HOSES REMOVED FOR CLARITY)

320-23

•

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

DRIVE MOTOR (R.H. SHOWN)

3. Reinstall the minimum displacement adjusting screw and locknut into the motor housing. For a 90mm long screw, it should be adjusted such that the dimension from the top of the locknut to the end of the exposed screw is 19.2mm. (For different length screws, measure the length and subtract 70.8 mm from this total length. This is the amount of screw that should be exposed above the locknut.) (For example: 100 mm screw, minus 70.8 mm will leave 29.2 mm above locknut).

X

• ••

TEST PORT COMPARTMENT

NOTE: Repeat for the other motor.

8.38

Tigercat 620 Skidder B.

MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ADJUSTMENT

IMPORTANT NOTES: The goal of this procedure is to set motor control pressures 'RM1' and 'LM1' at 2075 psi (50 % of work port pressure, 4150 psi) when a pilot pressure from the foot pedal of 130 psi is applied at the 'X' port. It is not possible to make this adjustment directly.

Drive PREPARATION FOR ADJUSTMENT 1. Set parking brake ON, lower grapple and dozer to the ground, place the speed control (if equipped) lever in the fully forward position, and shut off the engine.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF/FT.

The procedure used to make this adjustment is based on the assumption that: If applying a pressure of 135 psi at 'X' results in a reading at 'RM1' and 'LM1' of 2125 psi or more.

•

And applying a pressure of 125 psi at 'X' results in a reading at 'RM1' and 'LM1' of 2025 psi or less.

Then the goal of approximately 2075 psi (50 % of work port pressure, 4150 psi) at 'RM1' and 'LM1' when a pilot pressure of 130 psi is applied at the 'X' port will have been achieved. (The test drive procedure will confirm these settings.)

It is important to understand that there is no "correct" pressure for 'RM1' and 'LM1'. The reading must simply be 'or less' and 'or more' as described above (and in the steps of this procedure).

It is not necessary for both motors to have the same reading at 'M1'. Motors may perform differently from one machine to another or even from one motor to another on the same machine.

336-3AX

2. Adjust auxiliary brake set-up caliper to 50 lbf/ft, to lock the rotating Brake disc.

3. Connect a 0-1000 psi gauge to the ‘X’ test port , two 0-10,000 psi gauges to the ‘LM1’ and 'RM1' testports a 0-10,000 psi gauge to the ‘M2’ port on the drive pump.

4. To set the motor begin of displacement control pressure, it is necessary to temporarily adjust the hydrostatic PUMP pressure override to 4150 psi.

5. Disconnect power wire from the parking brake switch terminal.

This procedure describes adjusting both motors at the same time. However, it may be simpler and less time consuming in the long run to perform this procedure on one motor at a time. This is a personal preference and will not affect the end result of the procedure.

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected from the parking brake. Also, avoid the risk of unintentionally driving the machine with the auxiliary brake set-up caliper engaged.

Driving the machine with either brake engaged will result in overheating of the brakes which could cause a fire in the machine.

Two procedures will be described.

• • •

Either procedure can be used.

If one procedure proves difficult then try the other.

Both procedures require 2 people to perform.

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

AUXILIARY BRAKE SET-UP CALIPER

6. Start the engine, set throttle control to FULL.

8.39

Tigercat 620 Skidder

Drive MOTOR BEGIN OF DISPLACMENT ADJUSTING SCREW

PUMP PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.) • 5/16" ALLEN KEY • 15/16" WRENCH

MINIMUM DISPLACEMENT ADJUSTING SCREW

•

•• ••

(SOME HOSES REMOVED FOR CLARITY)

•

320-23

••

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

DRIVE MOTOR (R.H. SHOWN)

GAUGE TEST PORT 'M2' • PORT SIZE - 06 JIC

SAUER DRIVE PUMP P.O.R. VALVE 7. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the hydrostatic drive PUMP pressure override (POR) to achieve a pressure at ‘M2’ of 4150 psi @full throttle.

• ••

333-9

REVERSE LIMITING SCREW

FORWARD AND REVERSE DRIVE PEDALS 189-10

9. With the aid of an assistant, hold down the brake pedal and while fully depressing the REVERSE foot pedal, adjust the reverse drive pedal stroke limiting screw (located under pedal) upwards to limit the stroke of the reverse pedal to give a pressure reading at the ‘X’ test port of 125 psi @full throttle for 15 seconds.

CAUTION The machine should not be able to move while the brake pedal is depressed.

8. Adjust the MOTOR pressure override screw (POR) IN until it lightly seats, and back out 1/4 turn. This screw points backwards and is located on top of the motor. Do not over tighten. Do this for BOTH motors.

MINIMUM DISPLACEMENT ADJUSTING SCREW - 6MM ALLEN KEY - 19MM WRENCH DIM. 'X' = 3/4" (19.2 MM) FOR A 90MM LONG SCREW

•

FORWARD LIMITING SCREW

Repeat this until it is correct. Repeat this procedure again with the FORWARD foot pedal to get a reading at the ‘X’ test port of 135 psi @full throttle for 15 seconds.

P.O.R. ADJUSTING SCREW

•

PORT 'X'

•

•

AQ010-1

BEGIN OF DISPLACEMENT ADJUSTING SCREW - 3MM ALLEN KEY - 10MM WRENCH PORT 'B'

AQ010-5Y

PORT 'A'

'A'

• MAXIMUM DISPLACEMENT ADJUSTING SCREW (DO NOT ADJUST) FOR REFERENCE ONLY: DIM. 'X' = 5/8" (16MM) FOR A 50MM LONG SCREW

VIEW 'A'

• DRIVE MOTOR (160CC SIZE) 8.40

PORT 'M1' • 6 ORB 1/4" ALLEN KEY

Tigercat 620 Skidder NOTICE the difference in the pressure settings for forward and reverse pedals.

These settings are important.

NOTE: Alternatively, it is possible to adjust the speed control lever (if equipped) to give pressure readings at the 'X' test port of 125 psi and 135 psi. The lever must be readjusted for each step in the procedure to give a reading at 'X' of either 125 psi or 135 psi as required.

Drive @full throttle at ‘RM1’ and 'LM1' test ports.

12. Alternately apply 135 psi and 125 psi at 'X'.

Confirm that at 135 psi 'RM1' and 'LM1' ports read 2125 psi or more and at 125 psi 'RM1' and 'LM1' ports read 2025 psi or less. Repeat several times to ensure that the setting does not change.

13. If these readings are obtained, then the motor begin of displacement control setpoint is now between 125 and 135 psi.

PROCEDURE ONE

If not, readjust begin of displacement screw on failing motor and check again for 125 psi (low pressure and 135 psi (high pressure).

This is the first of two alternative procedures for motor begin of displacement control adjustment.

Perform steps 1 to 9 (PREPARATION FOR ADJUSTMENT) before proceeding to step 10.

10. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal (135 psi at 'X'), adjust the motor begin of displacement screw (small screw in pocket, points upwards) to give a reading of 2125 psi or more @full throttle at 'RM1' and 'LM1' test ports with the locknut tightened. Use TWO gauges and set BOTH MOTORS, moving back and forth between the two motors.

If the reading is HIGH; turn the motor begin of displacement control adjusting screw OUT (counter-clockwise). Release the FORWARD foot pedal and re-apply several times to ensure that both gauges read 2125 psi or more. If not ,re-adjust the motor begin of displacement control adjusting screw on the motor that is incorrect.

If the reading is LOW; turn the motor begin of displacement control adjusting screw IN (clockwise)

When properly set, this means that the motors will begin to stroke in the pressure range 125135 psi. This is a critical setting for the smooth and efficient drive operation of the machine 14. The motor pressure override (POR) must be re-adjusted to complete this procedure. Refer to MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR) below.

PROCEDURE TWO This is the second of two alternative procedures for motor begin of displacement control adjustment.

Perform steps 1 to 9 (PREPARATION FOR ADJUSTMENT) before proceeding to step 10.

10. With the aid of an assistant, hold down the brake pedal and while fully depressing the REVERSE foot pedal (125 psi at 'X'), adjust the motor begin of displacement screw (small screw in pocket, points upwards) to give a reading of 800-1000 psi @full throttle at 'RM1' and 'LM1' test ports with the locknut tightened.

Use TWO gauges and set BOTH MOTORS, moving back and forth between the two motors.

If the reading is HIGH; turn the motor begin of displacement control adjusting screw OUT (counter-clockwise). Release the REVERSE foot pedal and re-apply several times to ensure that both gauges read 800-1000 psi. If not, readjust the motor begin of displacement control adjusting screw on the motor that is incorrect.

It is important to understand that there is no "correct" pressure for 'RM1' and 'LM1'.

The reading must simply be 'or more' as described above. It is NOT NECESSARY for both motors to have the same settings.

Motors may perform differently from one machine to another or even from one motor to another on the same machine.

If the reading is LOW; turn the motor begin of displacement control adjusting screw IN (clockwise).

CAUTION The machine should not be able to move while the brake pedal is depressed.

It is NOT NECESSARY for both motors to have the same settings. Motors may perform

11. With the aid of an assistant, hold down the brake pedal, full throttle and while fully depressing the REVERSE foot pedal (125 psi at 'X') check for a reading of 2025 psi or less

CAUTION The machine should not be able to move while the brake pedal is depressed.

8.41

Tigercat 620 Skidder

Drive

differently from one machine to another or even from one motor to another on the same machine.

C. MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR) NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

11. With the aid of an assistant, hold down the brake pedal, full throttle and while fully depressing the FORWARD foot pedal (135 psi at 'X') check for a reading of 2125 psi or more @full throttle at ‘RM1’ and 'LM1' test ports.

Perform this procedure on BOTH MOTORS. Note: Steps 1 to 7 were completed in BEGIN OF DISPLACEMENT. If this procedure was just finished move to step 8.

It is important to understand that there is no "correct" pressure for 'RM1' and 'LM1'.

The reading must simply be 'or more' as described above. It is NOT NECESSARY for both motors to have the same readings. Motors may perform differently from one machine to another or even from one motor to another on the same machine.

1. Set parking brake ON, adjust speed control (if equipped) to the fully forward position, lower grapple and dozer and shut off the engine.

2. Adjust auxiliary brake set-up caliper to 50 lbf/ft, to lock the rotating Brake disc.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF/FT.

12. Alternately apply 125 psi and 135 psi at 'X'.

Confirm that at 125 psi 'RM1' and 'LM1' ports read 800-1000 psi and at 135 psi 'RM1' and 'LM1' ports read 2125 psi or more. Repeat several times to ensure that the setting does not change.

•

13. If these readings are obtained, then the motor begin of displacement control setpoint is now between 125 and 135 psi.

If not, readjust begin of displacement screw on failing motor and check again for 125 psi (low pressure) and 135 psi (high pressure).

336-3AX

When properly set, this means that the motors will begin to stroke in the pressure range of 125-135 psi. This is a critical setting for the smooth and efficient drive operation of the machine.

AUXILIARY BRAKE SET-UP CALIPER

3. Connect a 0-1000 psi gauge to the ‘X’ test port , two 0-10,000 psi gauges to the ‘LM1’ and 'RM1' testports a 0-10,000 psi gauge to the ‘M2’ port on the drive pump.

14. The motor pressure override (POR) must be re-adjusted to complete this procedure.

Refer to MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR) below.

LM1

••

620-M6

RM1

X

•• ••

TEST PORT COMPARTMENT

4. To set the motor begin of displacement control pressure, it is necessary to temporarily adjust the hydrostatic PUMP pressure override to 4150 psi.

8.42

Tigercat 620 Skidder

Drive

5. Disconnect power wire from the parking brake switch terminal.

PUMP PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.) • 5/16" ALLEN KEY • 15/16" WRENCH

CAUTION Avoid the risk of unintentionally driving the machine with this wire disconnected from the parking brake. Also, avoid the risk of unintentionally driving the machine with the auxiliary brake set-up caliper engaged.

Driving the machine with either brake engaged will result in overheating of the brakes which could cause a fire in the machine.

•• GAUGE TEST PORT 'M2' • PORT SIZE - 06 JIC

6. Start the engine, set throttle control to FULL. 7. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the hydrostatic drive PUMP pressure override (POR) to achieve a pressure at ‘M2’ of 4150 psi @full throttle.

333-9

Reconnect the pilot control lines to the drive pump at X1 and X2 before proceeding to the next step.

The machine should not be able to move while the brake pedal is depressed.

9. Temporarily disconnect the pilot control lines entering the drive pump at X1 and X2. Both hoses must be plugged to achieve the pressure reading.

SAUER DRIVE PUMP P.O.R. VALVE

throttle (the same value as charge pressure) at the ‘X’ test port. It must read this for 15 seconds, to ensure that the reading is correct. If it is not correct, repeat the procedure until it is correct for both pedals.

CAUTION

8. To set the motor pressure override adjustment (POR), it is ALSO necessary to achieve a 450-460 psi pressure reading at the ‘X’ test port in order to reset correct foot pedal travel.

•

10. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, observe the pressure at ‘LM1’ and 'RM1'. A reading of 2075 psi (half of ‘M2’) @ full throttle should register if the motor pressure override adjustment is set correctly. Check both motors.

If the reading is LOW; turn the motor pressure override adjusting screw IN (clockwise) until a correct reading at the ‘LM1’ and 'RM1' test ports (2075 psi @full throttle, half of ‘M2’) is obtained with the locknut tightened. Release the FORWARD foot pedal and re-apply to ensure that the gauge reading at ‘RM1’ and 'LM1' is 2075 psi. If it is not correct re-adjust the motor pressure override adjusting screw.

CAUTION To avoid spraying of hydraulic oil under pressure DO NOT press drive pedals while hoses are disconnected and unplugged.

CAUTION

If the reading is HIGH; turn the motor pressure override adjusting screw OUT (counter-clockwise) until a correct gauge reading at ‘LM1’ and 'RM1' port (2075 psi @full throttle, half of ‘M2’) is obtained with the locknut tightened. Release the FORWARD foot pedal and re-apply to ensure that the gauge reading at ‘RM1’ and 'LM1' is 2075 psi. If it is not correct re-adjust the motor pressure override adjusting screw.

Do NOT adjust the drive pedal stroke limiting screw IN any further than the minimum required to achieve 450-460 psi (the same value as charge pressure). Damage to the foot pedal can occur if the pedal is allowed to stroke more than is required.

With the aid of an assistant, hold down the brake pedal and adjust the FORWARD and the REVERSE foot pedal stroke limiting screws (located under pedals) to give a pressure reading of 450-460 psi @full

This adjustment must be done on both motors. When properly set the motor 8.43

Tigercat 620 Skidder

Drive

pressure override adjustment setpoint will be 4150 psi. Re-check frequently while adjusting by having assistant release and depress pedals.

SUMMARY: The settings must be made in the order shown.

MOTOR MINIMUM DISPLACEMENT ADJUSTMENT:

NOTE: The 'X' gauge reading (charge pressure) will drop from its set value of 450-460 psi while depressing the brake and FORWARD foot pedal. This is normal. The 'X' gauge should read no lower than 380 psi.

1. Check adjusting screw for proper length BEGIN OF DISPLACEMENT ADJUSTMENT: 1. Adjust pump POR to 4150 psi @ full throttle.

2. Turn both motor POR IN carefully until lightly seated.

MOTOR BEGIN OF DISPLACMENT ADJUSTING SCREW MINIMUM DISPLACEMENT ADJUSTING SCREW

3. Adjust reverse pedal to 125 psi and forward pedal to 135 psi @ full throttle at 'X'.

• ••

4. Apply 135 psi at 'X' (forward pedal).

5. Adjust both motor begin of displacement to 2125 psi or more @ full throttle.

••

6. Apply 125 psi at 'X' (reverse pedal).

(SOME HOSES REMOVED FOR CLARITY)

320-23

7. Check for a reading of 2025 psi or less @ full throttle.

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

8. Apply 135 psi at 'X' (forward pedal).

DRIVE MOTOR (R.H. SHOWN)

9. Check for a reading of 2125 psi or more @full throttle at 'RM1' and 'LM1'.

11. With the aid of an assistant, hold down the brake pedal, full throttle and while depressing the REVERSE foot pedal, reset the POR on the drive PUMP @full throttle at ‘M1’. See chart at the beginning of DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS for SAUER PUMP in this manual for the correct pump POR setting.

10. Motor POR must be reset. See below.

POR ADJUSTMENT: 1. Adjust pump POR to 4150 psi @ full throttle.

(Done in step 1 above) 2. Adjust forward and reverse pedals to give 450-460 @ full throttle. Note that the pilot control lines entering the drive pump at X1 and X2 need to be temporarily disconnected to achieved this reading, then reconnected.

12. With the aid of an assistant, hold down the brake pedal, full throttle and while depressing the FORWARD foot pedal, reset the POR on the drive PUMP @full throttle at ‘M2’. See chart at the beginning of DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS for SAUER PUMP in this manual for the correct pump POR setting.

3. Adjust both motor POR to 2050-2100 psi @ full throttle (half of 'M2'). The motor POR set point is now 4150 psi.

4. Adjust REVERSE pump POR at 'M1' @ full throttle. See chart at the beginning of DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS for SAUER PUMP in this manual for the correct pump POR setting.

13. Set the parking brake ON, and shut off the engine.

14. Remove all pressure gauges and reinstall all plugs and caps.

15. Reconnect the PARK BRAKE SWITCH POWER WIRE to the switch.

5. Adjust FORWARD pump POR at 'M2' @ full throttle. See chart at the beginning of DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS for SAUER PUMP in this manual for the correct pump POR setting.

16. Re-adjust the auxiliary set-up caliper to its ORIGINAL POSITION (loose and locked with a cotter pin) using a wrench to back-off the screw adjustment. Friction between the brake caliper and the rotating brake disc can cause a fire.

8.44

Tigercat 620 Skidder

Drive

TRANSMISSION The transmission drives both the front and rear axles of the machine. Power is supplied by two hydraulic motors mounted to the input side of the transmission. The output shafts transmit the power to both the front and rear axles.

