Tigercat 635 SKIDDER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL Tigercat 635 SKIDDER ISSUE 2.0, OCTOBER 2003

TABLE OF CONTENTS SECTION INTRODUCTION .............................................................................................................. iii SAE STANDARDS ........................................................................................................... iv NON-APPROVED FIELD PRODUCT CHANGES ............................................................. v 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 CROSS-FLOW FAN ..................................................... 10 STEERING AND CENTER JOINT .................................................................................. 11 GRAPPLE , ARCH AND BOOM ...................................................................................... 12 WINCH ............................................................................................................................ 13 DOZER ............................................................................................................................ 14

635-SM00

635 Available Literature Operator's Manual .................................................................... Part No. 15160A Manual de Operación (Español) .............................................. Part No. 20487A Service Manual (This Manual) .................................................. Part No. 14968A NAF Bogie Axle, Service and Repair ....................................... Part No. 15023A Tandem de Ejes NAF, Servicio y Raparación (Español) ......... Part No. 20645A Parts Catalog ............................................................................ Part No. 15195A Hydraulic Adapters Book ............................................................ Part No. 1472A Hose Assemblies Book .............................................................. Part No. 3707A

Tigercat

®

Tigercat Industries Inc. P.O. Box 544 Paris, Ontario Canada N3L 3T6 Tel: (519) 442-1000 Fax: (519) 442-1855

ii

Tigercat 635 Skidder

Introduction

Tigercat 635 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 635 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.

iii

Tigercat 635 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.

iv

47,000 lbs.

901099

6958A R03

Tigercat 635 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 635 Skidder

Introduction

vi

Tigercat 635 Skidder

SECTION 1 - SAFETY MARCH 2003

CONTENTS - SECTION 1 ARTICULATION LOCK ................................................................................ 1.10 BATTERY DISCONNECT SWITCH .............................................................. 1.7 CAB SAFETY CABLE .................................................................................. 1.11 CAB SUPPORT BRACE .............................................................................. 1.11 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 ................................................... 1.4, 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 635 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 is used in areas where failure to follow

CAUTION listed procedures may cause personal injury, component damage or subsequent malfunction.

IMPORTANT is used to focus attention on items

IMPORTANT that should be checked, controlled, adjusted or cleaned to ensure the efficiency and long term operation of the machine.

Remember that safety is a prime responsibility of

1.2

Tigercat 635 Skidder

Safety good condition. Repair or replace damaged labels.

GENERAL SAFETY PRECAUTIONS 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.

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 illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in

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

1.3

Tigercat 635 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.

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

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

Machine should be washed completely at every major service.

•

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

•

If these are found, Do Not Touch!!!

•

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

•

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

•

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

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.

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

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

NOTE:

Check all fluid levels.

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

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 635 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

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.

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

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 635 Skidder

Safety Secure loose items in the 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 the 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 brakes 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 onto the ground.

1.6

Tigercat 635 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.

•

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

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.

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

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

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

Use caution when loosening hydraulic connections.

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

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

Do not work below or behind a 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 635 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 635 Skidder

SERVICING SAFETY PRECAUTIONS

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.

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.

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

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

This machine is equipped with a reversible cooling fan to facilitate cleaning of the radiator/oil cooler assembly and engine compartment doors.

Exercise care when working in this area with the engine running. If the FAN CONTROL SWITCH (later machines) is in the AUTOMATIC position, the fan could turn ON and/or go into PURGE mode.

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

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.

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 on how to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

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

1.9

Tigercat 635 Skidder

Safety

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

SAFETY CABLE

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.

302-13

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.

302-16

•• 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.

SAFETY7

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

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, chains or logs.

1.10

Tigercat 635 Skidder

Safety

SERVICING SAFETY PRECAUTIONS continued

HAND KNOBS

••

UPPER DOORS

••

••

•

••

•• LOWER PANELS

HAND KNOBS

•• •

• QUICK ACCESS

302-15

ENGINE COMPARTMENT ACCESS PANELS 285-14

ARTICLUATION LOCK IN POSITION

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

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

191-5ALT

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.

REMOVE LOWER PANELS

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

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

Tigercat 635 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 635 Skidder

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

FIRE PREVENTION

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

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

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.

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

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

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

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

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

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.

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

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.

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.

Continued on page 14

1.13

Tigercat 635 Skidder FIRE PREVENTION continued

Safety WHAT TO DO IN CASE OF A MACHINE FIRE •

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 635 Skidder FIRE PREVENTION continued

20229A

Safety WHAT TO DO AFTER A FIRE •

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.

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

Tigercat 635 Skidder

Safety

1.16

Tigercat 635 Skidder SECTION 3 - LUBRICATION & MAINTENANCE SEPTEMBER 2003

CONTENTS - SECTION 3 AIR CLEANER MAINTENANCE ............................................................................... 3.16 AIR CONDITIONING SYSTEM, CHECKING ............................................................ 3.22 APPROVED HYDRAULIC OILS ................................................................................. 3.7 CENTER JOINT LUBRICATION ....................................................................................................... 3.27 MAINTENANCE ..................................................................................................... 3.27 EMERGENCY EXITS, CHECK MONTHLY ................................................................. 3.3 FILTERS AXLE RETURN FILTERS ...................................................................................... 3.15 CHARGE PRESSURE FILTER - DRIVE PUMP .................................................... 3.13 CHARGE PRESSURE FILTER - FAN DRIVE PUMP ............................................ 3.13 ENGINE AIR INTAKE ............................................................................................ 3.16 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 HOUR METER ~ MAINTENANCE .............................................................................. 3.2 LUBRICATION AND SERVICE POINTS .................................................................... 3.9 NEW MACHINE MAINTENANCE ...............................................................................

FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT ...............................

INITIAL PRE-DELIVERY INSPECTION ...................................................................

TIGHTENING POINTS .............................................................................................

3.2 3.2 3.2 3.2

OIL LOST FROM LEAKAGE ....................................................................................... 3.2 PRESSURIZED WATER SYSTEM MAINTENANCE ................................................ 3.20 REAR (BOGIE) AXLE ................................................................................................

BOGIE HOUSINGS (2 FILLING POINTS) .............................................................

DIFFERENTIAL (1 FILLING POINT) ......................................................................

DRAINING AND REFILLING BOGIE AXLE ...........................................................

PLANETARY DRIVES (4 FILLING POINTS) .........................................................

REPLACING THE ENGINE SERPENTINE BELT ....................................................