The gears and bearings in the transmission are lubricated by splash lubrication inside the case.

The oil level in the transmission must always be kept up to the proper level indicated on the dipstick. Refer SECTION 3 of this manual for the recommended lubricant.

DIPSTICK

•

620-M6

TRANSMISSION OIL LEVEL

The transmission disconnect lever is used to shift the transmission between the DRIVE and NEUTRAL positions, e.g. NEUTRAL for towing the machine.

DISCONNECT LEVER

•

312-14A

TRANSMISSION DISCONNECT LEVER

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

CAUTION When the transmission is in neutral, never tow the machine at over 2 m.p.h. and never press the forward or reverse pedals, as this will cause significant damage to the transmission.

For more information on towing, Refer to TOWING INSTRUCTIONS in SECTION 2 of the OPERATOR'S MANUAL.

8.45

Tigercat 620 Skidder AXLES

Drive

Power from the two drive motors is transmitted to the front and rear axles via a transmission and the front and rear drive shafts.

DRAIN (TOP)

The rear axle assembly is bolted directly to the rear frame. The front axle assembly is pivot mounted to the front frame allowing it to oscillate.

Apart from the mounting, both front and rear axle assemblies are configured in a similar way except that the front axle has internal brakes and the rear has none.

DIFFERENTIAL LOCK (BOTTOM)

Each axle assembly consists of (1) input yoke, (2) spiral bevel gear set, (3) differential gear set, (4) Hydraulic differential lock, (5) Inboard multiple wet disk brakes, (1-each side in front axle only) (6) inboard planetary final drives, 1-each side and (7) axle housings and shafts.

REAR AXLE

26KSM

DIFFERENTIAL LOCK (BOTTOM)

BRAKE

The final drive (6) is an inboard mounted planetary gear arrangement which further reduces speed and increases torque to the axles. The input side receives drive power from the differential via a sun gear shaft. The output side (planetary carrier) is splined on to the axle.

DRAIN

The lubricant in both axle assemblies is hydraulic oil. There are drain lines from each axle plumbed into the machine hydraulic system. These drain lines take care of internal leakage from the differential locks and brakes, which use the same hydraulic oil as the machine. Refer also to AXLE LUBRICATION in THIS SECTION. 1

27KSM

FRONT AXLE HYDRAULIC CONNECTIONS

2 GREASE SEAL

3

GREASE FITTING

4

6

7

OUTER BEARING

GREASE SEAL

5 AXL-3

AXLE ASSEMBLY CROSS SECTION (FRONT SHOWN) - EARLIER DESIGN 8.46

Tigercat 620 Skidder

Drive

DIFFERENTIAL AND DIFFERENTIAL LOCKS The differentials (3) distribute the power to each side of the axle while allowing the wheels to turn at different speeds. The differential locks (4), in the front and rear axle assemblies, are hydraulically controlled and can be independently turned ON or OFF by switches in the cab.

BRAKE DISK BACKING PLATE

Placing one or both switches in the ON position, energizes the differential lock control valve solenoid (located on the multifunction valve) and directs pilot oil to the corresponding differential clutch pack assembly pistons to lock the differential(s).

ANNULAR PISTON AXL-BRK

SERVICE BRAKES (FRONT AXLE ONLY)

This condition provides positive drive to both wheels of the axle when tractive conditions might otherwise allow one wheel to spin.

The "wet" disk type service brakes consist of an annular piston, a brake disk with brake facing material, and a brake backing plate. One brake assembly is located on each side of the differential case and before the final drive.

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

1

ANNULAR BRAKE

The piston and the backing plate are attached to the case and the brake disk is splined on to the sun gear of the planetary final drive.

When the brake foot control in the cab is depressed, brake pressure oil moves the piston up against the brake disk and traps it between the piston and the backing plate to apply the brakes. Maximum operating pressure for the brakes is 1000 psi. For information on the hydraulic circuit refer to SECTION 9 of THIS MANUAL.

2 4

6

7

3

5 AXL-4X

AXLE ASSEMBLY CROSS SECTION (FRONT SHOWN) - LATER DESIGN 8.47

Tigercat 620 Skidder

Drive AXLE LUBRICATION The axles are allowed to completely fill with oil to the top of the differential case. This hydraulic oil buildup inside the differential case is due to normal internal leakage from the differential locks and is used as lubricant for the differential. The excess oil drains back to the hydraulic tank via the axle drain line.

BRAKE LINING INSPECTION Inspection ports are provided in the differential case on the front axle and are located on each side of the pivot boss when viewed from the side opposite the input shaft.

• •

Remove brake inspection port plugs Inspect brake linings on both sides of the disk.

• If brake lining material is worn down to the bottom of the oil grooves, brake backing plate and annular piston pressure plate assemblies must be replaced.

BRAKE BLEEDING

DRAINING THE AXLES Care should be taken when draining the hydraulic oil from the axles, not to also drain the oil from the hydraulic tank. To prevent oil from siphoning from the tank, first remove the hydraulic drain line from the top of the axle to allow air to vent into the axle when the bottom drain plug is removed and oil drains out. The line that is removed must be capped to prevent draining from the hydraulic tank.

The front axle assembly is equipped with two brake bleed screws, one for each side. Brakes must be bled whenever there has been potential for air to enter the system, such as removal of hydraulic line. Both passages must be bled one at a time.

The time to schedule an oil change in the axles is when doing the seasonal oil change on the hydraulic oil tank, as they are part of the overall system and use the same oil.

BLEED SCREWS SINGLE BRAKE LINE ACTUATES BOTH BRAKES

IMPORTANT

SINGLE BRAKE PEDAL

Care should be taken to refill the axle(s) before moving the machine after draining.

• •

•

FILLING THE AXLES The axles must be filled by pumping oil in through the case drain plug port on the top right side of the differential housing on the front axle and the top left side of the differential housing on the rear axle. A vent plug also at the top of the axle should be removed to allow air to vent out and to allow oil to exit when the axle is full of oil.

• • FRONT AXLE ASSEMBLY AXL-BRK1

DUAL BRAKES (FRONT AXLE)

PROCEDURE

Rear Axle: There are two vent plugs (11/16") on top of the rear axle. One on each side under the grapple valve. Remove cover plate to access.

1. Place parking brake ON. 2. Place a clear plastic tube over bleed screw with other end in a container.

3. Start engine and run at IDLE 4. Loosen bleed screw 5. Push and hold brake pedal down until brake bleeding procedure is complete (no air bubbles in clear plastic tube).

6. Close bleed screw when oil is free of air.

7. Release brake pedal.

8. Repeat above procedure for each bleed screw.

REMOVE BOTH PLUGS, USE ONE FOR FILLING AND ONE FOR BREATHER

•

724D-D30

8.48

••

REAR AXLE

Tigercat 620 Skidder

Drive ALTERNATE METHOD OF FILLING AXLES The following alternative method of filling the axles is suitable for refilling drained axles only. If you have done major service, a rebuild, replaced any major component or drained the machine of hydraulic oil refer to STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE in SECTION 3 of THIS MANUAL.

•• ••

1. Ensure the articulation lock pin is installed.

CASE DRAIN PLUG

VENT PLUG

2. With engine at IDLE, parking brake ON, hold foot brake down, bleed brakes in front axle.

3. Turn both differential locks ON and run engine at IDLE for 30 minutes to purge air and fill axles with oil (axles fill with leakage from differential locks). If wheels have been removed, operate forward and reverse pedals very slowly to fill axles with oil.

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

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

6.

635-P06

FRONT AXLE (RIGHT SIDE OF MACHINE)

Front Axle: Access to the vent plug (1 1/4") on the back, right side, near the top, of the front axle.

Tilt the right side of the axle down for easier access.

Note: If ONLY the axles were drained and not the entire hydraulic system, the port from which the drainline was removed will provide the vent and oil will exit from this port when the axle is full of oil. The drainline should remain capped until it is reinstalled.

Care must be taken to ensure that both axles are completely full of oil and that all plugs, fittings and lines are tight.

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

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

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

CAPACITIES For front and rear axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in SECTION 3 of THIS MANUAL.

8.49

Tigercat 620 Skidder

Drive

WHEEL INSTALLATION NOTE: All wheel installation joints and surfaces should be clean, flat surfaces (free of paint, grease and oil etc.) using grade 8 bolts, hardened washers and standard torque practices.

• Use tapered assembly studs to help with wheel installation. Two or three studs can be used on each side.

2.17" MIN. FULL THREAD

.79" .406" DRILL

.06" X 45° 3/4" - 10 UNC THREAD OR 7/8" - 14 UNF THREAD

20°

2.64" 3.41"

TAPERED ASSEMBLY STUD 3/4" & 7/8" AXL-WHL

The tapered assembly stud shown can be fabricated to aid in wheel installation on an axle flange.

•

Thoroughly clean the wheel bolts, washers and the tapped holes in the axle flange. Two wheel bolt thread sizes are in use. All early machines used 3/4" - UNC bolts. All later machines used 7/8" - UNC bolts. When cleaning in flange, double check and be sure to use the proper size tap for the threads.

• Install the wheel with the aid of the tapered assembly studs.

• Install wheel bolts by hand to insure bolts are not cross threaded.

• Remove assembly studs and install the remaining bolts.

• Torque wheel bolts to the following values: 3/4"-10 UNC torque to 282-310 lbf/ft.

7/8"-14 UNF torque to 500-550 lbf/ft.

WARNING If a power wrench is used, be sure that the wheel bolts are first hand-engaged to prevent stripping. Operate the wrench slowly to prevent damage to the threads.

8.50

Tigercat 620 Skidder FRONT AXLE OSCILLATION SHIM CHECK AND ADJUSTMENT

Drive 3.

Set a dial indicator against the spiral bevel input pinion shaft on the input end of the axle.

1. The axle must be securely bolted to the chassis through the axle supports (front and back). Torque all axle mounting bolts. Refer to TORQUE CHART in SECTION 3 of THIS MANUAL. 2. Temporarily remove the two grease hoses from the axle pivot to prevent grease pressure from affecting the set-up. Plug hose ends to avoid contamination.

AXLE-05

SET DIAL INDICATOR

4. Using a long pry bar between the chassis and the axle housing pry the axle backward. It may be necessary to tip the axle from side to side to position the axle fully back for a proper reading.

AXLE-13

AXLE-17

REMOVE GREASE HOSE

AXLE-06

USE LONG PRY BAR

AXLE-07

BETWEEN CHASSIS AND AXLE HOUSING

REMOVE GREASE HOSE

8.51

Tigercat 620 Skidder

Drive 10. Remove the outer cover plate. Carefully remove the centre pivot cover plate from the axle (6 bolts). Care must be taken to ensure that the thrust washer (a round perforated disk) and shims do not fall.

AXLE-10

TIP AXLE SIDE TO SIDE

AXLE-12

REMOVE CENTER PIVOT COVER

SHIMS

•• AXLE-11

TIP AXLE SIDE TO SIDE

THRUST WASHER

••

5. Zero the dial indicator.

6. Using a long pry bar between the chassis and the axle housing pry the axle forward. It may be necessary to tip the axle from side to side to position the axle fully forward for a proper reading.

AXLE-16

THRUST WASHER AND SHIMS

11. If the measurement was below .004” ADD shims to get the required range. A 0.010” shim will change the reading by 0.010”. Stock shims are 0.010” and 0.040” thick.

7. Read the dial indicator. Axle movement should be .004” to .014”. Check the reading twice by repeating steps 4 through 7.

12. If the measurement was above .014” REMOVE SHIMS to correct the reading. A 0.010” shim will change the reading by 0.010”. Stock shims are 0.010” and 0.040” thick.

8. If the reading is within the required range go to step 16.

9. If the reading is not within the required range follow steps 10 through 15 to adjust.

13. Replace the thrust washer.

14. Replace the center pivot front cover plate.

Make sure that the thrust washer and shims do not slide out of place and become damaged.

Torque cover bolts (6) to 80 lbf-ft.

15. Repeat steps 4 to 7 to check the adjustment again. This reading should be checked twice.

16. Reinstall grease hoses in the axle pivot and add grease until back pressure is felt.

8.52

Tigercat 620 Skidder SECTION 9 - BRAKES SEPTEMBER 2003

CONTENTS - SECTION 9 ACCUMULATOR ACCUMULATOR ........................................................................................ 9.2 CHARGING AND TESTING DEVICE ......................................................... 9.3 CHARGING THE ACCUMULATOR ............................................................ 9.3 CHECKING GAS PRESSURE .................................................................... 9.2 BRAKES ACCUMULATOR AND SERVICE BRAKES ................................................ 9.8 BRAKE PILOT VALVE ................................................................................ 9.2 PARKING BRAKE ..................................................................................... 9.10 CHARGING VALVE, ACCUMULATOR .......................................................... 9.3 CIRCUIT DIAGRAM ....................................................................................... 9.5 DIFFERENTIAL LOCKS ADJUSTING DIFFERENTIAL LOCK VALVES: ........................................... 9.8 CIRCUIT DESCRIPTION ............................................................................ 9.8 MAIN PUMP ................................................................................................... 9.4 MULTIFUNCTION VALVE ADJUSTING HIGH PRESS RELIEF AND MAIN PUMP ............................. 9.6 DESCRIPTION ........................................................................................... 9.6 HIGH PRESSURE RELIEF ......................................................................... 9.6 PARKING BRAKE ........................................................................................ 9.10

Tigercat 620 Skidder

Brakes

BRAKE PILOT VALVE

ACCU MULATOR

The pilot valve is a manually operated directional valve and operates on the same principal as a pressure reducing valve.

The accumulator is bladder type and is installed with a nitrogen pre-charge pressure of approximately 750 psi.

As the pedal is depressed, pressure is provided to the brakes in the front axle from the accumulator.

A reaction piston in the valve senses this increase in brake pressure and relays feedback to the operator, i.e. as brake pressure increases the pedal effort increases proportionately.

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

A positive stop in the brake valve limits the brake pressure to a preset value.

Prior to performing any maintenance or system modifications, exercise CAUTION to bleed off any stored system pressure by stopping the engine and fully applying the brake foot pedal 50 times or more

This preset value is determined by the requirements of the brakes in the front axle, which in this case is 1000 psi. The brake pedal therefore regulates the pressure in the brake lines to 1000 psi.

VALVE GUARD VALVE CAP

When the pedal is released, the spool returns to its neutral position and allows the brake cylinders to drain to tank.

GAS VALVE

BODY A

P

BLADDER

T

POPPET (Seats against oil port after oil evacuation)

HYDRAULIC CONNECTION T

ACCU-1

A

ACCUMULATOR (BLADDER TYPE)

CHECKING THE GAS PRE-CHARGE PRESSURE

P

Bleed off the system pressure as stated earlier.

MO-02

CROSS SECTION OF VALVE BODY

After the accumulator has been put in service, the pre-charge pressure should be checked with an accumulator charging a nd testing device.

MO-01

BRAKE VALVE

Install the charging and testing device onto the gas valve. While depressing the button on the charging device, observe gas pressure reading on gauge.

If the gas pre-charge is low, investigate cause and correct. Possible causes of lost pre-charge pressure include leaking or damaged gas valve, or damaged bladder.

WARNING The accumulator must not be altered. DO NOT weld or machine the pressure vessel.

9.2

Tigercat 620 Skidder

Brakes

CHARGING THE ACCUMULATOR

WARNING USE ONLY NITROGEN for charging accumulators, NEVER USE OXYGEN OR AIR, due to the risk of explosion.

NOTE: A detailed instruction sheet is provided with the charging and testing device. The following is only a suggested guide.

NITROGEN BOTTLE HOSE*

PRESSURE GAUGE*

ADAPTER* ADAPTER* ACCUMULATOR ASSEMBLY PART NO. 90254 INCLUDES PARTS SHOWN * ACCU-2

CHARGING AND TESTING DEVICE

•

Close the drain valve on the charging and testing device and connect the hose to the nitrogen bottle.

•

Remove the valve guard and cap.

•

Screw the charging and testing device onto the gas valve.

•

Open the gas shut-off valve on the nitrogen bottle and allow gas to flow slowly into the accumulator.

•

Close the shut-off valve frequently and check the value of the pre-charge by depressing the button on the charging device and observe the gauge.

•

If the pre-charge pressure is too high, it may be reduced by opening the drain valve and carefully depressing the button on the charging device.

Note: The pre-charge pressure will vary dependant upon the temperature. Once the desired pre-charge is reached, wait two minutes for the gas temperature to equalize.

Re-check pre-charge and adjust if necessary.

•

Disconnect hose from nitrogen bottle.

•

Remove charging and testing device from accumulator and install valve cap and guard, torque to 175-350 lbf/ins.

•

Check to ensure there are no leaks, if gas valve is leaking, it should be replaced. Use only valves approved for accumulator service.

NEVER USE AN AUTOMOTIVE TYPE VALVE. 9.3

Tigercat 620 Skidder MAIN PUMP

••

Brakes The main pump is controlled by a pressure compensator mounted on the top of the main pump. The pressure compensator provides maximum pump flow until the main pump reaches the preset main pump POR (pressure override) setting. The pressure compensator then regulates output flow to match machine requirements for the steering, brake, grapple, and dozer functions.

MAIN PUMP P.O.R. ADJUSTING SCREW

For later machines with a dozer valve inlet relief installed the dozer inlet relief valve acts as the primary main pump high pressure relief and the multifunction valve high pressure relief is the secondary relief.

For earlier machines without a dozer valve inlet relief valve installed the multifunction valve high pressure relief is the only main pump relief valve.

Refer to DOZER VALVE INLET RELIEF in SECTION 14 of this MANUAL for information about converting existing machines to include a dozer valve inlet relief.

HOSES REMOVED FOR CLARITY

630-PH2

MAIN PUMP The main pump is mounted at the top left of the pump drive gearbox. A splined adapter connects the input drive shaft of the pump directly to the output of the gearbox. The gearbox is driven directly by the diesel engine through a flexible plate coupling.

The main pump provides hydraulic oil to the multifunction valve, which in turn supplies oil to the brake/differential lock circuit, steer circuit, grapple control valve related circuits and the dozer circuit.

The main pump is a variable displacement pressure compensated axial piston pump. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume of oil flow from the piston pump is determined by the angle of this swashplate. When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow to the open loop. As the swashplate is de-stroked the flow smoothly decreases until there is no flow at an angle of zero (0o).

9.4

Tigercat 620 Skidder

630B-16

Brakes

BRAKE/DIFFERENTIAL LOCK CIRCUIT 9.5

Tigercat 620 Skidder MULTIFUNCTION VALVE

Brakes

THE MULTIFUNCTION VALVE PROVIDES THE FOLLOWING:

RP1 TEST PORT

P3 TEST PORT

•

1. High pressure relief for the main hydraulic pump (earlier machines). For machines with a dozer valve inlet relief installed as the primary main pump relief the multifunction valve high pressure relief becomes a secondary relief (later machines).

•

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

620-M6

2. The two solenoid pilot valves direct pressure from the main pump to operate the differential locks.

3. Supplies system pressure oil for the emergency braking system (accumulator and brakes in front axle).

PRESSURE REDUCING VALVE

HIGH PRESSURE RELIEF VALVE

SEQUENCE VALVE

4. It also serves as a distribution point for oil to the steering, grapple, dozer and winch functions.

Note: The pressure reducing valve, sequence valve and relief valves on the multifunction valve are set by loosening the locknut and turning the adjusting screw OUT (counter-clockwise) to reduce the pressure setting and IN (clockwise) to increase the pressure setting.

• ••

•

HOSES REMOVED FOR CLARITY

MULTIFUNCTION VALVE

321-2A

1. HIGH PRESSURE RELIEF The multifunction valve manifold is used as a connection/distribution point for the high pressure oil from the main hydraulic pump. A high pressure relief valve is installed in this manifold to divert excess oil back to tank through port T1. For machines with a dozer valve inlet relief installed as the primary main pump relief the multifunction valve high pressure relief becomes a secondary relief (later machines).

•

MAIN PUMP P.O.R. ADJUSTING SCREW

TO ADJUST HIGH PRESSURE RELIEF VALVE AND MAIN PUMP PRESSURE: 1. Parking brake ON, grapple down, dozer down and shut off the engine.

HOSES REMOVED FOR CLARITY

630-PH2

MAIN PUMP

2. Connect a 0-5000 psi gauge to the ‘P3’ test port.

DOZER VALVE INLET RELIEF

3. Remove the right front cover plate of the engine enclosure.

4. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

•

5. Start the engine, hold down the brake pedal and set the throttle to IDLE.

DOZER VALVE INLET RELIEF 630-D42

9.6

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF.

Tigercat 620 Skidder

Brakes adjusting screw on the side of the pump. (through the cover plate hole).

6. It is necessary to temporarily increase the pressure of the main pump to 3850-3900 psi.

7. Reset the multifunction valve high pressure relief (reading on the 'P3' gauge).

a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

For machines with dozer inlet relief valve set to 3575-3600 psi plus 4 flats.

Turn the dozer inlet relief valve (if equipped) IN all the way (clockwise) until lightly seated.

For machines without a dozer inlet relief valve set the multifunction to 3500-3600 psi .

WARNING: Observe the pressure gauge while turning the relief valve adjusting screw(s) IN. The main pump could be stuck in the fully stroked position. Back off the adjusting screw if the pressure rises above 3600 psi and investigate the main pump for proper operation.

8. Reset the dozer valve inlet relief (if equipped) to 3500-3525 psi.

9. Reset the pump POR to 3000-3100 psi on 'P3' gauge, using the adjusting screw on the side of the pump.

10. Turn off the engine, remove the gauge, install the cap on the port and replace the cover plate.

b. Turn the main pump POR to 3850-3900 psi on 'P3' gauge using the pressure

AW110SCH

2

1

•

SEQUENCE VALVE

SOLENOID VALVE(S)

1 SOLENOID VALVES

AW108-2

90016

3 PRESSURE REDUCING VALVE

DIRECTIONAL VALVE

•

4 HIGH PRESS. RELIEF VALVE 91983

AW108-1

HIGH PRESS. RELIEF VALVE 4

CHECK VALVE

• •

SEQUENCE VALVE

AW110

•

2

PRESSURE

•

MULTIFUNCTION VALVE 9.7

3 REDUCING VALVE

Tigercat 620 Skidder

Brakes

2. DIFFERENTIAL LOCKS The differential locks in both front and rear axles are controlled by two switches located on the joystick control lever in the cab. (Note some later machines have differential lock switches located on the side control panel.) The switches control two solenoid pilot valves in ports ‘C1’ and ‘C2’ of the multifunction valve manifold. Placing the switch(es) in the ON position energizes the solenoid pilot valve(s) which direct pilot oil to the differential lock clutch packs in one or both axles to lock the differentials and provide drive torque to both wheels.

P3 TEST PORT

RP1 TEST PORT

• ••

620-M6

The pressure reducing valve supplies oil through the directional valve and the two solenoid valves to the differential locks at a reduced pressure of 625 psi. If the pressure rises above 750 psi the sequence valve sends a pilot signal to the directional valve, which closes and cuts-off the oil supply to the differential locks, preventing problems due to high pressures.

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

PRESSURE REDUCING VALVE

HIGH PRESSURE RELIEF VALVE

SEQUENCE VALVE

TO ADJUST DIFFERENTIAL LOCK VALVES: 1. Parking brake ON, grapple down, dozer down and shut off the engine.

••

2. Connect a 0-1000 psi gauge to the ‘RP1’ test port.

• •• HOSES REMOVED FOR CLARITY

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

321-2A

MULTIFUNCTION VALVE

3. EMERGENCY BRAKING SYSTEM (ACCUMULATOR AND BRAKES IN FRONT AXLE)

4. Start the engine, hold down the brake pedal and set the throttle to IDLE. Turn OFF the Differential Locks.

The main pump supplies oil directly to the accumulator, via a check valve inside the multifunction valve manifold and out through port 'A', charging the accumulator to a pressure of 3000psi.

5. Temporarily turn the sequence valve (closest to the mounting surface) on the multifunction valve, all the way IN, very carefully, until it just touches bottom. Do not over tighten.

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.

6. Adjust the pressure reducing valve (beside sequence valve) to get 750-760 psi on 'RP1' gauge.

This oil from the accumulator side of the check valve is sent, through an orifice at port 'B' to the brake pilot valve.

7. Re-adjust sequence valve OUT, until the pressure (at RP1 gauge) rapidly drops to near ZERO. Turn it back IN until the pressure rises to 750-760 psi and then VERY SLOWLY turn it back OUT until it drops to near ZERO. Lock it at this point.

NOTE: The accumulator will hold sufficient pressure, after the engine is turned off, for up to 5 brake applications, beyond this the pressure drops substantially.

8. Re-adjust the pressure reducing valve OUT to get 625-635 psi at 'RP1'gauge. Lock it at this point.

Refer to BRAKE PILOT VALVE and ACCUMULATOR in THIS SECTION for further information on this brake valve and the accumulator.

9. Engine off, remove gauge and install cap on port.

9.8

Tigercat 620 Skidder

Brakes

TO CHECK ACCUMULATOR AND BRAKE PILOT VALVE 1. Parking brake ON, grapple down, dozer down and shut off the engine.

2. Press the brake pedal 30 to 40 times to release the pressure stored in the accumulator.

CAUTION Serious injury can result if this is not done.

3. Connect a 0-5000 psi gauge to the ACCUM test port in the test port compartment.

4. Ensure that the hydraulic oil temperature is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 5. Start the engine and run for 10 seconds, then shut it off. The pressure should rise rapidly to 3000 psi and start to fall when the engine is shut off. The accumulator is now holding pressure for the braking system.

6. There will be a slow drop in pressure as the accumulator drains, through valve leakage in the system. The pressure should not drop below 1500 psi in the first 5 minutes. Leakage rate will be rapid at first and will slow down as the pressure drops.

7. Start and run the engine for a further 10 seconds and shut it off, to recharge accumulator. Pump the brakes 5 times, the pressure should remain above 800 psi. It should take 5 or more additional (total of 10 or more) brake applications to drain the accumulator from a full charge of 3000 psi.

8. Remove the gauge and fitting and reinstall the plug in the port.

4. DISTRIBUTION POINT TO GRAPPLE, DOZER AND WINCH FUNCTIONS Pressure port 'P1' supplies oil to the priority valve which in turn feeds the steer, grapple and dozer control valves.

For information on the STEER, GRAPPLE AND DOZER CIRCUITS, refer to the appropriate sections in THIS SERVICE MANUAL.

9.9

Tigercat 620 Skidder PARKING BRAKE

Brakes There are two ways to adjust the parking brake to compensate for wear; (1) Turning the knob on the end of the brake lever or, (2) at the caliper by loosening the jamnut on the cable clevis, removing the clevis and screwing the clevis further onto the cable end.

A parking brake lever is located in the cab to the left of the drivers seat. It is connected by a cable to a disk brake caliper assembly mounted on the rear axle output shaft of the transmission.

The parking brake operates ONE of the TWO disc brake calipers on the transmission rear axle output shaft.

The brake is correctly adjusted when resistance is encountered half way through the brake lever's free travel.

The SECOND, AUXILIARY SET-UP Caliper is used in setting up the hydraulics on the machine.

When the auxiliary set-up caliper is not being used, the adjusting nut should be loose with the jam nut tightened against it. Friction between the brake caliper and the rotating brake disc can cause a fire. Refer to individual set-up procedures for further in formation on the use of the auxiliary brake set-up caliper.

A proximity switch, part of a drive prevent circuit, is attached to the brake lever housing. When the brake lever is in the ON position the proximity switch contacts are CLOSED. When the brake lever is in the OFF position the proximity switch contacts are OPEN. The drive prevent circuit prevents the machine from being driven when the parking brake is ON.

WHEN NOT IN USE FOR SET-UP: ADJUSTING NUT SHOULD BE LOOSE WITH JAM NUT TIGHTENED AGAINST IT.

••

336-3AX

AUXILIARY BRAKE SET-UP CALIPER

Pulling up on the parking brake lever applies the brake. Pushing down on lever releases the brake.

Spring force in the caliper assembly holds the brake pads away from the disk.

••

ADJUSTING KNOB

320-8

9.10

Tigercat 620 Skidder SECTION 10 - OIL COOLER/RADIATOR AND FLEXXAIRE® FAN JANUARY 2003

CONTENTS - SECTION 10 CIRCUIT DESCRIPTION AND OPERATION .............................................. 10.4 CIRCUIT DIAGRAM ..................................................................................... 10.5 FLEXXAIRE® FAN MAINTENANCE (OPTIONAL ITEM) ............................. 10.6 BLADE LOCK-OUT PROCEDURE ......................................................... 10.10 CHECKING HUB OIL .............................................................................. 10.12 CIRCUIT DIAGRAM.................................................................................. 10.9 FAN OVERVIEW ...................................................................................... 10.8 HUB OIL CAPACITY (APPROXIMATE) .................................................. 10.12 LUBRICATION AND SERVICE INTERVALS .......................................... 10.11 MAINTENANCE CHECKLIST ................................................................. 10.13 REMOVE DEBRIS USING CLEAN FUNCTION ....................................... 10.8 SAFETY .................................................................................................... 10.6 OIL COOLER/RADIATOR DESCRIPTION .................................................. 10.2 RADIATOR/OIL COOLER DESCRIPTION .................................................. 10.2

Oil cooler/Radiator and Flexxaire® Fan

Tigercat 620 Skidder OIL COOLER/RADIATOR The hydraulic oil cooler and engine radiator are mounted side by side as an assembly. The assembly is mounted between the fan and A/C condenser core. The A/C condenser core is on hinges to facilitate cleaning. A debris screen is used to protect the complete cooling assembly.

The engine fan draws air from the front of the cab through the engine doors and the debris screen.

This air passes through the A/C condenser core, then the oil cooler/radiator assembly and is blown across the engine. This cooling assembly must be checked daily for accumulation of debris.

For detailed cleaning procedures, refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR'S MANUAL. DOUBLE ELEMENT FILTERS

FROM OIL COOLER

•• ••

RESERVOIR

• ••

COOLING PUMP SUCTION LINE

•

•

CHARGE PRESSURE OUTLET FILTER

TO DISTRIBUTION MANIFOLD

•• •• COOLING PUMP 303-24

COOLING PUMP TO OIL COOLER CONNECTION

PUMPS

10.2

Oil cooler/Radiator and Flexxaire® Fan

Tigercat 620 Skidder

DEBRIS SCREEN

OIL COOLER

••

PLENUM

RADIATOR

•

•

OIL COOLER 'OUT' CONNECTION TO DOUBLE FILTER

••

•

COOLER TANK RADIATOR TOP HOSE

•

FAN FINGER GUARD

•• A/C CONDENSER

•

••

•• RUBBER BAFFLE

••

•

••

RADIATOR AND OIL COOLER MOUNTS

ENGINE FAN SHROUD

••

7638BIL2

RADIATOR BOTTOM HOSE

RADIATOR AND OIL COOLER INSTALLATION 10.3

NOTE: REGULARLY CHECK FOR DEBRIS ACCUMULATION BETWEEN RADIATOR/ OIL COOLER AND A/C CONDENSER AND BETWEEN SCREENS AND A/C CONDENSER

Tigercat 620 Skidder OIL COOLER CIRCUIT DESCRIPTION AND OPERATION

Oil cooler/Radiator and Flexxaire® Fan

Oil for the entire hydraulic system first passes through the oil cooler. The oil cooler is situated down stream from the cooling pump. The cooling pump draws oil from the reservoir and sends it to the oil cooler. From the oil cooler it passes through the double element filter and on to a distribution manifold located in the front chassis on the right inside wall.

The distribution manifold consists of two main work ports and four return (tank) ports. The last tank port is connected to the hydraulic tank, thus completing a "loop" allowing cooled surplus oil to be returned to the reservoir.

The main pump and the drive pump suction lines are connected to the two work ports in the distribution manifold and draw oil as and when required to perform machine functions such as operate the grapple or drive.

The three tank ports in the distribution manifold collect return oil from the front chassis pilot return manifold, the drive pump and from the dozer valve.

Oil is added to the hydraulic reservoir using the hydraulic hand fill pump located in the step compartment on the right side of the machine.

This oil is pumped through the hydraulic oil fill filter element and directly into the reservoir.

Oil entering the hydraulic reservoir passes through 2 strainers situated inside the reservoir below the oil surface.

For hydraulic oil filling instructions refer to HYDRAULIC HAND FILL PUMP in SECTION 2 of the OPERATOR'S MANUAL. For more information on the hydraulic reservoir, refer to HYDRAULIC OIL RESERVOIR in SECTION 2 of the OPERATOR'S MANUAL.

10.4

Tigercat 620 Skidder

620-12

Oil cooler/Radiator and Flexxaire® Fan

OIL COOLER CIRCUIT 10.5

Tigercat 620 Skidder MAINTENANCE OF FLEXXAIRE® FAN (NOTE THAT THIS FAN IS OPTIONAL) The following information is an excerpt from the manufacturer’s manual. For further information about the Flexxaire® fan please refer to the manufacturer’s installation and maintenance manual.

SAFETY In addition to the safety information presented here, please refer to all the safety instructions outlined in the SECTION 1 of THIS MANUAL prior to working on the Flexxaire® Fan Assembly.

WARNING Please refer to all safety information supplied, prior to doing any work on the Flexxaire® Fan Assembly.

Improper operation, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

The person(s) servicing the product may be unfamiliar with many of the systems or components on the product. This makes it important to use caution when performing any type of service work. A knowledge of the product and/or its components is important before the removal or disassembly of any component.

Oil cooler/Radiator and Flexxaire® Fan A. If possible, make all repairs to the fan assembly on an engine stand or any other suitable stand. Do not attempt to work on the fan assembly if not safely supported or mounted.

B. If repair is to be done to the internal fan components, drain oil from the hub prior to removing any components.

C.

Always use the required tools and be sure you understand how to use them before performing any service work. Keep tools in good condition and replace if necessary.

D. Replace all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.

E. Do not attempt to weld any components on the fan assembly without first contacting Flexxaire® Engineering or one of their approved dealers.

F.

Do not damage wiring harnesses during removal operations. Secure the wiring harnesses so they are not contacting sharp corners, hot surfaces, or rubbing against objects. Do not connect wires to lines containing fluid for the possibility of exploding.

G. If a guard or shield must be removed to perform repair work, use extra caution. Repair any loose or damaged fluid lines, tubes or hoses because leaks can cause fires.

WARNING

WARNING Because of the size of the product and/or its components, the service person(s) should use proper lifting procedures when removing the product and/or any of its components.

Use a hoist when lifting the assembly or any of its components that approximately weigh 23 kg (50 lb.) or more, to avoid back injury.

Make sure all chains, hooks, slings, etc., are in good condition and are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during any lifting operation.

Never use your bare hand to check for fluid leaks.

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

10.6

Tigercat 620 Skidder

Oil cooler/Radiator and Flexxaire® Fan

H. Tighten fasteners to the correct torque. Make sure all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust in an event of a line, tube or seal failure must be installed correctly.

I.

Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. Make sure all guards and shields are properly installed and functioning correctly, before starting the engine or operating the machine.

10.7

Tigercat 620 Skidder

Oil cooler/Radiator and Flexxaire® Fan

FAN OVERVIEW

REMOVE DEBRIS DURING OPERATION USING THE CLEAN FUNCTION

®

The Flexxaire F/X fan systems are designed to minimize overheating caused by debris plugging radiators, screens and guards, and can be used to reduce over cooling due to low ambient temperatures. The fan blades of the Flexxaire® fan vary pitch, not fan speed, to control air flow and direction.

The blade pitch on an F/X fan is controlled hydraulically through two hydraulic ports. These ports supply fluid to a small double acting hydraulic cylinder embedded within the mainshaft.