3.28 3.29 3.28 3.28 3.29 3.32

SCHEDULED MAINTENANCE ................................................................... 3.4, 3.5, 3.6 FREQUENTLY ......................................................................................................... 3.4 8 HOURS ................................................................................................................. 3.4 48 HOURS ............................................................................................................... 3.5 125 HOURS ............................................................................................................. 3.5 250 HOURS ............................................................................................................. 3.5 500 HOURS ............................................................................................................. 3.5 1000 HOURS ........................................................................................................... 3.6 SERVICE AND LUBRICATION POINTS .................................................................... 3.9 SPEED CONTROL LEVER ADJUSTMENT .............................................................. 3.33 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE .................................... 3.30 TILTING THE CAB .................................................................................................... 3.24 TORQUE CHART ...................................................................................................... 3.34 TORQUE CHART, GENERAL ................................................................................... 3.35 WHEELS, INSTALLING .............................................................................................. 3.2 WINCH LUBRICATION - LANTEC ONLY ................................................................. 3.26

Tigercat 635 Skidder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 635 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 635 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.

3.3

Tigercat 635 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE FREQUENTLY:~

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.

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

• Lubricate mid drive shaft, 1-fitting, purge

EVERY 8 HOURS (EVERY SHIFT):~

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

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

• Perform "frequently" maintenance check,

• Lubricate center joint bearings, 2-fittings, purge

And in addition:~ • Check engine coolant level

• Lubricate steering cylinder ends, 4-fittings, purge

• Check engine oil level • Drain fuel/water separator

• Lubricate arch cylinders and pivots, 12-fittings, purge

• Check air intake precleaner, clean as required • Check air cleaner unloader valve

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

• Check engine air filter restriction indicator • Check hydraulic oil level

Clean:~ • Potentially damaging limbs or sticks from machine

• Check pump drive gearbox oil level with dipstick • Check transmission 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 winch sump oil level • Lubricate front axle pivot, 2-fittings, purge • Lubricate front axle - outer bearings ‡ 1-fitting; 2-places; lubricate until grease flows out past the outer seals.

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

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

• For loose nuts, bolts and fittings

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

• Condition and tension of fan belts.

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

Note: Manual lubrication of outer axle bearings applies only to earlier axles with CARTRIDGE LIP SEAL

GREASE FITTING

••

••

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

FACE SEAL

•

• Conduct an overall visual inspection.

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

EARLIER AXLES

M724D-15

LATER AXLES 3.4

Tigercat 635 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE 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.

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

EVERY 125 HOURS:~ • Perform "frequently" maintenance

Clean/replace:• Air conditioner re-circulation filter • 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:~ • Check fuel tank filler screen • Lubricate front drive shaft, 1-fitting, purge • Lubricate front axle - outer bearings 1-fitting; 2-places; lubricate until grease flows out past the outer seals.

EVERY 250 HOURS:~ • Perform "frequently" maintenance

Note: Do not use a power greaser 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 8 hour maintenance • Perform 125 hour maintenance And in addition:~ • Replace engine oil and change oil filter • Replace engine fuel filter • Replace fuel/water separator filter • Replace air intake primary element • Replace oil in pump drive gearbox • Replace oil in transmission

Check:~ • Fluid level in batteries unless maintenance free

• Check oil level in bogie axle differentials • Check oil level in bogie axle housings, 2 places

• Engine rpm.

• Hydraulic pump and motor securing bolts

• Check oil level in bogie axle planetary drives, 4 places

• Torque tightening points as per new machine maintenance

• Lubricate bogie axle slewing rings, 12-fittings; 2-places

• All hydraulic pressures

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

• Proper operation of pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

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

3.5

Continued on page 8

Tigercat 635 Skidder

Lubrication and Maintenance

SCHEDULED MAINTENANCE Continued from page 7

SEASONAL:~

EVERY 500 HOURS:~

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

• Perform "frequently" maintenance • Perform 8 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance

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

• Drain and refill bogie axle differential, housings and planetary drives. Refer to REAR (BOGIE) AXLES in THIS SECTION. Refer also to bogie axle service and repair manual for recommended gear oils and service intervals.

• Replace charge pressure filter-drive pump †

• Replace hydraulic hand fill pump filter. †

• Replace charge pressure filter-cooling fan pump †

• Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

And in addition:~ • Replace air intake safety element

• 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.

EVERY 1000 HOURS:~ • Perform "frequently" maintenance • Perform 8 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance And in addition:~ • Replace air cleaner unloader valve • Check center joint preload with a dial indicator.

Refer to CENTER JOINT ~ CHECKING CENTER JOINT PRELOAD in SECTION 11 of the SERVICE MANUAL. If a problem is found corrective action should be taken immediately, refer to CENTER JOINT PRELOAD ADJUSTMENT in SECTION 11 of the SERVICE MANUAL. • Replace oil in winch sump • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

† Use only Genuine Tigercat replacement hydraulic oil filters.

3.6

Tigercat 635 Skidder

Lubrication and Maintenance

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

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

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

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

THE FOLLOWING ARE APPROVED BY Tigercat FOR USE IN THIS MACHINE:

®

CHEVRON CITGO IMPERIAL/ESSO SHELL SUN JOHN DEERE

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

3.7

Tigercat 635 Skidder

Lubrication and Maintenance

20

REAR DRIVE SHAFTS 23 3 FTG/8

OUTER AXLE BEARINGS 18 2 FTG/8

4

10

3

12

19

11

GRAPPLE YOKE 28

4 FTG/8

13 GRAPPLE ROTATOR 28 3 FTG/125 5 SHOTS GRAPPLE SNUBBERS 28 4 FTG /8

GRAPPLE PINION GEAR 28 1 FTG/250 5 SHOTS

BOGIE AXLE SLEWING RINGS 22 24 FTG/250

NOTE: REMOVE PIPEPLUG TO ACCESS

ARCH

12 FTG/8 29

STEER CYLINDERS

4 FTG/8

30

AXLE - PIVOT 25

2 FTG/8

17

DOOR HINGES 26

8 FTG/500

5

15

1

7 8

DOZER

6

6 FTG/8

CENTER JOINT

GRAPPLE 28

8 FTG/8

21

24

2 FTG/8

MID DRIVE SHAFT 23

1 FTG/8

FRONT DRIVE SHAFT 23 1 FTG/125

16

14

9

LEGEND *

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

**

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

*** ****

2 FTG/125

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

†

Use only Genuine T igercat replacement Hydraulic oil filters.

12804BR5

3.8

CHK REP DRN D/R LUB

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

27

Tigercat 635 Skidder

Lubrication and Maintenance

Tigercat® Model 635 SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

1

COOLING SYSTEM

CHK

2

ENGINE OIL/FILTER CUMMINS C SERIES FUEL FILTER (ENGINE) FUEL/WATER SEPARATOR FUEL TANK FILLER SCREEN AIR INTAKE PRECLEANER AIR INTAKE PRIMARY ELEMENT AIR INTAKE SAFETY ELEMENT

CHK

3 4 5 6 7

CHANGE COOLANT EVERY 2 YEARS REP

40

10.6

18.9

5

REP REP

DRN

DESCRIPTION QTY

USG

LITERS

500

250

125

8

ITEM

CAPACITY

1000

SERVICE POINT NO.