Pressuring either hydraulic port will move the fan blades into BLOWER (PUSH) or SUCTION (PULL) positions, respectively.

The Flexxaire® F/X fan has a CLEAN MODE used to clean debris from the radiator, oil cooler, A/C condenser and air intake screens during operation. Clean mode changes the pitch of the fan blades causing air flow to move in the opposite direction, thereby forcing dust and debris off the radiator, oil cooler, A/C condenser and air intake screen. Ensure that there are no personnel standing near the machine when performing this operation, as dust and debris will fly out. Refer to FAN SWITCH (OPTIONAL) in SECTION 2 of the OPERATOR’S MANUAL for operating instructions.

When installed on the Tigercat 620 pilot oil is supplied to the hydraulic ports from pilot manifold via two remotely mounted solenoid valves, one for the blower (push) function and another for the suction(pull) function. Refer to FLEXXAIRE® FAN CIRCUIT DIAGRAM in THIS SECTION. For additional information regarding the operation of the Flexxaire® fan refer to FAN SWITCH (OPTIONAL) and CLEANING A/C CONDENSER AND OIL COOLER/RADIATOR in SECTION 2 of THE OPERATOR'S MANUAL.

Standard suction mode. Prescreened air passes through the coolers.

Clean mode. Quickly and effectively removes debris from the heat exchangers and air intake screens.

FLEXXAIRE® FAN OPERATION

10.8

Tigercat 620 Skidder

Oil cooler/Radiator and Flexxaire® Fan

FLEXXAIRE® FAN CIRCUIT (OPTIONAL) 620-34

10.9

Tigercat 620 Skidder

Oil cooler/Radiator and Flexxaire® Fan

BLADE LOCK-OUT PROCEDURE

F.

®

Flexxaire ’s F/X fan contains two lockout pins, 180° apart, built into the hub assembly. In the event that a hydraulic and/or electrical system failure occurs and these systems are unable to change pitch, the blades can be locked-out in a full SUCTION (PULL - Figure 2) or BLOWER (PUSH - Figure 3) blade orientation as required.

The following procedure describes how to lockout the blades.

Deactivate/plug disconnected hydraulic lines.

G. Manually rotate the blades into the desired full pitch orientation.

CAUTION: Hot oil may eject from the hydraulic fittings.

H. Slide the lock-out pins towards the blade and into the holes of the blade mounting shafts.

I.

Tighten the capscrews while the pins are in the holes of the blade mounting shafts. As shown in Figure 5.

#8 CAPSCREW IN EXTENDED POSITION

718-D32

FIGURE 2 SUCTION (PULL)

FIGURE 3 BLOWER (PUSH)

A. Stop the engine of the machine.

718-D30

B. Gain access to the two - #8 capscrews on the rear of the fan hub. Refer to Figure 4.

NOTE: Two - #8 capscrews are spaced 180° apart from one another.

C. Loosen, but do not remove the two capscrews.

D. Disconnect the hydraulic lines from main shaft assembly.

J. Attempt to manually rotate the blades; they should remain locked in the desired pitch mode. However if they do not lock, repeat Steps G through J until blades are locked and then continue.

K. Blades will now maintain their full pitch orientation when the machine engine is started.

E. Cover the hydraulic fittings on the main shaft assembly and hydraulic lines with caps.

#8 CAPSCREW IN RETRACTED POSITION

718-D31

FIGURE 5 LOCKED POSITION

NOTE: No purging will be available until the hydraulic failure is corrected. Contact your local dealer and/or Flexxaire® Manufacturing Inc. for further assistance.

L. Blade lock-out procedure is complete.

FIGURE 4 UNLOCKED POSITION

10.10

Tigercat 620 Skidder FLEXXAIRE® FAN LUBRICATION AND SERVICE INTERVALS The Flexxaire® F/X Fan does require visual inspections and oil checks to be done as illustrated in Table 1.. See Figure 16 for location of oil fill and drain plugs and oil level plug.

A. Mechanical Review •

Ensure that the fan and blades rotate smoothly.

•

Check for damage to fan blades.

•

Monitor wear of internal fan components by oil analysis (optional).

Oil cooler/Radiator and Flexxaire® Fan Table 1: Flexxaire® Fan Service Interval Chart Monthly or 250 hrs.

Visual check for oil leaks.

6 months or 1000 hrs. Check oil level, fan blades. Perform mechanical review.

4 years or 6000 hrs. Oil change.

FLEXXAIRESERVICE.XLS OIL FILL PLUG (DRAIN PLUG LOCATED 180° ON OTHER SIDE OF HUB.

B. Fan Blades Typical service life for fan blades is 10,000 hours or higher. Actual blade is dependent on operating conditions. High abrasive environments will subject the blades to considerably higher wear.

NOTE: If blades are wearing out before 10,000 hours due to abrasive wear, contact the Product Support Department for Abrasion Resistant Blades.

LOCATION OF OIL LEVEL PLUG AND STATO SEAL LOCATION. 718-D29

718-D27

10.11

FIGURE 16

Tigercat 620 Skidder

Oil cooler/Radiator and Flexxaire® Fan

CHECKING HUB OIL OIL FILL PLUG

The hydraulic hub contains MOBIL Synthetic SHC629 oil. Refer to Table 2 on the previous page for other oil alternatives. A visual inspection should be done every 1000 hours. If necessary oil should be added as per following procedures for 6 blade hub assemblies.

12 O’CLOCK

10O’CLOCK

AIR FILLED AREA

2 O’CLOCK

OIL LEVEL PLUG

Checking Oil Level And Adding Oil A.

Rotate the hub until the “FILL” plug is at the 12:00 position. As indicated in Figure 18.

OIL FILLED AREA

B. Remove the Oil Level Plug from Bearing Carrier.

C. Rotate hub until oil starts to drip. If rotation is more than 45N (2:00 position) oil is required.

6 O’CLOCK 718-D28

D. Rotate hub back to the 12:00 position. See Figure 18.

OIL DRAIN PLUG

FIGURE 18

CAUTION

OIL FILL PLUG (DRAIN PLUG LOCATED 180° ON OTHER SIDE OF HUB.

DO NOT OVER FILL HUB. An air space is required to allow for oil expansion, as shown in Figure 18. Failure to do so will result in seal failure.

Hub Oil Capacity (Approximate) 6 Blade fan - 1.3 liters (1.4 U.S. quarts)

LOCATION OF OIL LEVEL PLUG AND STATO SEAL LOCATION. 718-D29

FIGURE 16

NOTE: Use the above capacities as a guide only.

Refer to the above Adding Oil procedures to ensure the correct amount of recommended oil is put into the hub.

E. Add oil until it drips from the Oil Level Hole, not the “FILL” plug.

F.

Reinstall plugs after applying pipe thread sealant.

G. Check for leaks.

CAUTION Low oil may indicate a leak.

10.12

Tigercat 620 Skidder

Oil cooler/Radiator and Flexxaire® Fan

MAINTENANCE CHECKLIST FLEXXAIRE® FAN This checklist is to provide some basic information to be used at time of machinery delivery and at regular maintenance intervals.

718-D34

10.13

Tigercat 620 Skidder

Oil cooler/Radiator and Flexxaire® Fan

10.14

Tigercat 620 Skidder SECTION 11 - STEERING AND CENTER JOINT SEPTEMBER 2003

CONTENTS - SECTION 11 CENTER JOINT CHECKING CENTER JOINT VISUALLY FOR LOOSENESS ................... 11.8 CHECKING THE CENTER JOINT PRELOAD ........................................ 11.10 CENTER JOINT PRELOAD ADJUSTMENT ....................................... 11.11 DIAGRAM ............................................................................................... 11.10 GREASE SEALS - ORIENTATION ......................................................... 11.11 IDENTIFYING EARLIER AND LATER BEARINGS ................................... 11.9 LUBRICATION .......................................................................................... 11.8 MAINTENANCE ........................................................................................ 11.8 IDENTIFYING EARLIER AND LATER BEARINGS ...................................... 11.9 PRIORITY VALVE ........................................................................................ 11.4 STEER CONTROL VALVE .......................................................................... 11.2 STEERING CIRCUIT DIAGRAM .................................................................................. 11.7 TESTING THE STEERING OPERATION .................................................... 11.6

Tigercat 620 Skidder

Steering and Center Joint

STEERING STEER CONTROL VALVE This is a manually operated directional control valve. The steering wheel is directly connected to the steer valve through the floor of the cab.

The use of load sensing power steering and a priority valve provides smooth pressure compensated steering that is unaffected by axle response or steering rate.

The output flow of the steering control unit varies with the speed that the steering wheel is rotated.

When moving the wheel slowly the output of the steering control is low, causing the machine to steer slowly. When the wheel is turned rapidly the output of the steering control is high, causing the machine to steer much faster.

Fast steering (turning the steering wheel rapidly) is necessary when operating in the woods to provide the required maneuverability.

Travelling on the road requires a slower steering response (turning the steering wheel slowly), making it easier to make minor corrections when travelling in a straight line.

The cylinder ports 'L' and 'R' contain built-in cylinder port relief valves and anti-cavitation valves to protect against pressure surges created by ground forces on the steered axle and vacuum (cavitation) conditions.

OPERATING DESCRIPTION The steering control valve has a spool that is able to rotate inside a sleeve. When the steering wheel is stationary, the unit is in the neutral position and the spool is aligned in the sleeve so that oil cannot flow through the valve. The steering cylinders to the rear chassis are prevented from moving by the oil that is trapped on both sides of the pistons.

When the steering wheel is turned, the spool rotates inside the sleeve and opens passages to allow oil flow through the spool/sleeve assembly.

This oil flows to the Gerotor section of the valve, causing the gerotor to rotate and then continues back into the valve and out the workport to the end of each steer cylinder.

320-15

STEER CONTROL VALVE (BELOW CAB)

The return oil from the cylinders, enters back in the other workport, through the spool/sleeve assembly and back to tank. A load sense line, between the steering valve and priority valve, drains oil out of the load sense port in the priority valve. The oil drains to tank through an orifice located between the sleeve and gerotor on the steer valve.

When the steering wheel has stopped moving, the gerotor gear continues to move and turns the sleeve until the sleeve moves to its center (neutral) position and stops sending oil to the gerotor. The valve is no longer sending oil to the cylinders.

The speed that the steering wheel is rotated, determines the speed that the machine will turn.

Turning the steering wheel slowly causes the variable orifice to decrease in size and it will take more turns of the wheel from stop to stop. If the wheel is turned quickly the orifice opens and it will take fewer turns of the wheel from stop to stop.

The cylinder port relief valves are factory set to 3850 psi.

There is a small, variable bypass orifice in the spool/sleeve assembly that allows a small amount of oil into the pressure side of the steering valve.

This will suppress the initial pressure surge when the steering wheel is partially turned. The orifice is closed off when the wheel is fully turned.

11.2

Tigercat 620 Skidder

Steering and Center Joint 'LS' LOAD SENSING PORT 'P' PRESSURE

'R' RIGHT 'L' LEFT

• ••

'T' TANK P

R

L

T

P

R

L

T

•

•• STEERING COLUMN CONNECTION

CROSS SECTION OF CYLINDER PORT RELIEF VALVE VALVES

LEFT

RIGHT

PUMP IN

PUMP RETURN (TANK)

•R

•

•T

L

•P

HOUSING

• BEARING

SPOOL

• •

•

•

•

• • •

•

STEERING COLUMN CONNECTION

• • CENTERING SPRINGS

AT027-1

SLEEVE

PIN

CHECK VALVE

DRIVE

STEER CONTROL VALVE 11.3

WEAR PLATE

GEROTOR RING AND STAR

• SPACER

END CAP

Tigercat 620 Skidder

Steering and Center Joint

PRIORITY VALVE

P

The priority valve receives hydraulic oil from the main hydraulic pump via the 'P1' port on the multifunction valve manifold.

T

The oil then passes through the priority valve, where it is divided up to go to either the steer valve and on to the steer cylinders, or the grapple, dozer or winch functions.

LS

The priority valve is a feature that allows the steer circuit to have first call on oil before the grapple, dozer or winch circuit.

This control is accomplished by a load-sensing feedback circuit from the steer valve to the priority valve.

By splitting the system into two independent circuits, pressure transients are isolated in each circuit and only the flow required for steering goes to the steering circuit. The remaining flow is available for the grapple, dozer and winch functions. This provides safe, reliable operation because the steering circuit always has flow and pressure priority.

EF

CF

PRIORITY VALVE

AT028-2

Backflow into the steering system is prevented by a check valve in the steer control valve.

The priority valve contains a built-in relief valve which is factory set to 2750 psi. When this relief setting is exceeded, most of the flow will be directed to the auxiliary circuit (EF).

When full oil flow is not required for steering the excess supply of oil is directed to the other circuits.

OIL 'IN' FROM MULTIFUNCTION VALVE RELIEF VALVE CARTRIDGE

RETURN OIL TO TANK

P

•

T

LS

• AT028-1

LOAD SENSE CONNECTION TO STEER VALVE

EF

CF

HIGH PRESSURE CARRYOVER TO GRAPPLE, WINCH AND DOZER VALVES

TO STEER VALVE

PRIORITY VALVE AT028

11.4

Tigercat 620 Skidder

STEER1

Steering and Center Joint

SYSTEM DIAGRAM 11.5

Tigercat 620 Skidder

Steering and Center Joint

TESTING THE STEERING OPERATION: 1. Move the skidder to a suitable, level and smooth test area, where it can be safely operated at full throttle. Grapple UP, CLOSED and ROTATED TO CENTER. Dozer blade UP. 2. With the parking brake OFF, differential locks OFF, NO service brakes applied and full throttle, turn the steering completely one way until it hits the stop..

3. Turn the steering wheel the opposite way, as SLOWLY as possible, until it hits the end stop. This should take 7 1/2 to 8 turns of the wheel.

4. Turn the wheel back to the other end stop, very slowly to verify the 7 1/2 - 8 turns.

5. Turn the wheel back to the other end stop, as fast as possible. Resistance to turning the wheel will be felt during this operation. This should take 3 1/2 to 4 turns of the wheel.

6. Turn the wheel back to the other end stop, as fast as possible to verify the 3 1/2 - 4 turns.

7. If these values are not obtained, check the priority valve and/or steering control unit.

11.6

Tigercat 620 Skidder

Steering and Center Joint

STEER CIRCUIT 620-13

11.7

Tigercat 620 Skidder

Steering and Center Joint

CENTER JOINT MAINTENANCE OF CENTER JOINT Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint grease fittings (item 11) to purge the pivot bearings of debris and water. Refer to SCHEDULED MAINTENANCE in THIS SECTION for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint pivot for looseness every 48 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

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

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

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

REAR CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

DIG-003

FRONT CHASSIS

CENTER JOINT PRELOAD CHECK

11.8

Tigercat 620 Skidder

Steering and Center Joint

IDENTIFYING EARLIER AND LATER BEARINGS It is important to identify the type of bearing installed on the machine before proceeding with CHECKING THE CENTER JOINT PRELOAD and/or CENTER JOINT PRELOAD ADJUSTMENT procedures. Earlier and later bearing types require different settings for proper adjustment and operation.

PIN DIAMETER

MEASURE CENTER JOINT PIN DIAMETER TO IDENTIFY TYPE OF BEARING INSTALLED 630B-51

To identify the type of bearing installed on your machine, measure the center joint pin diameter as shown.

BEARING TYPE EARLIER (AA003) LATER (AA164)

PIN DIAMETER 3.25" (82 mm) 3.35" (85 mm)

EARLIER BEARINGS (PART NUMBER AA003) Factory installed machines with the following serial number ranges.

MODEL 620 630B 635 640

SERIAL NUMBER RANGE 6200111 TO 6200270 6301001 TO 6301379, 6301441 6350101 TO 6350138 6401001 TO 6401030

Please note that some of the above listed machines may have been modified in the field to accept later style bearings.

LATER BEARINGS (PART NUMBER AA164) Later style bearings were factory installed on machines with the following serial number ranges.

MODEL 620 630B 635 640

SERIAL NUMBER RANGE 6200271 AND UP 6301380 TO 6301440 6301442 AND UP 6350139 AND UP 6401031 AND UP 11.9

Tigercat 620 Skidder

Steering and Center Joint

CHECKING THE CENTER JOINT PRELOAD It is important to identify the type of bearing installed on the machine before proceeding with this procedure. Refer to IDENTIFYING EARLIER AND LATER BEARINGS in THIS SECTION.

FRONT CHASSIS

B ••

DIAL INDICATOR PLUNGER

•

1. Park the machine on level ground. Set parking brake ON, grapple and dozer blade UP and shut off engine.

DIAL INDICATOR

REAR CHASSIS

2. Torque the top and bottom retainer bolts (items 1 and 2) to 282 - 310 lbf-ft.

Later style pin retainers use 4 bolts each.

DIAL INDICATOR BASE

Earlier style pin retainers use 6 bolts each.

•

A

3. Place the magnetic base of a dial indicator on the top surface of the rear chassis lower lug 'A' as close to the center pin as possible.

CHECK PRELOAD

DIG-06

4. Partially depress the plunger end of the dial indicator against the bottom surface of the rear chassis upper lug 'B' as close to center 1

•

TORQUE TO 282 - 310 LBF-FT. NO LOCTITE REQUIRED (NOTE: EARLIER STYLE NOT SHOWN USED 6 BOLTS)

1

3 4 BOLT TIGHTENING SEQUENCE

4

FRONT CHASSIS

11

1

2 3

5 6 BOLT TIGHTENING SEQUENCE

6

•

4

2

• • •• SEAL ORIENTATION

REAR CHASSIS

•

9

• • • 6

• • • • 11 630B-20

4

•

5

• •

8 7

TORQUE TO 80 - 88 LBF-FT. USE 243 LOCTITE (REMOVABLE)

CENTER JOINT 11.10

10 3 2 TORQUE TO 282 - 310 LBF-FT. NO LOCTITE REQUIRED (EARLIER STYLE NOT SHOWN USED 6 BOLTS)

Tigercat 620 Skidder

Steering and Center Joint

pin as possible. Zero the dial indicator.

5. Fully loosen only the bottom pin retainer bolts (item 2) that were torqued in step 2. DO NOT REMOVE BOLTS. 6. The dial indicator should now show a change between lug 'A' and 'B' within the preload setting range. Refer to chart for proper bearing preload settings for your machine. Refer also to IDENTIFIYING EARLIER AND LATER BEARINGS in THIS SECTION to determine the type of bearings used on your machine.

This is the proper bearing preload setting.

A change of less than the lower preload range limit indicates that the bearing preload is too low. No change on the dial indicator is the result of a loose center joint. In these cases, proceed to CENTER JOINT PRELOAD ADJUSTMENT. BEARING TYPE LATER BEARINGS (AA164) EARLIER BEARINGS (AA003)

PRELOAD RANGE LOWER

UPPER

0.021"

0.023 "

0.016 "

0.018 "

11. A change within the bearing preload setting range should register on the dial indicator.

Refer to chart for proper bearing preload settings for your machine. Refer also to IDENTIFYING EARLIER AND LATER BEARINGS in THIS SECTION to determine the type of bearings used on your machine.

This is the proper bearing preload setting. a) If change in dial indicator reading is greater than upper preload range limit the shim removed (in step 8) may not have been the thinnest shim in the pack. Repeat steps 7 through 11, replacing this shim and removing only the thinnest shim from the bottom shim pack (item 9). b) If the change in the dial indicator reading is less than lower preload range limit another shim will have to be removed. Repeat steps 7 through 11, removing additional shims but only the thinnest shim each time, until the change in the reading on dial indicator is within the proper range. c) It is possible that the total thickness of two shims is too great and a single shim, of lesser thickness than these two, must be removed.

ORIENTATION OF GREASE SEALS The pivot bearings (item 4) are sealed on both sides by grease seals (items 5 and 6). These seals have proven to have a long life.

CENTER JOINT PRELOAD ADJUSTMENT Before making any adjustments to the center joint, please follow CHECKING THE CENTER JOINT PRELOAD procedure in THIS SECTION.

If replacement becomes necessary, new seals must be installed in the proper orientation. Refer to the center joint diagram and follow these guidelines for correct installation;

With dial indicator still in place;

•

7. Remove all bottom pin retainer bolts (item 2), the bottom pin retainer plate (item 3) and all of the shims in the shim pack (items 10).

CAUTION: Keep upward pressure on the bottom pin (item 9) and do not allow pin to fall out of bearing. These pivot pins are very heavy, block the pin in place if necessary.

The two seals installed on either side of the top and bottom bearings must be installed with the seal lips facing away from the bearings.

Apply blue 243 Loctite (removable) and torque the six bolts (item 7) for the bearing retainer plate (item 8) to 80 - 88 lbf-ft.

8. Remove the thinnest shim from the pack.

9. Reinstall the remaining shims, the retainer plate and the bolts. Leave the bolts loose.

10. Zero the dial indicator again and torque the bottom bolts in sequence to 282-310 lbf-ft.

11.11

Tigercat 620 Skidder

Steering and Center Joint

11.12

Tigercat 620 Skidder SECTION 12 - GRAPPLE, ARCH AND BOOM NOVEMBER 2002

CONTENTS - SECTION 12 CIRCUIT DESCRIPTION ARCH ....................................................................................................... 12.7 ARCH/BOOM .......................................................................................... 12.13 GRAPPLE OPEN/CLOSE ....................................................................... 12.21 GRAPPLE ROTATE - ESCO GRAPPLE ................................................ 12.21 GRAPPLE ROTATE - TIGERCAT GRAPPLE WITH DANFOSS MOTOR .................................................................. 12.20 WITH WHITE HYDRAULICS MOTOR ............................................... 12.20 CIRCUIT DIAGRAMS ARCH/BOOM .......................................................................................... 12.12 GRAPPLE ............................................................................................... 12.19 SINGLE ARCH ......................................................................................... 12.6 GRAPPLE CONTROL VALVE DUAL FUNCTION ARCH SECTION ....................................................... 12.10 GRAPPLE ROTATE AND OPEN/CLOSE SECTIONS ............................ 12.17 SINGLE FUNCTION ARCH SECTION ..................................................... 12.4 GRAPPLE SNUBBER MAINTENANCE .................................. SEE SECTION 3 JOYSTICK CONTROL VALVE, ARCH AND GRAPPLE .............................. 12.3 PORT RELIEF VALVE DESCRIPTION (GRAPPLE VALVE) ..................... 12.27 ADJUSTING PROCEDURE .................................................................... 12.26 PRESSURE SETTINGS DUAL ARCH/BOOM ............................................................................... 12.13 GRAPPLE ROTATE - DANFOSS MOTOR ............................................ 12.23 GRAPPLE ROTATE - WHITE HYDRAULICS MOTOR ......................... 12.22 GRAPPLE OPEN/CLOSE ....................................................................... 12.24 SINGLE ARCH ......................................................................................... 12.7 RELIEF VALVES ADJUSTING PROCEDURE .................................................................... 12.26 SNUBBER MAINTENANCE - GRAPPLE ................................ SEE SECTION 3

Tigercat 620 Skidder

Grapple, Arch and Boom

12.2

Tigercat 620 Skidder

Grapple, Arch and Boom

JOYSTICK CONTROL VALVE

OPERATING DESCRIPTION

ARCH - SINGLE AND DOUBLE

In the neutral position the joystick lever is held centered by return spring (4).

This pilot valve is a manually operated directional control valve and operates on the same principal as a direct operating pressure reducing valve.

Both the joystick and foot control valves use similar spool arrangements.

This joystick control valve directs pilot pressure to the pilot end caps of the boom and arch sections of the grapple control valve. The corresponding spool valve then shifts from its center position and directs pump flow to operate a cylinder.

The handle incorporates push button control switches and a trigger switch. The two push buttons at the top left are for the grapple rotate function and the two bottom push buttons are for the grapple arm open/close function. The trigger switch is used to apply constant pressure to the closed grapple arms.

•

5

•

When the lever (1) is operated, the plunger (5) is pushed against the return spring (4).

At the same time the regulating spool (2) is moved through the regulating spring (3).

When the regulating stroke begins, there is a connection from port 'P' via hole (8) in the spool and work ports 1, 2, 3 or 4 in the base of the valve, to the grapple valve pilot end caps.

Flow is directly proportional to the operator position of the joystick and the regulating spring characteristic.

T

1

• P

• •

4

•

2

3

1

• • • •

•

8

'P' WORK PORT PORTS 1, 2, 3 OR 4 AU013-1

SPOOL ARRANGEMENT

•

5

AU013-2

••

•• •••

T

•

4 3 8 2

T 5858AX

12.3

P

2

JOYSTICK PILOT VALVE

Tigercat 620 Skidder

Grapple, Arch and Boom to direct oil back to tank via the "out" port. The outlet section would normally be used to direct oil back to tank but for this application the internal and external ports of the outlet section have been plugged so that oil is internally redirected back to the "out" port of the inlet section.

GRAPPLE CONTROL VALVE WITH SINGLE FUNCTION ARCH The grapple control valve is located on the rear chassis above the rear axle and under the cover plate.

This grapple control valve consists of four spool sections if a winch is used or three spool sections without a winch. Each spool in the section is an open center type, spring centered and is pilot operated. The grapple control valve also consists of an inlet section and an outlet section. The inlet section is used to receive oil from the pump and to supply the grapple control valve sections. For this application it is also used

*NOTE: There are several variations of the grapple control valve in use, depending on whether the machine has a single or dual function arch and whether a winch is included.

A dual function arch and a winch will both add a spool section to the grapple control valve, making it either a four or five spool section valve. If the machine has a winch and no arch it will be a single spool section valve.

FRONT OIL OUT

OIL IN INLET SECTION

• •

• •

OUT PORT RELIEF

OUTLET SECTION

INLET SECTION

GAUGE TEST PORT OIL IN

PORT RELIEF

B

WINCH A

B

ARCH

•

AT093IL2

FRONT GAUGE TEST PORT

OUT PORT RELIEF

• •

• •

•

•

A

OIL OUT

B

ARCH

IN PORT RELIEF

B GRAPPLE

A

B GRAPPLE

A

B ROTATE

A

B

ROTATE

A

OUTLET SECTION

•

GRAPPLE CONTROL VALVE (single function arch)

RELIEF VALVE PORT 'b'

LOAD CHECK VALVE

AT092XX

WORK PORT BRIDGE

•

GRAPPLE CONTROL VALVE (single function arch - no winch)

PARALLEL PASSAGE

B

RELIEF VALVE PORT 'a'

A

•

• • •

•

• PILOT END CAP 90136-3

•

A

•

•

•

•

•

SPOOL

SPOOL PILOT END THRU' NEUTRAL PASSAGE CENTERING SPRING CAP

TANK PASSAGE

CROSS SECTION OF SPOOL SECTIONS WITH PORT RELIEFS 12.4

Tigercat 620 Skidder

Grapple, Arch and Boom

OPERATING DESCRIPTION Oil is supplied by a variable displacement piston pump via the priority valve to the inlet section of the grapple control valve. Oil enters the inlet section and is allowed to pass through the four open center spool sections to the outlet section and is prevented from returning to tank by a power beyond plug. If none of the functions of the grapple control valve are in use there will be no oil flow through the valve, therefore oil flow to the grapple control valve will be regulated to zero as the piston pump de-strokes to a zero angle.

directs oil to operate any one of the four functions (or all at the same time if required but with reduced flow to each). Return oil from the function in use is directed through the grapple control valve to the inlet section "out" port where it returns to tank.

To prevent over pressurizing of the operating circuits, some of the work ports in the spool sections have a port relief valve. All relief valves are anti-cavitation relief valves.

For a detailed description of these relief valves, refer to RELIEF VALVES in THIS SECTION.

Each of these spool sections has a self centering 3position spool which is open centered. A spring in the spool end cap holds the spool in the open center neutral position. When a function is brought into use the spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool WINCH IN PORT RELIEF

FRONT OIL IN INLET SECTION

OIL OUT

•

GAUGE TEST PORT

•

•

ARCH IN PORT RELIEF

WINCH IN PORT

•

ARCH OUT PORT RELIEF

B

WINCH

A

B

ARCH

A

B

GRAPPLE

A

ROTATE

A

•

•

•

•

•

•

GRAPPLE OPEN PORT RELIEF

•

•

B

•

GRAPPLE CLOCKWISE ROTATION PORT RELIEF

GRAPPLE CLOSE PORT RELIEF GRAPPLE COUNTERCLOCKWISE ROTATION PORT RELIEF

GRAPPLE CLOCKWISE ROTATION PORT

• OUTLET SECTION

AT093IL2

•

GRAPPLE COUNTERCLOCKWISE ROTATION PORT

GRAPPLE CONTROL VALVE (single function arch) 12.5

Tigercat 620 Skidder

630B-18

Grapple, Arch and Boom

SINGLE ARCH CIRCUIT 12.6

Tigercat 620 Skidder

Grapple, Arch and Boom

ARCH CIRCUIT CIRCUIT DESCRIPTION Two cylinders are used to RAISE and LOWER the ARCH. Moving the joystick located in the operator's cab to the LEFT or RIGHT directs pilot oil to either end of the spool in the ARCH spool section. When the spool shifts, oil from the main piston pump is directed to either end of the two cylinders to RAISE or LOWER the ARCH. Return oil from the cylinders is directed to the inlet section OUT port and from there back to tank.

12.7

Tigercat 620 Skidder

Grapple, Arch and Boom

SINGLE ARCH PRESSURE SETTINGS

WARNING

P3 TEST PORT

••

Do not stand above or below the arch assembly, grapple or between the arch and rear chassis during this procedure.

Before performing work on the arch assembly, lower it to the ground and/or use proper support devices.

620-M6

CAUTION Avoid blowing oil over the relief for longer than 5 seconds, as this will cause excessive heating of the hydraulic fluid and possible damage to hydraulic components.

WARNING Use caution when working on top of the rear chassis, as there are many pinch areas between the arch, arch cylinders and winch. DO NOT move arch when workers are in this area.

WARNING Do not work under the arch without properly supporting the arch/grapple assembly. NEVER move the arch/grapple assembly when workers are in this area.

*Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION. IMPORTANT: Approach the gauge reading slowly and deliberately by turning adjusting nut IN a little at a time. The pressure settings must not exceed the designated values.

ARCH IN/OUT PORT RELIEF ADJUSTMENT 1. Park machine on level ground and before shutting off the engine position grapple as described in step 2.

2. IMPORTANT: To prevent lifting of the rear wheels when the arch is moved out during this procedure it is necessary to position the grapple as follows.

Close grapple and rotate it to center. Lower grapple slowly to the ground and slowly move the machine backward while continuing to lower the grapple. This will fold the grapple under (towards the machine) and allow the arch to be fully extended in its out position without lifting the rear wheels off the ground.

Take care to avoid damaging hydraulic hoses while positioning the grapple.

WARNING Park machine on level ground, stop engine, set parking brake ON, lower dozer and grapple to the ground and block wheels.

HOSES REMOVED FOR CLARITY

HIGH PRESSURE RELIEF VALVE

POSITION GRAPPLE FOR ARCH IN/OUT PRESSURE SETTINGS PRESSURE REDUCING VALVE

•• •

••

SEQUENCE VALVE 308-19 321-2A

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

MULTIFUNCTION VALVE

12.8

Tigercat 620 Skidder

Grapple, Arch and Boom

3. Set parking brake ON, dozer blade DOWN and shut off the engine.

DOZER VALVE INLET RELIEF

4. Connect a 0-5000 psi gauge to the ‘P3’ test port.

5. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

••

6. Start the engine, hold down the brake pedal and set the throttle to IDLE.

DOZER VALVE INLET RELIEF

7. It is necessary to temporarily increase the pressure of the main pump to 3850-3900 psi.

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF.

630-D42

a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

••

MAIN PUMP POR ADJUSTING SCREW

Turn the dozer inlet relief valve (if equipped) IN all the way (clockwise) until lightly seated.

WARNING: Observe the pressure gauge while turning the relief valve adjusting screw(s) IN. The main pump could be stuck in the fully stroked position. Back off the adjusting screw if the pressure rises above 3600 psi and investigate the main pump for proper operation. b. Turn the main pump POR to 3850-3900 psi on the 'P3' gauge using the pressure adjusting screw on the side of the pump. (through the cover plate hole).

8. Make sure that the area is clear.

HOSES REMOVED FOR CLARITY 630-PH2

MAIN PUMP

15. Reset the main pump POR to 3000-3100 psi on the 'P3' gauge.

16. Turn off the engine, remove gauge, reinstall plugs on test ports and replace the cover plates.

9. With the aid of an assistant, operate the arch OUT control and hold pressure.

10. Adjust the arch OUT, port relief valve to give a reading of 2500-2600 psi on the 'P3' gauge.

11. With the aid of an assistant operate the arch IN control and hold pressure. NOTE: Care must be taken as this will unfold and lift the grapple from the ground.

12. Adjust the arch IN, port relief valve to give a reading of 3500-3600 psi on the 'P3' gauge.

13. Reset the multifunction valve high pressure relief (reading on the 'P3' gauge).

For machines with dozer inlet relief valve set to 3575-3600 psi plus 4 flats.

For machines without a dozer inlet relief valve set the multifunction to 3500-3600 psi .

14. Reset the dozer valve inlet relief (if equipped) to 3500-3525 psi.

12.9

Tigercat 620 Skidder GRAPPLE CONTROL VALVE

Grapple, Arch and Boom supply the grapple control valve sections. For this application it is also used to direct oil back to tank via the "out" port. The outlet section would normally be used to direct oil back to tank but for this application the internal and external ports of the outlet section have been plugged so that oil is internally redirected back to the "out" port of the inlet section.

WITH DUAL FUNCTION ARCH The grapple control valve is located on the rear chassis above the rear axle and under the cover plate.

This grapple control valve consists of five spool sections if a winch is used or four spool sections without a winch. Each spool in the section is an open center type, spring centered and is pilot operated. The grapple control valve also consists of an inlet section and an outlet section. The inlet section is used to receive oil from the pump and to

*NOTE: There are several variations of the grapple control valve in use, depending on whether the machine has a single or dual function arch and whether a winch is included.

INLET SECTION

FRONT INLET SECTION OIL IN

•

•

OUT PORT RELIEF

• •

B

ARCH

B GRAPPLE

OUTLET SECTION AT094IL2

A

B

ARCH

A

•

A

ROTATE A

UP PORT RELIEF VALVE

GRAPPLE CONTROL VALVE (dual function arch - no winch)

AT095IL2

WORK PORT BRIDGE

DOWN PORT RELIEF VALVE

• GRAPPLE CONTROL VALVE (dual function arch)

PARALLEL PASSAGE

RELIEF VALVE PORT 'a'

A

B

•

• • •

•

• PILOT END CAP 90136-3

•

•

OUTLET SECTION

LOAD CHECK VALVE

•

BOOM

• DOWN PORT RELIEF VALVE

RELIEF VALVE PORT 'b'

WINCH

B

ROTATE A

BOOM

IN PORT RELIEF

B

B GRAPPLE

A

• UP PORT RELIEF VALVE

• •

•

•

A

GAUGE TEST PORT OIL OUT

• •

IN PORT RELIEF

•

B

OUT PORT RELIEF

OIL OUT GAUGE TEST PORT

FRONT OIL IN

•

•

•

•

•

SPOOL

SPOOL PILOT END THRU' NEUTRAL PASSAGE CENTERING SPRING CAP

TANK PASSAGE

CROSS SECTION OF SPOOL SECTIONS WITH PORT RELIEFS 12.10

Tigercat 620 Skidder

Grapple, Arch and Boom

A dual function arch and a winch will both add a spool section to the grapple control valve, making it either a four or five spool section valve. If the machine has a winch and no arch it will be a single spool section valve.