SERVICE EVERY

60/40 ANTIFREEZE * SEE ENGINE MANUFACTURERS MAINTENANCE MANUAL 1 1 1 1 1 1

CHK CHK REP REP

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 ELEMENT

DRN REP †

12

CHARGE PRESSURE FILTER (DRIVE PUMP)

13

CHARGE PRESSURE FILTER (FAN DRIVE PUMP)

14

PUMP DRIVE GEARBOX CHECK LEVEL WITH DIPSTICK

CHK

D/R

3

0.8

1

15

TRANSMISSION

CHK

D/R

6

1.6

1

FRONT AXLE - (EARLIER AXLE WITH GREASE LUBRICATED OUTER BEARINGS)

28

7.4

1

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

FRONT AXLE - (LATER AXLE WITHOUT GREASE LUBRICATED OUTER BEARINGS)

31

8.2

1

D/R WITH SEASONAL OIL CHANGE

16

CAST

17

FRONT AXLE - PIVOT

LUB LUB ***

18

FRONT AXLE-OUTER BEARINGS EARLIER AXLE WITH GREASE LUBRICATED OUTER BEARINGS

19 20 21 22

23

REP

CLEAN AS REQUIRED CHECK FILTER RESTRICTION INDICATOR WITH ENGINE RUNNING

95

25

1

REFER TO SECTION 3 IN MANUAL

1

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.

REP †

1

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

REP †

1

LUB ***

PURGE

2

LITHIUM BASE EP2 GREASE

** SEE NOTE

2

LITHIUM BASE EP2 GREASE

FRONT AXLE OUTER BEARINGS LATER AXLE THERE ARE NO LUBRICATION FITTINGS, AXLE OUTER BEARINGS ARE LUBRICATED WITH OIL FROM "SERVICE POINT NO. 16" BOGIE AXLE - DIFFERENTIAL (LATER CHK 22.5 6 1 REFER TO BOGIE AXLE SERVICE AND REPAIR MANUAL FOR RECOMMENDED BOGIE AXLE - HOUSINGS CHK 35 9.2 2 GEAR OILS BOGIE AXLE - PLANETARY DRIVES BOGIE AXLE - SLEWING RINGS FRONT DRIVE SHAFT MID DRIVE SHAFT REAR DRIVE SHAFTS: BEARING FRONT BEARING INTERMEDIATE DIFFERENTIAL YOKE

CHK LUB LUB

5 1.3 PURGE PURGE PURGE

4 24 LITHIUM BASE EP2 GREASE 1 1

LUB LUB LUB

PURGE PURGE PURGE

1 1 1

PURGE

2

LUB

CENTER JOINT

LUB

24

CENTER JOINT BEARING PRELOAD

25 26 27 28 29

STEERING CYLINDERS DOUBLE ARCH CYLINDER & PIVOTS DOZER BLADE CYLINDER & PIVOTS GRAPPLE, Tigercat WINCH LANTEC

CHK 48 LUB LUB LUB CHK

30

PRESSURIZED WATER SYSTEM

CHK

635LUBCHARTMOD0903.XLS/PDF

CHK

TEST

LITHIUM BASE EP2 GREASE

LITHIUM BASE EP2 GREASE

REFER TO SECTION 3 OF THE MANUAL FOR DETAILS 4 LITHIUM BASE EP2 GREASE PURGE 12 LITHIUM BASE EP2 GREASE PURGE 6 LITHIUM BASE EP2 GREASE PURGE SEE LUBRICATION POINTS DIAGRAM D/R 18 4.7 SEE WINCH MANUFACTURER'S MAINTENANCE MANUAL D/R 52 13.7 SEASONAL DRAIN AND REFILL

3.9

Tigercat 635 Skidder

Lubrication and Maintenance

FILTERS

Changing the filter: 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.

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

•

FUEL WATER SEPARATOR

PRIMER PUMP

•

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.

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

WATER SEPARATOR BOWL

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

• DRAIN TAP

•

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

13. Start the engine and check for leaks.

270-9A

FUEL WATER SEPARATOR

3.10

Tigercat 635 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 635 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:

• •

GASKET

•

FILTER ELEMENT

SQUARE SECTION GASKET INSTALLATION FILTR_SEALS

Square Section Gasket Remove used gasket and clean groove in head.

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

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

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS SECTION. Changing the filters:

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

FILTER HEAD

• •

•

• GASKET

• BLUE ELEMENT

•

DRIVE PUMP CHARGE PRESSURE FILTER FILTR_SEALS

630-D38

HYDRAULIC FILTERS

z

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.

'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)

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

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

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

5. The new Tigercat filters are 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 635 Skidder 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.

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

Lubrication and Maintenance CHARGE PRESSURE FILTERSDRIVE PUMP AND FAN DRIVE PUMP 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.

The fan drive 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 for this filter is not connected to a warning light.

When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the fan drive circuit.

Continued on page 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.

DOUBLE ELEMENT FILTER

•

• •

DRIVE PUMP CHARGE PRESSURE FILTER

• BLUE ELEMENT

630-D38

HYDRAULIC FILTERS

LEFT SIDE BELOW COOLING FAN

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.

333-3

3.13

FAN DRIVE CHARGE PRESSURE FILTER

Tigercat 635 Skidder

Lubrication and Maintenance

Continued from page 13

Changing a pressure filter:

IMPORTANT

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

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 spray), unscrew the filter.

5. Drain filter and dispose of any oil properly.

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

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

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

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.

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 635 Skidder AXLE RETURN FILTERS (LATER MACHINES)

Lubrication and Maintenance HYDRAULIC TANK BREATHER FILTER (LATER MACHINES) HYDRAULIC TANK BREATHER FILTER

•

635-P07

FRONT AXLE RETURN FILTER

Later machines are equipped with a front axle return oil filter in the drain line of the front axle.

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

630-D44

HYRAULIC 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 bar, 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 635 Skidder

Lubrication and Maintenance

AIR CLEANER MAINTENANCE ENGINE AIR PRECLEANER

AIR CLEANER

•

•

SENDING UNIT FOR WARNING LIGHT IN CAB

FILTER RESTRICTION INDICATOR

ENGINE AIR CLEANER

•

• •

291-3

ENGINE AIR CLEANER

303-8

EXHAUST PORT AREA

ENGINE AIR CLEANER

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

284-25A

REAR VIEW OF PRECLEANER

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

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.

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

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

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

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

•

• 303-7

• •

TURBO 3

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

•

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

AIR CLEANER UNLOADER VALVE

ONLY THE PURIFIED AIR GOES TO THE AIR FILTER

TURBO II PRECLEANER OPERATION

This valve should be replaced every 1000 hours.

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

Tigercat 635 Skidder

Lubrication and Maintenance

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

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

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

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

In addition to the SCHEDULED MAINTENANCE, the following instructions should also be noted.

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

The most common and damaging servicing problems are:

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

PRIMARY ELEMENT

OUTLET TUBE

SAFETY ELEMENT

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.

• •

•

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.