OPERATING DESCRIPTION Oil is supplied by a variable displacement piston pump via the priority valve to the inlet section of the grapple control valve. Oil enters the inlet section and is allowed to pass through the four open center spool sections to the outlet section and is prevented from returning to tank by a power beyond plug. If none of the functions of the grapple control valve are in use there will be no oil flow through the valve, therefore oil flow to the grapple control valve will be regulated to zero as the piston pump de-strokes to a zero angle.

3-position spool which is open centered. A spring in the spool end cap holds the spool in the open center neutral position. When a function is brought into use the spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool directs oil to operate any one of the four functions (or all at the same time if required but with reduced flow to each). Return oil from the function in use is directed through the grapple control valve to the inlet section "out" port where it returns to tank.

To prevent over pressurizing of the operating circuits, some of the work ports in the spool sections have a port relief valve. All relief valves are anti-cavitation relief valves.

For a detailed description of these relief valves, refer to RELIEF VALVES in THIS SECTION.

Each of these spool sections has a self centering INLET SECTION

OIL IN

FRONT

OIL OUT GAUGE TEST PORT

•

•

•

WINCH IN PORT RELIEF

•

WINCH IN PORT

ARCH OUT PORT RELIEF

•

B

WINCH

A

B

ARCH

A

B

GRAPPLE

A

ROTATE

A

•

•

•

GRAPPLE OPEN PORT RELIEF

•

GRAPPLE CLOCKWISE ROTATION PORT RELIEF

•B

• GRAPPLE CLOCKWISE ROTATION PORT

B

BOOM

•

•

A

•

ARCH IN PORT RELIEF

GRAPPLE CLOSE PORT RELIEF

GRAPPLE COUNTERCLOCKWISE ROTATION PORT RELIEF

•

•

GRAPPLE COUNTERCLOCKWISE ROTATION PORT

BOOM UP PORT RELIEF VALVE OUTLET SECTION

AT095IL2

BOOM DOWN PORT RELIEF VALVE

• GRAPPLE CONTROL VALVE (dual function arch) 12.11

Tigercat 620 Skidder

630B-22

Grapple, Arch and Boom

ARCH/BOOM CIRCUIT 12.12

Tigercat 620 Skidder

Grapple, Arch and Boom

ARCH/BOOM CIRCUIT CIRCUIT DESCRIPTION Two cylinders are used to RAISE and LOWER the ARCH and two cylinders are used to RAISE and LOWER the BOOM. Moving the joystick located in the operator's cab to the LEFT or RIGHT directs pilot oil to either end of the spool in the ARCH spool section. Moving the joystick FORWARD or BACK directs pilot oil to either end of the spool in the BOOM spool section.

When the spool(s) shifts, oil from the main piston pump is directed to either end of these cylinders to RAISE or LOWER the ARCH or BOOM. Return oil from the cylinders is directed to the inlet section OUT port and from there back to tank.

12.13

Tigercat 620 Skidder

Grapple, Arch and Boom

DUAL ARCH/BOOM PRESSURE SETTINGS P3 TEST PORT

WARNING

••

Do not stand above or below the arch, boom or grapple assembly, or between the arch/ boom and rear chassis during this procedure.

Before performing work on the arch/boom assembly, lower it to the ground and/or use proper support devices.

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR *Refer to RELIEF VALVE ADJUSTING PROCEDURE in this section.

620-M6

CAUTION Avoid blowing oil over the relief for longer than 5 seconds, as this will cause excessive heating of the hydraulic fluid and possible damage to hydraulic components.

WARNING

ARCH IN/OUT PORT RELIEF ADJUSTMENT

Use caution when working on top of the rear chassis, as there are many pinch areas between the arch, arch cylinders boom, boom cylinders and winch. DO NOT move arch or boom when workers are in this area.

WARNING Do not work under the arch or boom without properly supporting the arch/grapple assembly. NEVER move the arch/grapple assembly when workers are in this area.

WARNING Park machine on level ground, stop engine, set parking brake ON, lower dozer and grapple to the ground and block wheels.

HOSES REMOVED FOR CLARITY

HIGH PRESSURE RELIEF VALVE

PRESSURE REDUCING VALVE

•• ••

•

SEQUENCE VALVE

321-2A

IMPORTANT: Approach the gauge reading slowly and deliberately by turning adjusting nut IN a little at a time. The pressure settings must not exceed the designated values.

MULTIFUNCTION VALVE

1. Set parking brake ON, grapple and dozer DOWN and shut off engine.

2. Connect a 0-5000 psi gauge to the ‘P3’ test port.

3. Ensure that the hydraulic oil is at operating temperature is between. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 4. Start the engine, hold down the brake pedal and set the throttle to IDLE .

5. It is necessary to temporarily increase the pressure of the main pump to 3850-3900 psi. a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

Turn the dozer inlet relief valve (if equipped) IN all the way (clockwise) until lightly seated.

WARNING: Observe the pressure gauge while turning the relief valve adjusting screw(s) IN. The main pump could be stuck in the fully stroked position. Back off the adjusting screw if the pressure rises above 3600 psi and investigate the main pump for proper operation. b. Turn the main pump POR to 3850-3900 psi on the 'P3' gauge using the pressure adjusting screw on the side of the pump. (through the cover plate hole).

6. Make sure that the area is clear, grapple is off the ground, closed and rotated to center position.

7. With the aid of an assistant, operate the arch IN control and hold pressure.

12.14

Tigercat 620 Skidder

Grapple, Arch and Boom

8. Adjust the arch IN, port relief valve to give a reading of 3500-3600 psi on the 'P3' gauge.

BOOM UP/DOWN PORT RELIEF ADJUSTMENT 1. Set parking brake ON, grapple and dozer blade DOWN and shut off the engine.

9. Move the arch OUT (adjust the boom UP to prevent the grapple from touching the ground) until the arch reaches the end of its OUTWARD travel and hold the pressure.

CAUTION:- this should NOT raise the rear wheels off the ground.

2. Connect a 0-5000 psi gauge to the ‘P3’ test port.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

10. Adjust the arch OUT, port relief valve to give a reading of 2500-2600 psi on the 'P3' gauge.

4. Start the engine, hold down the brake pedal and set the throttle to IDLE.

11. Reset the multifunction valve high pressure relief (reading on the 'P3' gauge).

For machines with dozer inlet relief valve set to 3575-3600 psi plus 4 flats.

6. It is necessary to temporarily increase the pressure of the main pump to 3850-3900 psi. a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

For machines without a dozer inlet relief valve set the multifunction to 3500-3600 psi .

12. Reset the dozer valve inlet relief (if equipped) to 3500-3525 psi.

Turn the dozer inlet relief valve (if equipped) IN all the way (clockwise) until lightly seated.

13. Reset the main pump POR to 3000-3100 psi on the 'P3' gauge.

WARNING: Observe the pressure gauge while turning the relief valve adjusting screw(s) IN. The main pump could be stuck in the fully stroked position. Back off the adjusting screw if the pressure rises above 3600 psi and investigate the main pump for proper operation.

14. Turn off the engine, remove gauges, reinstall plugs on test ports and replace the cover plates.

DOZER VALVE INLET RELIEF

b. Turn the main pump POR to 3850-3900 psi on the 'P3' gauge using the pressure adjusting screw on the side of the pump. (through the cover plate hole).

•• DOZER VALVE INLET RELIEF 630-D42

•

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF.

7. Make sure that the area is clear, grapple is off the ground, closed and rotated to center position.

8. With the aid of an assistant, operate the boom UP control and hold pressure.

9. Adjust the boom UP, port relief valve to give a reading of 3500-3600 psi on the 'P3' gauge.

MAIN PUMP POR ADJUSTING SCREW

10. Move boom DOWN and maintain pressure. (adjust the arch OUT to prevent the grapple from touching the ground) and maintain pressure. CAUTION - This should NOT raise the rear wheels off the ground.

11. Adjust the boom DOWN, port relief valve to give a reading of 2500-2600 psi on the 'P3' gauge.

Continued on page 16 HOSES REMOVED FOR CLARITY

630-PH2

MAIN PUMP 12.15

Tigercat 620 Skidder

Grapple, Arch and Boom

Continued from page 15

12. Reset the multifunction valve high pressure relief (reading on the 'P3' gauge).

For machines with dozer inlet relief valve set to 3575-3600 psi plus 4 flats.

For machines without a dozer inlet relief valve set the multifunction to 3500-3600 psi .

13. Reset the dozer valve inlet relief (if equipped) to 3500-3525 psi.

14. Reset the main pump POR to 3000-3100 psi on the 'P3' gauge.

15. Turn off the engine, remove gauges, reinstall plugs on the test ports and replace the cover plates.

12.16

Tigercat 620 Skidder

Grapple, Arch and Boom application it is also used to direct oil back to tank via the "out" port. The outlet section would normally be used to direct oil back to tank but for this application the internal and external ports of the outlet section have been plugged so that oil is internally redirected back to the "out" port of the inlet section.

GRAPPLE CONTROL VALVE GRAPPLE ROTATE AND OPEN/CLOSE FUNCTIONS The grapple control valve is located on the rear chassis above the rear axle and under the cover plate.

This grapple control valve consists of four spool sections if a winch is used or three spool sections without a winch. Each spool in the section is an open center type, spring centered and is pilot operated. The grapple control valve also consists of an inlet section and an outlet section. The inlet section is used to receive oil from the pump and to supply the grapple control valve sections. For this

*NOTE: There are several variations of the grapple control valve in use, depending on whether the machine has a single or dual function arch and whether a winch is included.

A dual function arch and a winch will both add a spool section to the grapple control valve, making it either a four or five spool section valve. If the

FRONT OIL IN INLET SECTION

OIL OUT

•

•

FRONT GAUGE TEST PORT

•

•

CLOSE PORT RELIEF

B

WINCH

A

B

ARCH

A

B GRAPPLE

A

B

A

•

•

ROTATE

•

ARCH

CLOSE PORT RELIEF

A

B GRAPPLE

A

ROTATE

A

B

•

OUTLET SECTION AT092XX3

WORK PORT BRIDGE

GRAPPLE CONTROL VALVE (grapple - no winch) RELIEF VALVE PORT 'a'

A • • •

90136-3

CCW PORT

•

•

PILOT END CAP

•

•

PARALLEL PASSAGE

B

•

•

•

CCW PORT RELIEF

CW PORT

GRAPPLE CONTROL VALVE (GRAPPLE) LOAD CHECK VALVE

• •

CW PORT RELIEF

CCW PORT

RELIEF VALVE PORT 'b'

• •

•

•

•

OIL OUT

•

•

CCW PORT RELIEF

OUTLET SECTION AT093IL3

OPEN PORT RELIEF

B

CW PORT RELIEF CW PORT

GAUGE TEST PORT OIL IN

•

OPEN PORT RELIEF

INLET SECTION

•

•

•

•

•

SPOOL

SPOOL PILOT END THRU' NEUTRAL PASSAGE CENTERING SPRING CAP

TANK PASSAGE

CROSS SECTION OF SPOOL SECTIONS WITH PORT RELIEFS 12.17

Tigercat 620 Skidder

Grapple, Arch and Boom

machine has a winch and no arch it will be a single spool section valve.

center neutral position. When a function is brought into use the spool is shifted by pilot pressure being applied to either end of the spool. Shifting the spool directs oil to operate any one of the four functions (or all at the same time if required but with reduced flow to each). Return oil from the function in use is directed through the grapple control valve to the inlet section "out" port where it returns to tank.

OPERATING DESCRIPTION Oil is supplied by a variable displacement piston pump via the priority valve to the inlet section of the grapple control valve. Oil enters the inlet section and is allowed to pass through the four open center spool sections to the outlet section and is prevented from returning to tank by a power beyond plug. If none of the functions of the grapple control valve are in use there will be no oil flow through the valve, therefore oil flow to the grapple control valve will be regulated to zero as the piston pump de-strokes to a zero angle.

To prevent over pressurizing of the operating circuits, some of the work ports in the spool sections have a port relief valve. All relief valves are anti-cavitation relief valves.

For a detailed description of these relief valves, refer to RELIEF VALVES in THIS SECTION.

Each of these spool sections has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the open FRONT OIL IN INLET SECTION

GAUGE TEST PORT

OIL OUT

•

• •

WINCH IN PORT RELIEF WINCH IN PORT

•

ARCH IN PORT RELIEF

ARCH OUT PORT RELIEF

B

WINCH

A

B

ARCH

A

B

GRAPPLE

A

ROTATE

A

•

•

•

•

•

•

GRAPPLE OPEN PORT RELIEF

•

•

B

•

GRAPPLE CLOCKWISE ROTATION PORT RELIEF

GRAPPLE CLOSE PORT RELIEF GRAPPLE CLOCKWISE ROTATION PORT

GRAPPLE COUNTERCLOCKWISE ROTATION PORT RELIEF

GRAPPLE COUNTERCLOCKWISE ROTATION PORT

•

OUTLET SECTION

AT093IL3

•

GRAPPLE CONTROL VALVE (grapple) 12.18

Tigercat 620 Skidder

630B-23

Grapple, Arch and Boom

GRAPPLE CIRCUIT 12.19

Tigercat 620 Skidder

Grapple, Arch and Boom

GRAPPLE ROTATE CIRCUIT CIRCUIT DESCRIPTION WITH TIGERCAT GRAPPLE

•

The grapple control valve is located on the rear chassis above the rear axle and under the cover plate.

REMOVABLE HOOD GRAPPLE ROTATE MOTOR (WHITE HYDRAULICS)

A hydraulic grapple rotate motor is mounted in the rotator box on the arch/boom, under a protective removeable hood. It is used to rotate the grapple head clockwise or counterclockwise. The tigercat grapple is capable of continuous 360° rotation clockwise or counterclockwise.

• GRAPPLE ROTARY MANIFOLD

•

The grapple rotate motor is operated by the two push buttons at the top left of the joystick control lever. The switches operate two solenoid pilot valves located on the pilot manifold which direct pilot oil to each end of the rotate spool section of the grapple control valve to shift the spool. The spool shifts and directs oil from the main pump to either side of the motor causing it to rotate clockwise/counterclockwise and rotate the grapple.

Return oil is directed back to tank.

Two flow control valves installed in each line to the grapple rotate motor, reduce the flow of oil and maintain a steady grapple rotate speed. They are located close to the grapple rotate valve ports. The arrow on each of these valves must point towards the valve.

Earlier Machines (White Hydraulics motor) The grapple rotate motor (White Hydraulics) is a hydraulic gerotor motor and has non-adjustable double cross-line relief valves for protection. If external rotational pressure is applied to the head, these valves bypass the oil to protect the motor and seals. In addition the grapple control rotate valve is equipped with port relief valves to protect the motor and seals.

262-11A

GRAPPLE ROTATOR BOX TIGERCAT GRAPPLE WHITE HYDRAULICS MOTOR

GRAPPLE MOTOR TEST PORT (DANFOSS)

GRAPPLE ROTATE MOTOR (DANFOSS)

• •

GRAPPLE ROTARY MANIFOLD

••

Later machines (Danfoss Motor) The grapple rotate motor (Danfoss) is a hydraulic gerotor motor and has adjustable double cross-line relief valves for protection. If external rotational pressure is applied to the head, these valves bypass the oil to protect the motor and seals. In addition the grapple control rotate valve is equipped with port relief valves to protect the motor and seals. The grapple rotate motor (Danfoss) has a drain line which returns excess hydraulic oil to tank.

630B-101

12.20

GRAPPLE ROTATOR BOX TIGERCAT GRAPPLE DANFOSS MOTOR

Tigercat 620 Skidder

Grapple, Arch and Boom GRAPPLE OPEN/CLOSE CIRCUIT

CIRCUIT DESCRIPTION WITH ESCO GRAPPLE

CIRCUIT DESCRIPTION

The control valve is located on the rear chassis above the rear axle and under the cover plate.

A hydraulic rotor attached to the end of the arch/boom is used to rotate the grapple head clockwise or counterclockwise.

The grapple rotor is operated by the two push buttons at the top left of the joystick control lever.

The switches operate two solenoid pilot valves located on the pilot manifold which direct pilot oil to each end of the rotate spool section of the grapple control valve to shift the spool. The spool shifts and directs oil from the main pump to either side of the rotor causing it to rotate clockwise/ counterclockwise and rotate the grapple. Return oil is directed back to tank.

Two flow control valves installed in each line to the grapple rotor, reduce the flow of oil and maintain a steady grapple rotate speed. They are located close to the grapple rotate valve ports. The arrow on each of these valves must point towards the valve.

The rotor body is attached to the grapple head housing and the rotor shaft is fastened to the swivel clevis on the arch/boom. When oil is supplied to either side of the rotor, the shaft is held stationary on the clevis and the rotor body rotates on the shaft and turns the grapple.

The grapple cylinders are operated by the two bottom push buttons, OPEN/CLOSE, on the joystick control lever. The switches operate two solenoid pilot valves located on the pilot manifold which direct pilot oil to each end of the grapple spool section of the grapple control valve to shift the spool. The spool shifts and directs oil from the main pump to either end of the cylinders causing the grapple arms to open or close. For later machines equipped with Tigercat continuous rotation grapples the oil is directed to the cylinders via a rotary manifold mounted in the rotator box allowing continuous 360° rotation of the grapple.

Return oil is directed back to tank.

A trigger switch on the joystick lever, when held in the ON position holds the grapple closed solenoid the grapple spool section of the main valve in the closed position. This will cause a constant pressure to be applied to the closed grapple arms to maintain a firm grip on the load and help prevent slippage. To release the constant pressure to the grapple, press the GRAPPLE OPEN button momentarily.

The rotor has non-adjustable cross-line relief valves for protection. If external rotational pressure is applied to the head, these valves bypass the oil to protect the motor and seals. In addition the grapple control rotate valve is equipped with port relief valves to protect the motor and seals.

12.21

Tigercat 620 Skidder GRAPPLE PRESSURE SETTINGS WARNING Do not stand above or below the arch, boom or grapple assembly, or between the arch/ boom and rear chassis during this procedure.

Before performing work on the arch/boom assembly, lower it to the ground and/or use proper support devices.