6. Inspect the new filter for damage.

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

8. 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 635 Skidder

Lubrication and Maintenance

GRAPPLE SNUBBER MAINTENANCE

QUADCO MODEL 300 SNUBBER USED ON TIGERCAT GRAPPLES

IMPORTANT

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.

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 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.

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.

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 635 Skidder

Lubrication and Maintenance CROSS GROOVE POSITION LINED UP WITH WEAR BLOCK

FRICTION SLEEVE REPLACEMENT QUADCO MODEL 300 AND 500 SNUBBERS 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. Remove the snubber end cap bolt, end cap, bearing, spring washer and housing.

•• ••

SPRING WASHER

•

•

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 CY044

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

QUADCO MODEL 500 SNUBBER CROSS GROOVE POSITION LINED UP WITH WEAR BLOCK

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.

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

WEAR SLOT

END CAP

•

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.

•

• ••

•

SPRING WASHER

••

• ••

•

CORE ASSEMBLY FRICTION SLEEVE

HOUSING BEARING

END CAP BOLT CY045

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

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 635 Skidder

Lubrication and Maintenance SYSTEM TEST

PRESSURIZED WATER SYSTEM MAINTENANCE

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 PRESSURE GAUGE

• •

• •

WATER SHUT-OFF 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.

HOSE STORAGE COMPARTMENT

PRESSURIZED WATER SYSTEM

630-D46

FILL & CHARGE PRESSURIZED WATER SYSTEM

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).

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

CAUTION

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.

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

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.

WATER SHUT-OFF VALVE (SHOWN OFF) PRESSURE GAUGE

WATER TANK

• •

•

FILL PLUG

OUTLET CONNECTION

•

•

AIR CHARGE VALVE 150-1A

•

WATER CONTROL VALVE DOZER BLADE

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

• 150-8A

PRESSURIZED WATER SYSTEM

3. Close water shut off valve.

4. Fill tank with clean water. Tank capacity is approximately 13.7 USgallons (52 litres).

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.

3.20

Tigercat 635 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.

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.

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

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

10. Close the water shut-off valve.

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

Do not substitute.

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.

13. Return the hose to the hose compartment.

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.

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.

3.21

Tigercat 635 Skidder

Lubrication and Maintenance

CHECKING THE AIR CONDITIONING SYSTEM

IMPORTANT

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

It is recommended that during cold weather when the A/C system is not in use, that it be run for a period of 5 minutes every 2 weeks.

This will circulate oil to all components of the A/C system.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

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.

302-19

a. Check and adjust compressor drive belt tension.

CAUTION

b. Check air intake filters and clean as required.

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 30 psi or less.

Always use personal protective equipment to guard against flying debris

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. d. Check the evaporator core and the inside of the A/C housing for dirt and debris.

Clean as required.

CAUTION

e. Run air conditioning system for 3 - 5 minutes. f.

CHECK A/C CONDENSER CORE

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.

Check to see that compressor clutch will engage.

3.22

Tigercat 635 Skidder

Lubrication and Maintenance FRESH AIR FILTER

• • •

ENGINE

SHUT-OFF VALVE

HOSE TO A/C HEATER UNIT

• 303-20

274-5

HOT WATER SHUT OFF

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

TEMPERATURE CONTROL

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.

350-4A

A/C-HEATER CONTROL PANEL

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.

3.23

Tigercat 635 Skidder

Lubrication and Maintenance

TILTING THE CAB 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.

5. Remove the left side Cab Locking Pins. (2 pins) This is done by first removing the locking bolts. (2 bolts) 6. Open the lower compartment door in left hand step below the cab door to access the cab tilt hand pump.

PUMP HANDLE

RAISING THE CAB

•

•

1. Position the Skidder on level ground.

PUMP

•

2. Lower the 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)

PUMP HANDLE STORAGE BRACKETS

•

HAND PUMP FOR CAB TILT

302-14

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

PUMP HANDLE

CANOPY SWEEP BOLTS

•

•

PUMP LEVER SHOWN IN "RAISE" POSITION

•

PUMP LEVER SHOWN IN "LOWER" POSITION

• • 303-14 138-8AX

PUMP CONTROL LEVER

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

The pump handle is stored on the inside of the battery access door located below the test port compartment.

CAUTION 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.

303-M2

•

303-12

•

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

3.24

Tigercat 635 Skidder

Lubrication and Maintenance

LOWERING THE CAB CAB SUPPORT BRACE (3291B).

MUST USE CAB & CHASSIS LUGS SHOWN

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.

•

SAFETY CABLE

CAB LOCKING PINS

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

•

•

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

•

5. Watch closely for pinching of hydraulic lines 302-16

PARTIAL TILT WITH CAB SUPPORT BRACE

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

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

8. Close and lock the lower door.

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

•

WARNING

Before working under cab; Machine must be parked on level ground.

Cab must be fully tilted with safety cable completely tight, or cab support brace must be installed.

CAB SAFETY CABLE (3361B)

302-13

CAB AT FULL TILT SUPPORTED SUPPORTED BY SAFETY CABLE

WARNING If cab support brace is damaged or lost, it must be replaced immediately with Tigercat brace PART 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.

3.25

Tigercat 635 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

3.26

LANTEC WINCH - RIGHT SIDE

Tigercat 635 Skidder

Lubrication and Maintenance

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

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

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

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

Refer SECTION 11 of the SERVICE MANUAL for more information.

REAR CHASSIS

CHECK FOR MOVEMENT IN THIS JOINT AREA

DIG-003

FRONT CHASSIS

CENTER JOINT PRE-LOAD CHECK

3.27

Tigercat 635 Skidder

Lubrication and Maintenance

REAR (BOGIE) AXLE

DIFFERENTIAL (1 FILLING POINT)

The bogie axle has 7 separate oil reservoirs.

Each reservoir must be filled separately to get the proper level of lubrication in the bogie axle.

Note: The volume of oil required for the differential case has been increased from the previously recommended level. Checking the increased fill level requires the installation of a dipstick kit per PSB 1373. Refer to SERVICE AND LUBRICATION POINTS CHART in THIS SECTION for correct volume.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

1. Remove the DIPSTICK from the TOP BREATHER PORT.

DRAINING AND REFILLING BOGIE AXLE •

Park the machine on level ground.

•

Stop the engine and place the parking brake in the ON position.

•

The bogie axle must be level in order to drain and refill it properly.

•

Note that it will be necessary to reposition the wheel hubs when draining and refilling the planetary drives.

•

The oil must be warm before draining and refilling.

•

Clean around all fill, level and drain plugs before removing them.