CAUTION Avoid blowing oil over the relief for longer than 5 seconds, as this will cause excessive heating of the hydraulic fluid and possible damage to hydraulic components.

WARNING Use caution when working on top of the rear chassis, as there are many pinch areas between the arch, arch cylinders boom, boom cylinders and winch. DO NOT move arch or boom when workers are in this area.

WARNING Do not work under the arch or boom without properly supporting the arch/grapple assembly. NEVER move the arch/grapple assembly when workers are in this area.

Grapple, Arch and Boom GRAPPLE ROTATE HYDRAULIC ADJUSTMENTS WITH "WHITE HYDRAULICS" MOTOR 1. Set parking brake ON, grapple and dozer DOWN and shut off engine.

2. Connect a 0-5000 psi gauge to the ‘P3’ test port. Place the gauge so that it can be read at a safe distance from the grapple.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 4. Start the engine, hold down the brake pedal and set the throttle to IDLE. 5. Make sure that the area is clear and position the grapple on the ground to prevent it from rotating.

6. With the aid of an assistant, operate the ROTATE CCW control and hold.

7. Adjust the grapple ROTATE CCW, port relief valve to give a reading of 2500-2600 psi on the 'P3' gauge.

8. Operate the ROTATE CW control and hold.

9. Adjust the grapple ROTATE CW, port relief valve to give a reading of 2500-2600 psi on the 'P3' gauge.

10 . Turn off the engine, remove gauges, reinstall plugs on the test ports and replace the cover plates.

WARNING Park machine on level ground, stop engine, set parking brake ON, lower dozer and grapple to the ground and block wheels. *Refer to RELIEF VALVE ADJUSTING PROCEDURE in this section.

IMPORTANT: Approach the gauge reading slowly and deliberately by turning adjusting nut IN a little at a time. The pressure settings must not exceed the designated values.

P3 TEST PORT

••

620-M6

308-15

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR 12.22

POSITION GRAPPLE ON GROUND TO PREVENT ROTATION

Tigercat 620 Skidder

Grapple, Arch and Boom

GRAPPLE ROTATE HYDRAULIC ADJUSTMENTS WITH "DANFOSS" MOTOR

CROSS-LINE RELIEF ADJUSTING SCREW

1. Set parking brake ON, grapple dozer blade DOWN and shut off the engine.

GRAPPLE MOTOR TEST PORT (DANFOSS)

2. Connect a 0-5000 psi gauge to the ‘P3’ test port. Connect a 0-5000 psi gauge to the test port on the grapple rotate motor (Danfoss).

Place both gauges so that they can be read at a safe distance from the grapple.

•

GRAPPLE ROTATE MOTOR (DANFOSS)

• •

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

GRAPPLE ROTARY MANIFOLD

•

4. Start the engine, hold down the brake pedal and set the throttle to IDLE. 5. Make sure that the area is clear and position the grapple on the ground to prevent it from rotating.

6. First turn the cross-line port relief adjusting screw OUT until the pressure reading falls well below 1900 psi on the motor test port gauge.

7. With the aid of an assistant activate the grapple rotate controls in the direction which pressurizes the test gauge. Then turn the adjusting screw IN until pressure rises to 1900 psi (no further) on the motor test port gauge and tighten the locknut.

630B-101

Note: Ensure that this adjustment is made as described above. It is possible to turn the adjusting screw in further than required without affecting the pressure reading on the gauge.

Over adjustment of the cross-line relief may cause damage to the grapple rotate motor.

8. Disconnect the gauge from the grapple motor test port and replace the test port cap.

6. With the aid of an assistant, operate the ROTATE CCW control and hold.

7. Adjust the grapple ROTATE CCW, port relief valve to give a reading of 2500-2600 psi on the 'P3' gauge.

8. Operate the ROTATE CW control and hold.

9. Adjust the grapple ROTATE CW, port relief valve to give a reading of 2500-2600 psi on the 'P3' gauge.

10 . Turn off the engine, remove gauges, reinstall plugs on the test ports and replace the cover plates.

GRAPPLE OPEN/CLOSE PORT RELIEF 12.23

GRAPPLE ROTATOR BOX TIGERCAT GRAPPLE DANFOSS MOTOR

Tigercat 620 Skidder ADJUSTMENT 1. Set parking brake ON, grapple and dozer DOWN and shut off engine.

Grapple, Arch and Boom 5. It is necessary to temporarily increase the pressure of the main pump to 3850-3900 psi. a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

2. Connect a 0-5000 psi gauge to the ‘P3’ test port.

Turn the dozer inlet relief valve (if equipped) IN all the way (clockwise) until lightly seated.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

WARNING: Observe the pressure gauge while turning the relief valve adjusting screw(s) IN. The main pump could be stuck in the fully stroked position. Back off the adjusting screw if the pressure rises above 3600 psi and investigate the main pump for proper operation.

4. Start the engine, hold down the brake pedal and set the throttle to IDLE.

WARNING Do not stand above or below the arch, boom or grapple assembly, or between the arch/ boom and rear chassis during this procedure.

Before performing work on the arch/boom assembly, lower it to the ground and/or use proper support devices.

CAUTION Avoid blowing oil over the relief for longer than 5 seconds, as this will cause excessive heating of the hydraulic fluid and possible damage to hydraulic components.

WARNING Use caution when working on top of the rear chassis, as there are many pinch areas between the arch, arch cylinders boom, boom cylinders and winch. DO NOT move arch or boom when workers are in this area.

b. Turn the main pump POR to 3850-3900 psi on the 'P3' gauge using the pressure adjusting screw on the side of the pump. (through the cover plate hole).

6. Make sure that the area is clear, grapple is off the ground, closed and rotated to center position.

7. With the aid of an assistant, operate the grapple CLOSE control and hold the closing pressure.

8. Adjust the grapple CLOSE, port relief valve to give a reading of 3650-3700 psi on the 'P3' gauge.

9. OPEN the grapple and maintain opening pressure.

10. Adjust the grapple OPEN, port relief valve to give a reading of 3500-3600 psi on the 'P3' gauge.

11. Reset the multifunction valve high pressure relief (reading on the 'P3' gauge).

WARNING Do not work under the arch or boom without properly supporting the arch/grapple assembly. NEVER move the arch/grapple assembly when workers are in this area.

WARNING Park machine on level ground, stop engine, set parking brake ON, lower dozer and grapple to the ground and block wheels.

For machines with dozer inlet relief valve set to 3575-3600 psi plus 4 flats.

For machines without a dozer inlet relief valve set the multifunction to 3500-3600 psi .

12. Reset the dozer valve inlet relief (if equipped) to 3500-3525 psi.

13. Reset the main pump POR to 3000-3100 psi on the 'P3' gauge.

14. Turn off the engine, remove gauges, reinstall plugs on the test ports and replace the cover plates.

12.24

Tigercat 620 Skidder

Grapple, Arch and Boom GRAPPLE SNUBBER MAINTENANCE

P3 TEST PORT

Refer to GRAPPLE SNUBBER MAINTENANCE in SECTION 3 of THIS MANUAL.

•

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

275-3

HOSES REMOVED FOR CLARITY

PRESSURE REDUCING VALVE

HIGH PRESSURE RELIEF VALVE

• •

•

SEQUENCE VALVE

MULTIFUNCTION VALVE

321-2A

DOZER VALVE INLET RELIEF

•• DOZER VALVE INLET RELIEF 630-D42

••

630-PH2

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF. MAIN PUMP POR ADJUSTING SCREW

HOSES REMOVED FOR CLARITY

MAIN PUMP

12.25

Tigercat 620 Skidder ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting nut ADJUSTING NUT

•

Grapple, Arch and Boom ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting screw ADJUSTING SCREW

JAMNUT

JAMNUT

•

• •

RELIEF VALVE

RELIEF VALVE 51055-2

WITH ADJUSTING NUT

51055-20

WITH ADJUSTING SCREW

1.

Loosen jamnut.

1.

Loosen jamnut.

2.

Turn adjusting nut to obtain desired pressure reading on gauge.

2.

Turn adjusting screw to obtain desired pressure reading on gauge.

3.

Lock jamnut against adjusting nut, making sure the adjusting nut does not turn.

3.

Lock jamnut against relief valve body, making sure the adjusting screw does not turn.

5.

Re-check relief setting.

5.

Re-check relief setting.

For complete step-by-step pressure setting procedures of circuits using these relief valves, refer to appropriate sections in THIS MANUAL.

For complete step-by-step pressure setting procedures of circuits using these relief valves, refer to appropriate sections in THIS MANUAL.

12.26

Tigercat 620 Skidder

Grapple, Arch and Boom ANTI-CAVITATION RELIEF VALVE

VALVE POPPET

T P

This valve is used as a MAIN and PORT relief valve in both the dozer and grapple control valves.

OPERATION: Step 1.

T

‘P’ represents a high pressure area and ‘T’ represents tank. Under normal operation, ‘P’ is below the relief pressures, the valve poppet is firmly seated and oil cannot flow to tank.

STEP 1 PILOT POPPET

T

Step 2.

P

STEP 2

T

Step 3.

SEATING POPPET

T

P

STEP 3

When the pressure at ‘P’ reaches the relief valve setting, the pilot poppet unseats and allows oil in the inner cavity to flow to tank, thus lowering the pressure in the cavity between the pilot poppet and the other poppets.

T

As a result of the opening of the pilot poppet, the seating poppet moves back, due to the pressure drop caused by oil flow through the bore of the seating poppet, and seats against the pilot poppet.

This shuts off the flow of oil through the seating poppet and the cavity pressure now drops to tank pressure.

Step 4.

VALVE POPPET

T

P

STEP 4

T

Step 5.

T

VALVE POPPET

P

STEP 5

T CHECK POPPET

When pressure ‘P’ drops the pilot poppet closes and then the seating poppet moves back to its original position and permits oil pressure to flow into the cavity behind the valve poppet. As the seating poppet moves back it comes in contact with the valve poppet and its spring force plus the oil pressure cause the valve poppet to move back to the closed position.

As an anti-void or check valve

T

P

ANTI-VOID CHECK OPERATION T

As the seating poppet began to move away from the valve poppet, the valve poppet began to open under the effect of the pressure at P thus allowing a large volume of flow to tank. The drop in pressure behind the valve poppet when the seating poppet seats on the pilot poppet ensures full opening of the valve poppet.

The anti-void unit supplies oil to the pressure area ‘P’ when its pressure drops below the pressure in the tank gallery of the valve. The valve then acts as a free flow check valve and prevents cavitation.

In this condition, the pressure at ‘P’ is lower than at ‘T’ and due to the shape of the check poppet, the pressure forces cause the poppet to unseat, allowing oil to flow from ‘T’ to ‘P’.

12.27

Tigercat 620 Skidder

Grapple, Arch and Boom

12.28

Tigercat 620 Skidder SECTION 13 - WINCH SEPTEMBER 2003

CONTENTS - SECTION 13 CONTROL LEVER VALVE .......................................................................... 13.3 GRAPPLE CONTROL VALVE WINCH SECTION .................................................................................... 13.4 LANTEC WINCH CIRCUIT DESCRIPTION .......................................................................... 13.8 CIRCUIT DIAGRAM (6200111 TO 6200196) ............................................ 13.9 CIRCUIT DIAGRAM (6200197 AND UP) ................................................ 13.11 WINCH ..................................................................................................... 13.8 WINCH MOTOR ....................................................................................... 13.8 LUFKIN WINCH CIRCUIT DESCRIPTION .......................................................................... 13.6 CIRCUIT DIAGRAM .................................................................................. 13.7 WINCH ..................................................................................................... 13.6 PRESSURE SETTINGS WINCH IN PORT RELIEF ADJUSTMENT ............................................. 13.12 WITHOUT WINCH IN PORT RELIEF, NON- ADJUSTABLE .................. 13.12

Tigercat 620 Skidder

Winch

13.2

Tigercat 620 Skidder

Winch OPERATING DESCRIPTION

WINCH CONTROL LEVER VALVE This pilot valve is a manually operated directional control valve and operates on the same principal as a direct operating pressure reducing valve.

The control lever, the joystick and foot control valves use similar spool arrangements.

This control valve directs pilot pressure to the pilot end cap of the winch section of the grapple control valve. The corresponding spool valve then shifts from its center position and directs pump flow to operate the winch motor.

•

5

• •

4

•

2

3

AU013-1

In the neutral position the control lever is held centered by return spring (4).

When the lever (1) is operated, plunger (5) is pushed against the return spring (4) At the same time, control spool (2) is moved by control spring (3).

•

As the spool moves down, the control chamber to tank connection is closed. As the spool continues to move, the connection between input pressure (P) and the control chamber is opened and the pressure is then able to build up in the control chamber.

• •

Once the pressure equals the value set by control spring (3), the control spool closes the loop and there is a connection to work ports (1,2).

•

•

1

•

Oil flow is directly proportional to the position of the control lever setting by the operator and the control spring (3) characteristics.

8

'P' PORT

The winch control lever valve is one section of a two section sandwich plate design valve. The second section of the valve is used to operate the dozer blade.

WORK PORTS 1, 2

SPOOL ARRANGEMENT

AU013-2

AU014-1

13.3

WINCH CONTROL LEVER VALVE

Tigercat 620 Skidder

Winch

GRAPPLE CONTROL VALVE

normally be used to direct oil back to tank but for this application the internal and external ports of the outlet section have been plugged so that oil is internally redirected back to the "out" port of the inlet section.

WINCH SECTION The grapple control valve is located on the rear chassis above the rear axle and under the cover plate.

*NOTE: There are several variations of the grapple control valve in use, depending on whether the machine has a single or dual function arch and whether a winch is included.

This grapple control valve consists of four or five spool sections. Each spool in the section is an open center type, spring centered and is pilot operated. The grapple control valve also consists of an inlet section and an outlet section. The inlet section is used to receive oil from the pump and to supply the grapple control valve sections. For this application it is also used to direct oil back to tank via the "out" port. The outlet section would

A dual function arch and a winch will both add a spool section to the grapple control valve, making it either a four or five spool section valve. If the machine has a winch and no arch it will be a single spool section valve.

FRONT INLET SECTION

OUTLET SECTION

•

•

INLET SECTION

OIL OUT

OIL IN

GAUGE TEST PORT

• •

• •

•

WINCH

A

B

ARCH

A

B GRAPPLE

A

B

A

B

OUTLET SECTION

GAUGE TEST PORT

OIL OUT

• •

WINCH IN PORT

B

ROTATE

FRONT OIL IN

WINCH

WINCH IN PORT

A

•

•

•

GRAPPLE CONTROL VALVE (WINCH) (single function arch)

AT093IL4

PORT 'B' RELIEF PORT PLUGGED

WORK PORT BRIDGE

LOAD CHECK VALVE

AT038XX1

WINCH CONTROL VALVE (no grapple)

PARALLEL PASSAGE

PORT 'A' RELIEF PORT PLUGGED

B

A

•

• • •

•

• PILOT END CAP

•

•

•

• SPOOL THRU' NEUTRAL PASSAGE

TANK PASSAGE 90136-4F

• SPOOL CENTERING SPRING

CROSS SECTION OF SPOOL SECTIONS WITHOUT PORT RELIEFS 13.4

PILOT END CAP

Tigercat 620 Skidder

Winch

OPERATING DESCRIPTION

spool directs oil to operate any one of the four functions (or all at the same time if required but with reduced flow to each). Return oil from the function in use is directed through the grapple control valve to the inlet section "out" port where it returns to tank.

Oil is supplied by a variable displacement piston pump via the priority valve to the inlet section of the grapple control valve. Oil enters the inlet section and is allowed to pass through the four open center spool sections to the outlet section and is prevented from returning to tank by a power beyond plug. If none of the functions of the grapple control valve are in use there will be no oil flow through the valve, therefore oil flow to the grapple control valve will be regulated to zero as the piston pump de-strokes to a zero angle.

To prevent over pressurizing of the operating circuits, some of the work ports in the spool sections have a port relief valve. All relief valves are anti-cavitation relief valves.

For a detailed description of these relief valves, refer to RELIEF VALVES in THIS SECTION.

Each of these spool sections has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the open center neutral position. When a function is brought into use the spool is shifted by pilot pressure being applied to either end of the spool. Shifting the FRONT OIL IN

OIL OUT GAUGE TEST PORT

INLET SECTION

•

•

•

ARCH OUT PORT RELIEF

WINCH IN PORT

•

ARCH IN PORT RELIEF

B

WINCH

A

B

ARCH

A

•

•

•

B

GRAPPLE

A

B

ROTATE

A

•

•

GRAPPLE OPEN PORT RELIEF

•

•

•

GRAPPLE CLOCKWISE ROTATION PORT RELIEF

GRAPPLE CLOCKWISE ROTATION PORT

GRAPPLE CLOSE PORT RELIEF GRAPPLE COUNTERCLOCKWISE ROTATION PORT RELIEF

•

GRAPPLE COUNTERCLOCKWISE ROTATION PORT

OUTLET SECTION

AT093IL4

•

GRAPPLE CONTROL VALVE (WINCH) (single function arch) 13.5

Tigercat 620 Skidder

Winch

WINCH CIRCUIT LUFKIN WINCH CIRCUIT DESCRIPTION - LUFKIN WINCH A hydraulic motor is used to drive the winch during the winding IN of the cable.

The hydraulic motor receives oil from the main pump via the winch spool section in the grapple control valve. The spool section in this control valve is pilot operated at both ends. It receives pilot oil from the lever control valve in the operator's cab to shift the spool. The spool directs oil from the pump to the motor and from the motor back to tank via the dozer valve.

LUFKIN WINCH The winch is driven by a hydraulic motor through the sprag clutch and winch drive components. The pinion sprag holds the load in conjunction with the free spool clutch to prevent reverse rotation of the drum. The free spool clutch separates the drum from other drive components and permits the cable to unwind freely.

switch operates the free spool clutch, allowing the cable to unwind freely from the drum. The cable can now be pulled from the drum by the operator.