2. Remove the DIFFERENTIAL DRAIN PLUG and drain the oil into a suitable container for disposal.

3. Clean any filings from the magnet on the oil drain plug.

4. Re-install the DIFFERENTIAL DRAIN PLUG. 5. Refill the differential with new oil until the level reaches the first flat section at the end of the DIPSTICK. Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

6. Re-install the DIPSTICK in the TOP BREATHER PORT.

DIFFERENTIAL DRAIN PLUG (1 PLACE)

BOGIE HOUSING LEVEL PLUG (4 PLACES)

•

TOP BREATHER PORT (DIPSTICK 1 PLACE)

•

•

•

•• BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

3.28

•

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

BM041

BOGIE HOUSING FILL PLUG (2 PLACES)

Tigercat 635 Skidder

Lubrication and Maintenance

PLANETARY DRIVES (4 FILLING POINTS)

19. Clean any fillings from the four drain plugs.

7. Position the wheel hub for draining the planetary, with the drain plug in the lowest possible position as shown.

20. Re-install the four drain plugs.

21. Remove the BOGIE HOUSING LEVEL PLUGS (2 per housing).

8. Remove the PLANETARY FILL PLUG.

22. Refill the housing through the BOGIE HOUSING FILL PLUG, using first the reusable portion of the oil drained from the bogie housing and then new oil, until the oil level reaches the bottom of the BOGIE HOUSING OIL FILL PLUG.

9. Remove the PLANETARY DRAIN/LEVEL PLUG and drain the oil into a suitable container for disposal.

10. Reposition the wheel hub for filling the planetary, with the PLANETARY DRAIN/ LEVEL PLUG at 9 o’clock and the fill plug at 1 o’clock as shown.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

11. Refill the planetary with new oil until the level reaches the bottom of the PLANETARY DRAIN/LEVEL PLUG. (Note: To get a correct filling level the wheel hub must be in the planetary fill position as shown.)

23. Re-install the BOGIE HOUSING FILL PLUG and BOGIE HOUSING LEVEL PLUGS. 24. Repeat steps 12 to 23 for the second bogie housing.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

AFTER DRAINING AND REFILLING 25. Check all drain, fill and level plugs for leaks.

12. Repeat steps 7 to 11 for each of the four planetary drives.

BOGIE HOUSINGS (2 FILLING POINTS) 13. Note that the bogie housing must be level to drain and refill it properly.

14. Before draining the oil from the bogie housings, the axle should sit for at least 30 minutes so that contaminants in the oil can settle in the oil pan.

15. Remove the BOGIE HOUSING FILL PLUG. 16. A portion of the oil drained from the housing can be reused. To drain the reusable oil remove the BOGIE HOUSING DRAIN PLUGS (2 per housing – upper plugs) and drain the oil into a clean container, as this part of the oil can be reused.

17. Set aside the reusable oil.

18. The remaining oil is contaminated and must be discarded. To drain the contaminated oil remove the BOGIE HOUSING CONTAMINATED OIL DRAIN PLUGS (2 per housing – lower plugs) and drain the remaining oil into a second container for disposal.

3.29

Tigercat 635 Skidder

Lubrication and Maintenance

STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE •

This procedure should be followed: •

after major service or a rebuild.

•

whenever the machine has been drained of hydraulic oil.

•

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

Loosen plug on the outside of the main pump.

•

PRE-STARTUP AND FILLING LOOSEN PLUG OUTSIDE OF MAIN PUMP

1. Ensure all filters are in place.

Pre-fill only the new hydraulic oil double element filters.

Do not pre-fill the new charge pressure filters.

Refer to FILTERS in THIS SECTION.

630-D30

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

•

Loosen plugs on both motors.

LOOSEN PLUGS ON BOTH MOTORS

3. Check coolant level in the radiator.

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

•

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

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

•

•

•

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

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

630-D31

•

Loosen plug in port 'N' on top of fan pump.

'N' PORT PLUG

Loosen plug on the top center of hydrostatic drive pump servo

•• LOOSEN PLUG ON TOP CENTER OF HYDROSTATIC DRIVE PUMP SERVO

•

SOME HOSES REMOVED FOR CLARITY 333-7

630-D35

3.30

FAN DRIVE PUMP

Tigercat 635 Skidder

Lubrication and Maintenance

•

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

•

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

•

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

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

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.

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.

MACHINE STARTUP 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.

3.31

Tigercat 635 Skidder

Lubrication and Maintenance

REPLACING THE ENGINE SERPENTINE BELT A/C COMPRESSOR BELT

In order to replace the engine serpentine belt it is necessary to disassemble the fan drive pump coupling.

BELT GUARD BOLT LOCATIONS

•

•

1. Park the machine on level ground. Parking brake ON, grapple and dozer down and engine off.

2. Remove the belt guard (4 bolts).

3. Remove the A/C compressor belt.

•

•

4. Remove the fasteners that hold the pump drive coupler together (8 bolts - 1/4"). Note the engine will have to be 'jogged' to access all of the bolts.

•

5. Carefully slide the black rubber section of the coupler towards the fan pump. This will provide enough clearance to replace the serpentine belt.

•

SERPENTINE BELT

•

COUPLER

6. Replace the serpentine belt. Ensure that all of the ribs on the serpentine belt align with the grooves on the engine pulleys.

•

FAN DRIVE PUMP

7. Reassemble the pump drive coupler, using the original bolts. Use loctite 242 (temporary) or equivalent. Torque all bolts to 8-10 lbf-ft using an opposing torque pattern.

SHOWN WITH FAN AND SOME HOSES REMOVED FOR CLARITY

8. Reinstall, align and tension the A/C compressor belt.

314-24

BELT GUARD

9. Reinstall the belt guard.

CAUTION Always install belt guard before running the engine.

FAN DRIVE PUMP BOLTS

COUPLER

• •• •

•

COUPLER 1/4" BOLTS

SHOWN WITH FAN AND SOME HOSES REMOVED FOR CLARITY

314-12

3.32

FAN DRIVE PUMP BOLT LOCATIONS

Tigercat 635 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.

SPEED CONTROL LEVER

CONTROL PANEL

•

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.

• ••

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

PROTECTIVE RUBBER 'BOOT'

630-D36

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

•• PROTECTIVE RUBBER BOOT

RIGHT HAND SIDE OF MACHINE

• ADJUSTABLE FRICTION SET SCREW

•

CONTROL PANEL

•

630B-31

SPEED CONTROL LEVER FRICTION SET SCREW LOCATION 3.33

SPEED CONTROL LEVER

Tigercat 635 Skidder

Lubrication and Maintenance

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

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

3/4" UNC 1" UNC M27

300 682-750 1000

406 925-1016 1350

Wheel bolts

7/8" UNF

501-550

679-745

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

5/8"UNC 7/8" UNC

159-175 450

216-237 610

Drive shafts Yoke retaining nut, rear shaft Pillow block retaining bolts Rear drive shaft assembly universal joint bolts Mid. drive shaft universal joint bolts Front drive shaft universal joint bolts Axle mounting bolts Front Axle Rear (Bogie) Axle

REV0 11/2000

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

3.34

Tigercat 635 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 LUBRICATED lbf-ft Nm lbf-ft Nm 11 - 12 15 - 16 8 - 10 11 - 13 20 - 28 27 - 38 26 - 30 35 - 40 44 -48 60 - 65 33 - 36 45 - 49 70 - 77 95 - 104 52 - 57 71 - 77 106 - 117 144 - 158 80 - 88 109 - 119 153 - 168 208 - 228 115 - 127 156 - 172 212 - 233 288 - 316 159 - 175 216 - 237 376 - 414 510 - 561 282 - 310 393 - 420 606 - 667 822 - 904 455 - 501 617 - 679 909 - 1000 1233 - 1355 682 - 750 925 - 1016 1288 - 1417 1746 - 1921 966 - 1062 1310 - 1441 1817 - 1999 2464 - 2710 1360 - 1496 1844 - 2027 DRY LUBRICATED lbf-ft Nm lbf-ft Nm 13 - 14 18 - 19 10 - 13 14 - 17 23 - 28 31 - 38 18 - 25 25 - 33 49 - 54 67 - 73 37 - 41 50 - 55 78 - 86 106 - 116 58 - 64 79 - 86 120 - 132 163 - 179 90 - 99 122 - 134 171 - 188 232 - 255 128 - 141 174 - 191 240 - 264 326 - 358 180 - 198 244 - 268 420 - 462 570 - 626 315 - 347 427 - 470 668 - 735 906 - 996 501 - 550 679 - 745 995 - 1096 1359 - 1486 746 - 821 1012 - 1113 1445 - 1590 1960 - 2155 1083 - 1191 1469 - 1613 2012 - 2213 2728 - 2997 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

3.35

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

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

Tigercat 635 Skidder

Lubrication and Maintenance

3.36

Tigercat 635 Skidder SECTION 5 - PILOT SYSTEM DECEMBER 2002

CONTENTS - SECTION 5 CHARGE PRESSURE FILTER ...................................................................... 5.3 CIRCUIT DESCRIPTION (6350111 TO 6350134) ......................................... 5.4 CIRCUIT DESCRIPTION (6350135 TO 6350499) ......................................... 5.6 CIRCUIT DIAGRAM (6350111 TO 6350134) ................................................. 5.5 CIRCUIT DIAGRAM (6350135 TO 6350499) ................................................. 5.7 PILOT MANIFOLD ......................................................................................... 5.3 PRESSURE SETTINGS ................................................................................ 5.8

Tigercat 635 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, 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.

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

324-1

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 635 Skidder

Pilot system

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

Drive Pedal Pilot Valve Arch/Boom Joystick Dozer Control Lever Winch Control Lever Winch Speed Range Grapple Open Grapple Close Grapple Rotate CW Grapple Rotate CCW WINCH FREESPOOL OR WINCH SPEED RANGE GRAPPLE 'OPEN' GRAPPLE 'CLOSE' GRAPPLE ROTATE 'CW' GRAPPLE ROTATE 'CCW'

(P1) End port (P1) End port (P1) End port (P1) End port (C1) Sol. valve (C2) Sol. valve (C3) Sol. valve (C4) Sol. valve (C5) Sol. valve

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.

DOUBLE ELEMENT FILTER

•

•• •

•• DRIVE PUMP CHARGE PRESSURE FILTER

BLUE ELEMENT

•• • • ••

MAIN PUMP DOZER, STEER & GRAPPLE

DRIVE PUMP

••

••

• 308-22

PILOT MANIFOLD

COOLING PUMP

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.

630B-11

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.

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.

• CAB PILOT RETURN MANIFOLD

•

DRIVE PREVENT VALVE FRONT CHASSIS PILOT RETURN MANIFOLD

•• 302-13

5.3

PUMPS AND FILTERS

DRIVE PREVENT SOLENOID VALVE UNDER CAB

Tigercat 635 Skidder

Pilot system

PILOT CIRCUIT DESCRIPTION (6350111 TO 6350134) 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 grapple open/close, grapple rotate and winch speed range 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 winch freespool function is operated by one of the two solenoid operated control valves (C1) on the multifunction valve.)

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.

5.4

Tigercat 635 Skidder

635-09

Pilot system

PILOT SUPPLY CIRCUIT SERIAL NUMBERS 6350111 TO 6350134 5.5

Tigercat 635 Skidder

Pilot system

PILOT CIRCUIT DESCRIPTION (6350135 TO 6350499) 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 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.

5.6

Tigercat 635 Skidder

630B-01-1

Pilot system

PILOT SUPPLY CIRCUIT SERIAL NUMBERS 6350135 TO 6350499 5.7

Tigercat 635 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 1100-1200 rpm idle HYDROSTATICS CHARGE PRESSURE Sauer Pump ............................................................................... 450-460 psi @ full throttle Rexroth Motor ............................................................................ Non-Adjustable MAIN RELIEFS P.O.R. Forward .......................................................................... See chart below @ full throttle P.O.R. Reverse .......................................................................... See chart below @ full throttle High Pressure Relief Forward .................................................................Non-Adjustable High Pressure Relief Reverse ................................................................ Non-Adjustable DRIVE MOTORS Drive Motor P.O.R. ..................................................................... 4250-4300 psi @ full throttle Drive Motor Begin of Displacement Control............................................110-120 psi @ full throttle Minimum Displacement (90mm screw length) ........................................ x = 16mm MAIN PUMP Pump P.O.R. .............................................................................. 3000-3100 psi @ idle FAN PUMP Relief .......................................................................................... 3700-3900 psi 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 ......................................... 625-635 psi Sequence Valve, Diff-Locks ....................................................... 750-760 psi DOZER VALVE Dozer Up Port Relief .................................................................. 3500-3600 psi Dozer Down Port Relief .............................................................. 3500-3600 psi Inlet Relief (if equipped) ............................................................. 3500-3525 psi GRAPPLE VALVE Boom Up Port Relief .................................................................. 3500-3600 psi Boom Down Port Relief .............................................................. 2500-2600 psi Rotate CW Port Relief ................................................................ 2500-2600 psi Rotate CCW Port Relief ............................................................. 2500-2600 psi Grapple Open Port Relief ........................................................... 3500-3600 psi Grapple Close Port Relief........................................................... 3650-3700 psi Arch In Port Relief ...................................................................... 3500-3600 psi Arch Out Port Relief ................................................................... 2500-2600 psi Winch In Port Relief - Lufkin Winch (if equipped) ...................... 3500-3600 psi Winch In Port Relief - Lantec Winch (if equipped) ..................... 2900-2950 psi BRAKES Brake Maximum Pressure .......................................................... 1000 psi Brake applications - engine off (5 applications) .......................... 800 psi minimum NOTE: The above values are for reference purposes only, SEE SERVICE MANUAL FOR SETTING PROCEDURES. ISSUE 1 12/02 TRANSMISSION DRIVE PUMP P.O.R. PART NUMBER FWD & REV (PSI) 9488B n/a 9491B n/a 11114B 6200 – 6250