The winch is self lubricated by the attached oil pump, which draws oil from the winch sump to lubricate the gearing and bearing surfaces as well as the motor input shaft spline. This lubrication pump is located behind the sprague clutch, on the outside of the winch, beside the drive motor and operates each time the pump is operated.

The sprag clutch in conjunction with the freespool brake holds the load and prevents the reverse rotation of the the drum and motor during the 'WINCH IN' or 'HOLD' operation.

See the manufacturer’s service manual for information on the winch.

The winch is controlled through a variable position lever and a free spool switch. The winch free spool

DRIVE MOTOR

•

FREE SPOOL CLUTCH

•• •

SPRAG CLUTCH

• LUBRICATION PUMP

•

• •

RING GEAR AND PINION WINCHXS

DRUM

CROSS SECTION OF WINCH

13.6

Tigercat 620 Skidder

Winch

630B-24

WINCH CIRCUIT - LUFKIN WINCH 13.7

Tigercat 620 Skidder

Winch

WINCH CIRCUIT LANTEC WINCH

LANTEC WINCH

CIRCUIT DESCRIPTION - LANTEC WINCH

The winch is driven by a hydraulic motor through the sprag clutch and winch drive components. The pinion sprag holds the load in conjunction with the free spool clutch to prevent reverse rotation of the drum. The free spool clutch separates the drum from other drive components and permits the cable to unwind freely.

A hydraulic motor is used to drive the winch during the winding IN of the cable.

The hydraulic motor receives oil from the main pump via the winch spool section in the grapple control valve. The spool section in this control valve is pilot operated . It receives pilot oil from the lever control valve in the operator's cab to shift the spool. The spool directs oil from the pump to the motor and from the motor back to tank via the dozer valve.

The winch speed range switch controls the flow of pilot oil through a solenoid valve. When the winch speed control switch is ON (high speed) pilot oil passes through the winch speed solenoid valve to winch motor speed control to provide higher speed. When the winch speed control switch is OFF (low speed) pilot oil passes through the solenoid valve and returns to tank, the winch motor speed control returns the winch motor to low speed.

Winch freespool is available in two ways. The first freespool method is a true freespool controlled by the winch freespool switch on the dash. This switch operates a solenoid valve, a pilot signal releases the freespool clutch, allowing the cable to unwind freely. The second freespool method is a controlled freespool, operated by the winch control lever. Pilot oil from the control lever winch control lever passes through the freespool shuttle valve to release the freespool clutch. As the variable position winch control lever is pushed forward a controlled freespool can be achieved.

The winch is controlled through a variable position lever, a winch speed range switch and a free spool switch. The winch free spool switch operates the free spool clutch, allowing the cable to unwind freely from the drum. When the winch free spool switch is ON the cable can be pulled from the drum by the operator. Winch freespool can also be controlled by pushing the winch control lever forward, which allows a controlled freespool by partially releasing the freespool clutch (pushing the winch control lever fully forward will result in a full winch freespool, similar to pushing the winch freespool switch).

The sprag clutch in conjunction with the freespool brake holds the load and prevents the reverse rotation of the the drum and motor during the 'WINCH IN' or 'HOLD' operation.

Refer to WINCH LUBRICATION in SECTION 3 of THIS MANUAL. Refer to the manufacturer’s service manual for information on the winch.

WINCH MOTOR (FOR LANTEC WINCH ONLY) The winch motor is an internal gear type two speed motor. Motor speed is controlled by a built in two speed valve operated by pilot pressure. Pilot pressure causes the motor to operate at high speed, when pilot pressure is removed the motor returns to low speed.

LANTEC MODEL 40 WINCH

248-22

13.8

Tigercat 620 Skidder

630B-25

Winch

WINCH CIRCUIT - LANTEC WINCH SERIAL NUMBERS 6200111 TO 6200196 13.9

Tigercat 620 Skidder

Winch

13.10

Tigercat 620 Skidder

630B-26

Winch

WINCH CIRCUIT - LANTEC WINCH SERIAL NUMBERS 6200197 AND UP 13.11

Tigercat 620 Skidder

Winch

WINCH PRESSURE SETTINGS P3 TEST PORT

WARNING

•

Do not stand above or below the arch assembly, grapple or between the arch and rear chassis when working on the winch.

Before performing work on the winch, lower the arch assembly to the ground and/or use proper support devices.

620-M6

CAUTION Avoid blowing oil over the relief for longer than 5 seconds, as this will cause excessive heating of the hydraulic fluid and possible damage to hydraulic components.

WARNING Use caution when working on top of the rear chassis, as there are many pinch areas between the arch, arch cylinders and winch.

DO NOT move arch when workers are in this area.

*Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 12 of THIS MANUAL. IMPORTANT: Approach the gauge reading slowly and deliberately by turning adjusting nut IN a little at a time. The pressure settings must not exceed the designated values.

MACHINES NOT EQUIPPED WITH A WINCH 'IN' PORT RELIEF NOTE: Some early machines were not equipped with a winch 'IN' port relief.

For these early machines there are no hydraulic adjustments necessary for the winch circuit.

WINCH 'IN' PORT RELIEF ADJUSTMENT

WARNING Do not work under the arch without properly supporting the arch/grapple assembly. NEVER move the arch/grapple assembly when workers are in this area.

WARNING Park machine on level ground, stop engine, set parking brake ON, lower dozer and grapple to the ground and block wheels.

HOSES REMOVED FOR CLARITY

HIGH PRESSURE RELIEF VALVE

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

1. Set parking brake ON, grapple dozer blade DOWN and shut off the engine.

2. Connect a 0-5000 psi gauge to the ‘P3’ test port.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 4. Start the engine, hold down the brake pedal and set the throttle to IDLE. 5. It is necessary to temporarily increase the pressure of the main pump to 3850-3900 psi. a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

PRESSURE REDUCING VALVE

Turn the dozer inlet relief valve (if equipped) IN all the way (clockwise) until lightly seated.

•

WARNING: Observe the pressure gauge while turning the relief valve adjusting screw(s) IN. The main pump could be stuck in the fully stroked position. Back off the adjusting screw if the pressure rises above 3600 psi and investigate the main pump for proper operation.

••

••

SEQUENCE VALVE

321-2A

MULTIFUNCTION VALVE 13.12

Tigercat 620 Skidder

Winch

b. Turn the main pump POR to 3850-3900 psi on the 'P3' gauge using the pressure adjusting screw on the side of the pump. (through the cover plate hole).

DOZER VALVE INLET RELIEF

6. Disconnect the main hoses from the winch section of the grapple control valve. Cap the ports on the winch section and plug the hose ends.

••

7. With the aid of an assistant, operate the winch IN control and hold pressure.

DOZER VALVE INLET RELIEF

8. FOR LANTEC WINCHES Adjust the winch IN, port relief valve to give a reading of 2900-2950 psi on the 'P3' gauge.

630-D42

•

FOR LUFKIN WINCHES Adjust the winch IN, port relief valve to give a reading of 3500-3600 psi on the 'P3' gauge.

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF. MAIN PUMP POR ADJUSTING SCREW

9. Reconnect main hoses to the winch section of the grapple control valve.

10. Reset the multifunction valve high pressure relief (reading on the 'P3' gauge).

For machines with dozer inlet relief valve set to 3575-3600 psi plus 4 flats.

For machines without a dozer inlet relief valve set the multifunction to 3500-3600 psi .

11. Reset the dozer valve inlet relief (if equipped) to 3500-3525 psi.

630-PH2

12. Reset the main pump POR to 3000-3100 psi on the 'P3' gauge.

13. Turn off the engine, remove gauges, reinstall plugs on the test ports and replace the cover plates.

13.13

MAIN PUMP

HOSES REMOVED FOR CLARITY

Tigercat 620 Skidder

Winch

13.14

Tigercat 620 Skidder SECTION 14 - DOZER BLADE SEPTEMBER 2003

CONTENTS - SECTION 14 CIRCUIT DESCRIPTION ............................................................................. 14.6 CIRCUIT DIAGRAM ..................................................................................... 14.7 CONTROL LEVER PILOT VALVE ............................................................... 14.3 DOZER CONTROL VALVE.......................................................................... 14.4 PRESSURE SETTINGS .............................................................................. 14.8

Tigercat 620 Skidder

Dozer blade

14.2

Tigercat 620 Skidder

Dozer blade

CONTROL LEVER

OPERATING DESCRIPTION

DOZER BLADE

The dozer blade control lever valve is one section of a two section sandwich plate design valve. The second section of the valve is used to operate the winch.

This pilot valve is a manually operated directional control valve and operates on the same principal as a direct operating pressure reducing valve.

The control lever, the joystick and foot control valves use similar spool arrangements.

This control valve directs pilot pressure to the pilot end caps of the dozer control valve. The spool valve then shifts from its center position and directs pump flow to operate the dozer cylinders.

•

5

• •

4

•

2

3

•

AU013-1

At the same time, control spool (2) is moved by control spring (3).

Once the pressure equals the value set by control spring (3), the control spool closes the loop and there is a connection to work ports (1,2).

• •

Oil flow is directly proportional to the position of the control lever setting by the operator and the control spring (3) characteristics.

•

8

'P' PORT

When the lever (1) is operated, plunger (5) is pushed against the return spring (4)

As the spool moves down, the control chamber to tank connection is closed. As the spool continues to move, the connection between input pressure (P) and the control chamber is opened and the pressure is then able to build up in the control chamber.

1

•

•

In the neutral position the control lever is held centered by return spring (4).

WORK PORTS 1, 2

SPOOL ARRANGEMENT

AU013-2

AU014-1

DOZER BLADE CONTROL LEVER VALVE 14.3

Tigercat 620 Skidder

Dozer blade the dozer cylinders and from the multifunction valve. Return oil is directed back to tank via the distribution manifold.

DOZER CONTROL VALVE The dozer valve is located on the valve bench in the front chassis just below the radiator in front of the cab.

Current production machines and many field updated machines are equipped with a dozer valve inlet relief which acts as the primary relief valve for the main pump. The multifunction valve high pressure relief remains in place on these machines and acts as a secondary relief valve for the main pump.

The dozer control valve consists of one spool section, one inlet section and one outlet section.

The inlet section is used to receive oil from the main pump via the priority valve and supply oil to the dozer spool section. The spool section is open center type, spring centered and pilot operated. The use of this open circuit spool section in a closed circuit application is accomplished by blocking the power beyond carry-over port using a special power beyond plug. The outlet section receives return oil from OIL OUT TO RETURN MANIFOLD

Some earlier machines were equipped with a relief on the outlet section of the dozer valve rather than the inlet section. All dozer valve outlet reliefs should be converted to dozer valve inlet reliefs. No additional parts are FRONT OUTLET SECTION

• DOZER DOWN PORT RELIEF

RETURN OIL FROM MULTIFUNCTION VALVE

• DOZER

A

B

•

•

GAUGE TEST PORT

DOZER INLET RELIEF VALVE (LATER MACHINES ONLY)

• •

'PRESSURE' OIL 'IN' FROM PRIORITY VALVE

INLET SECTION

DOZER CONTROL VALVE

630B-11

PARALLEL PASSAGE

RELIEF VALVE PORT 'A'

LOAD CHECK VALVE

WORK PORT BRIDGE

A

RELIEF VALVE PORT 'B'

B

•

• • •

•

•

•

•

•

• PILOT END CAP 90136-3

SPOOL CENTERING SPRING

PILOT END CAP

•

SPOOL TANK PASSAGE

THRU' NEUTRAL PASSAGE

CROSS SECTION OF SPOOL SECTION 14.4

Tigercat 620 Skidder

Dozer blade

required to complete the conversion refer to Service News Letter Bulletin Number 1262 for more information and instructions.

Tigercat recommends that all earlier machines not originally equipped with a dozer valve inlet relief be updated to include a dozer inlet relief valve. Refer to Service News Letter Bulletin Number 1262 for more information.

OPERATING DESCRIPTION Oil is supplied by a variable displacement piston pump via the priority valve to the inlet section of the dozer valve. Oil enters the dozer valve inlet section and is allowed to pass through the open center spool section to the outlet section and is prevented from returning to tank by a power beyond plug. When dozer function is not in use there will be no oil flow through the valve, therefore oil flow to the dozer control valve will be regulated to zero as the piston pump de-strokes to a zero angle.

The spool section has a self centering 3-position spool which is open centered. A spring in the spool end cap holds the spool in the open center neutral position. When the dozer function is operated the spool is shifted by pilot pressure applied to either end of the spool. Shifting the spool directs oil to operate the dozer blade cylinders. The return oil from the dozer cylinder flows back to the valve, through the spool and back to tank via the tank port in the outlet section.

To prevent over pressurizing of the operating circuit, the work ports in the valve section have a port relief valve. All relief valves are anticavitation relief valves.

For a detailed description of these relief valves, refer to RELIEF VALVES in SECTION 12 of THIS MANUAL.

14.5

Tigercat 620 Skidder

Dozer blade

DOZER CIRCUIT CIRCUIT DESCRIPTION Two cylinders are used to raise and lower the dozer blade.

The dozer circuit receives hydraulic oil from the main pump via the 'P1' port on the multifunction valve manifold.

The oil then passes through the priority valve, where it is divided to go to either the steer valve or to the dozer, grapple, or winch functions.

The priority valve is a safety feature that allows the steer circuit to have first call on oil before the dozer, grapple, or winch circuits.

By splitting the system into two independent circuits, pressure transients are isolated in each circuit and only the flow required for steering goes to the steering circuit. The remaining flow is available for the dozer, grapple, and winch functions. This provides safe, reliable operation because the steering circuit always has flow and pressure priority.

Oil from the priority valve 'EF' port is directed to the dozer control valve inlet section. When dozer function is not in use there is no oil flow through the valve, therefore oil flow to the dozer control valve will be regulated to zero as the pressure compensated piston pump de-stokes to zero angle.

The spool section in this control valve is pilot operated. Pilot oil to either end of the end caps is supplied via the dozer lever control valve in the operator's cab. Moving the dozer lever control valve one way or the other directs pilot oil to shift the spool.

When the spool is shifted, passages in the dozer valve are opened to supply oil to either end of the dozer cylinders to operate the blade. Return oil from the cylinders returns through the dozer valve section, to the outlet section and back to tank.

14.6

Tigercat 620 Skidder

Dozer blade

DOZER CIRCUIT 630B-27

14.7

Tigercat 620 Skidder

Dozer blade

DOZER PRESSURE SETTINGS P3 TEST PORT

WARNING

•

Do not stand above or below the dozer blade or between the blade and front chassis during this procedure.

Before performing work on the dozer blade, lower the blade to the ground, or use proper supporting devices.

620-M6

CAUTION Avoid blowing oil over the relief for longer than 5 seconds, as this will cause excessive heating of the hydraulic fluid and possible damage to hydraulic components.

WARNING Use caution when working around the dozer area, as there are many pinch areas between the dozer assembly, cylinders and front chassis. DO NOT move the blade when workers are in this area.

Do not work under the blade without properly supporting the dozer assembly.

NEVER move the dozer assembly when workers are in this area.

IMPORTANT: Approach the gauge reading slowly and deliberately by turning adjusting nut IN a little at a time. The pressure settings must not exceed the designated values.

DOZER BLADE UP/DOWN PORT RELIEF ADJUSTMENT NOTE: Park the machine on level ground as this procedure will lift the front wheels off the ground when the dozer blade is operated in its down position.

2. Connect a 0-5000 psi gauge to the ‘P3’ test port.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 4. Start the engine, hold down the brake pedal and set the throttle to IDLE.

WARNING Park machine on level ground, stop engine, set parking brake ON, lower dozer and grapple to the ground and block wheels.

••

*Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 12 of THIS MANUAL.

1. Set parking brake ON, grapple UP, dozer DOWN and shut off the engine.

WARNING

MAIN PUMP P.O.R. ADJUSTING SCREW

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

5. It is necessary to temporarily increase the pressure of the main pump to 3850-3900 psi. a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

HOSES REMOVED FOR CLARITY

Turn the dozer inlet relief valve (if equipped) IN all the way (clockwise) until lightly seated.

WARNING: Observe the pressure gauge while turning the relief valve adjusting screw(s) IN. The main pump could be stuck in the fully stroked position. Back off the adjusting screw if the pressure rises above 3600 psi and investigate the main pump for proper operation. b. Turn the main pump POR to 3850-3900 psi on the 'P3' gauge using the pressure adjusting screw on the side of the pump. (through the cover plate hole).

630-PH2

MAIN PUMP - DOZER, STEER & GRAPPLE

14.8

Tigercat 620 Skidder

Dozer blade

6. Make sure that the area is clear and the engine front door is closed.

HOSES REMOVED FOR CLARITY

CAUTION HIGH PRESSURE RELIEF VALVE

Do not operate machine with front door open.

Dozer blade will damage the door if operated with the front door open.

PRESSURE REDUCING VALVE

7. With the aid of an assistant operate the dozer UP control and hold.

•

8. Adjust the dozer UP, port relief valve to give a reading of 3500-3600 psi on the 'P3' gauge.

••

••

9. LOWER dozer blade completely and hold.

CAUTION - This will raise the front wheels off the ground.

SEQUENCE VALVE

321-2A

10. Adjust the dozer DOWN, port relief valve to give a reading of 3500-3600 psi on the 'P3' gauge.

MULTIFUNCTION VALVE DOZER VALVE INLET RELIEF

11. Raise the dozer blade to allow the front wheels to contact the ground.

12. Reset the multifunction valve high pressure relief (reading on the 'P3' gauge).

For machines with dozer inlet relief valve set to 3575-3600 psi plus 4 flats.

••

For machines without a dozer inlet relief valve set the multifunction to 3500-3600 psi.

DOZER VALVE INLET RELIEF 630-D42

13. Reset the dozer valve inlet relief (if equipped) to 3500-3525 psi .

14. Reset the main pump P.O.R. to 3000-3100 psi on the 'P3' gauge.

15. Turn off the engine, remove gauges, reinstall plugs on the test ports and replace the cover plates.

14.9

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF.

Tigercat 620 Skidder

Dozer blade

14.10