@ 2200rpm @ @ @ @

@ idle @ idle @ idle @ @ @ @ @ @ @ @ @ @

idle idle idle idle idle idle idle idle idle idle

@ idle

FRONT AXLE INSTALLED 1400 Series John Deere and Tigercat 1400 Series John Deere and Tigercat 1400 Series John Deere and Tigercat 5.8

idle idle idle idle

Tigercat 635 Skidder SECTION 6 - ELECTRICAL, GAUGES AND ALARMS SEPTEMBER 2003

CONTENTS - SECTION 6 FAN CONTROLLER RELAY ASSEMBLY LATER MACHINES ONLY WITH FAN CONTROL SWITCH (FDC) ........... 6.9 FUSE AND RELAY PANEL ............................................................................ 6.8 GAUGES AND ALARMS .............................................................................. 6.10 SCHEMATIC DIAGRAM (6350101 TO 6350134) .......................... 6.2, 6.3, 6.4 SCHEMATIC DIAGRAM (6350135 TO 6350499) .......................... 6.5, 6.6, 6.7 SENSOR DETAILS ...................................................................................... 6.10 SWITCH AND SENSOR LOCATIONS EARLIER MACHINES WITH FAN CONTROL LEVER ............................. 6.11 LATER MACHINES WITH FAN CONTROL SWITCH (FDC) .................... 6.12 TROUBLESHOOTING AND TESTING ........................................................ 6.10 WIRE COLOUR CODE CHART ..................................................................... 6.8

Tigercat 635 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

635-03

MACHINE SCHEMATIC DIAGRAM 13047B REV 1 (SHEET 1 OF 3) SERIAL NUMBERS 6350101 TO 6350134 6.2

Tigercat 635 Skidder

635-04

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM 13047B REV 1 (SHEET 2 OF 3) SERIAL NUMBERS 6350101 TO 6350134 6.3

Tigercat 635 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

635-05

MACHINE SCHEMATIC DIAGRAM 13047B REV 1 (SHEET 3 OF 3) SERIAL NUMBERS 6350101 TO 6350134 6.4

Tigercat 635 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

630B-05

MACHINE SCHEMATIC DIAGRAM 14189B REV.4 (SHEET 1 OF 3) (WITH FDC AND LOW ENGINE OIL PRESSURE SHUTDOWN SYSTEM) SERIAL NUMBERS 6350135 TO 6350499 6.5

Tigercat 635 Skidder

630B-06

Electrical, gauges and alarms

MACHINE SCHEMATIC DIAGRAM 14189B REV.4 (SHEET 2 OF 3) (WITH FDC AND LOW ENGINE OIL PRESSURE SHUTDOWN SYSTEM) SERIAL NUMBERS 6350135 TO 6350499 6.6

Tigercat 635 Skidder

Electrical, gauges and alarms

REFER TO COLOUR CODE CHART IN THIS SECTION

630B-07

MACHINE SCHEMATIC DIAGRAM 14189B REV.4 (SHEET 3 OF 3) (WITH FDC AND LOW ENGINE OIL PRESSURE SHUTDOWN SYSTEM) SERIAL NUMBERS 6350135 TO 6350499 6.7

Tigercat 635 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)

FUSE AND RELAY PANEL

630-D41

6.8

Tigercat 635 Skidder

FDC PROCESSING MODULE

FAN CONTROLLER RELAY ASSEMBLY

Electrical, gauges and alarms

• •

FAN CONTROLLER RELAY ASSEMBLY LATER MACHINES WITH FDC ONLY 630-D47

RELAY #13 (FWD COIL NEGATIVE)

RELAY #10 (POWER)

RELAY #11 (A/C ON)

RELAY #12 (A/C OFF)

FAN DRIVE CONTROLLER RELAY ASSEMBLY ACCESSORY POWER TO FORWARD COIL 'A' TO FORWARD COIL 'B' POWER, RELAY #10 POWER, RELAY #11 POWER, MOMENTARY PURGE NEGATIVE, OIL SENSOR POSITIVE, OIL SENSOR NEGATIVE, WATER SENSOR POSITIVE, WATER SENSOR A/C TEMP SWITCH SIGNAL POWER, A/C ON RELAY GROUND 62 68/68A 89 63 80A 64 93 92 91 90 84 84A 68A SPARE 67B SPARE 67 G25

TERMINAL STRIP 6.9

15228B R0

Tigercat 635 Skidder

Electrical, gauges and alarms

GAUGES AND ALARMS The 635 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 .........................

Drive 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 6301050 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

6.10

Tigercat 635 Skidder

Electrical, gauges and alarms

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

FRONT HYDRAULIC OIL FILTER BYPASS SENDER (LIGHT)

PARKING BRAKE PROXIMITY SENSOR

•

HYDRAULIC OIL TEMPERATURE SENDER (GAUGE)

• •

HYDRAULIC OIL TANK

• • • •

ENGINE AIR FILTER VACUUM SWITCH (LIGHT)

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

•

• •

ENGINE COOLANT TEMPERATURE SENDER (GAUGE)

•

HYDRAULIC OIL LEVEL SENDER (LIGHT AND HORN)

•

•

• •

•

ENGINE HOURS PRESSURE SWITCH (GAUGE) COOLANT TEMPERATURE SWITCH (LIGHT AND HORN) ELECTRIC THROTTLE ACTUATOR

•

ENGINE COOLANT LEVEL SENDER (LIGHT)

BACK-UP ALARM (DRIVE PEDAL ACTIVATED)

ENGINE OIL PRESSURE SENDER (LIGHT AND HORN)

•

•

RADIATOR

ENGINE OIL PRESSURE SENDER (GAUGE)

FUEL SOLENOID RELAY AND ENGINE START SOLENOID RELAY

BATTERIES

•

• •

• •

TRANSMISSION

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

•

FUEL LEVEL SENDER (GAUGE)

•

•

SWITCH AND SENSOR LOCATIONS - EARLIER MACHINES ( WITH FAN CONTROL LEVER) 11821BILX

6.11

BACK-UP ALARM SENDER (HORN)

HORN (PUSH BUTTON ON STEERING WHEEL) FUEL TANKS

Tigercat 635 Skidder

Electrical, gauges and alarms

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

FRONT PARKING BRAKE PROXIMITY SENSOR

HYDRAULIC OIL FILTER BYPASS SENDER (LIGHT)

•

HYDRAULIC OIL TEMPERATURE SENDER (GAUGE)

• •

HYDRAULIC OIL TANK

• •• • •

ENGINE AIR FILTER VACUUM SWITCH (LIGHT)

•

ENGINE COOLANT TEMPERATURE SENDER (GAUGE)

• • • •

FANCONTROL ENGINE COOLANT TEMPERATURE SENDER (FDC)

• BACK-UP ALARM (DRIVE PEDAL ACTIVATED)

•

• •

•

•

TACHOMETER PROXIMITY SWITCH (GAUGE) ENGINE HOURS PRESSURE SWITCH (GAUGE) COOLANT TEMPERATURE SWITCH (LIGHT AND HORN)

ENGINE OIL PRESSURE SENDER (LIGHT AND HORN)

•

ENGINE OIL PRESSURE SENDER (GAUGE)

FAN CONTROLLER (FDC)

•

HYDRAULIC OIL TEMPERATURE SWITCH (LIGHT AND HORN)

ELECTRIC THROTTLE ACTUATOR

ENGINE COOLANT LEVEL SENDER (LIGHT)

RADIATOR

•

HYDRAULIC OIL LEVEL SENDER (LIGHT AND HORN) FANCONTROL HYDRAULIC OIL TEMPERATURE SENDER (FDC)

FAN CONTROLLER RELAY ASSEMBLY (FDC) BATTERIES

•

•

BACK-UP ALARM SENDER (HORN)

• •

•

• • •

FUEL SOLENOID RELAY AND ENGINE START SOLENOID RELAY

BATTERY DISCONNECT SWITCH

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

•

FUEL LEVEL SENDER (GAUGE)

•

•

SWITCH AND SENSOR LOCATIONS - LATER MACHINES (WITH FAN CONTROL SWITCH - FDC) 15216BIL

6.12

TRANSMISSION

HORN (PUSH BUTTON ON STEERING WHEEL) FUEL TANKS

Tigercat 635 Skidder SECTION 7 - ENGINE START AND STOP DECEMBER 2002

CONTENTS - SECTION 7 DRIVE PREVENT VALVE ...................................................................... 7.3, 7.7 FUEL CONTROL VALVE ....................................................................... 7.3, 7.7 MAIN PUMP UNLOADING VALVE ........................................................ 7.3, 7.6 START CIRCUIT DESCRIPTION EARLIER DESIGN (6350101 TO 6350134) ................................................ 7.2 LATER DESIGN - WITH LOW OIL PRESSURE SHUT-DOWN (6350135 TO 6350499) ........................................................................... 7.6 START CIRCUIT DIAGRAM SERIAL NUMBERS 6350101 TO 6350134 ......................................... 7.4, 7.5 SERIAL NUMBERS 6350135 TO 6350499 ......................................... 7.8, 7.9 START MOTOR AND SOLENOID ......................................................... 7.3, 7.7 START SOLENOID RELAY ........................................................................... 7.6 TACHOMETER SET-UP .............................................................................. 7.10

Tigercat 635 Skidder

Engine start and stop

ENGINE START CIRCUIT EARLIER DESIGN (6350101 TO 6350134)

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 closes 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 a 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

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 14156BIL1

320-21

RUN

••

630-D39

START SOLENOID RELAY

PARKING BRAKE 'OFF' POSITION OFF

FRONT VIEW OF CONTROL PANEL

••

••

START

• •• 317-7A

IGNITION SWITCH

7.2

START SOLENOID RELAY AND FUEL SOLENOID RELAY

FUEL SOLENOID RELAY

Tigercat 635 Skidder

Engine start and stop

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

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 wire 13, to the fuel solenoid hold contact.

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.

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 wire 13 to the fuel solenoid hold contact.

FUEL CONTROL VALVE AND SOLENOID

•

••

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.

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

SOLENOID

• SOLENOID

•• START MOTOR

•• •

TO MULTIFUNCTION VALVE 320-2

274-5X

LOCATED ON RH SIDE OF FRONT CHASSIS

MAIN PUMP UNLOADING VALVE

MAIN PUMP UNLOADING VALVE

START MOTOR AND SOLENOID

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.

DRIVE PREVENT PILOT VALVE

•

DRIVE PREVENT VALVE 317-10A

••

TO MAIN PUMP

UNDER CAB

7.3

Tigercat 635 Skidder

Engine start and stop

START CIRCUIT -AT REST

620-24

SERIAL NUMBERS 6350101 TO 6350134

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

620-25

SERIAL NUMBERS 6350101 TO 6350134 7.4

Tigercat 635 Skidder

Engine start and stop

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

620-26

SERIAL NUMBERS 6350101 TO 6350134

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

620-27

SERIAL NUMBERS 6350101 TO 6350134 7.5

Tigercat 635 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.

(6350135 TO 6350499)

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 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 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 (6350161 TO 6350499)

IGNITION SWITCH

317-7A

7.6

•

••

START SOLENOID RELAY AND FUEL SOLENOID RELAY (6350135 TO 6350160)

FUEL SOLENOID RELAY

Tigercat 635 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

FUEL CONTROL VALVE AND SOLENOID

••

•

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

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.

SOLENOID

CAUTION

•

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

••

SOLENOID

• START MOTOR

••

TO MAIN PUMP

TO MULTIFUNCTION VALVE

••

320-2

LOCATED ON RH SIDE OF FRONT CHASSIS

MAIN PUMP UNLOADING VALVE

MAIN PUMP UNLOADING VALVE 274-5X

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

UNDER CAB

7.7

Tigercat 635 Skidder

Engine start and stop

START CIRCUIT -AT REST

630B-12

SERIAL NUMBERS 6350135 TO 6350499

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

630B-13

SERIAL NUMBERS 6350135 TO 6350499 7.8

Tigercat 635 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 6350135 TO 6350499

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

630B-15

SERIAL NUMBERS 6350135 TO 6350499 7.9

Tigercat 635 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).

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.

7.10

Tigercat 635 Skidder SECTION 8 - DRIVE OCTOBER 2003

CONTENTS - SECTION 8 CIRCUIT DESCRIPTION ............................................................................... 8.2 DRIVE SYSTEM CHECK VALVE ......................................................................................... 8.11 DRIVE CIRCUIT DIAGRAM SAUER PUMP AND REXROTH MOTORS ........................................... 8.12 DRIVE FOOT CONTROL VALVE ............................................................... 8.8 DRIVE MOTOR DESCRIPTION ................................................................. 8.6 DRIVE PREVENT VALVE ........................................................................... 8.9 DRIVE PUMP DESCRIPTION - SAUER PUMP .......................................... 8.3 DRIVE SPEED CONTROL VALVE ........................................................... 8.10 HYDRAULIC SET-UP - SAUER PUMP/ REXROTH MOTORS DRIVE MOTOR PRESSURE ADJUSTMENT ....................................... 8.19 DRIVE PUMP PRESSURE ADJUSTMENT .......................................... 8.16 MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ........... 8.20 MOTOR MINIMUM DISPLACEMENT ADJUSTMENT .......................... 8.19 MOTOR PRESSURE OVERRIDE ADJUSTMENT (P.O.R.) .................. 8.23 FRONT AXLE ............................................................................................... 8.28 AXLE IDENTIFICATION ........................................................................... 8.16 CAPACITY ................................................................................................ 8.30 DIFFERENTIAL AND DIFFERENTIAL LOCK ........................................... 8.28 DRAINING THE FRONT AXLE ................................................................. 8.30 FILLING FRONT AXLE, ALTERNATIVE METHOD ................................. 8.31 FILLING THE FRONT AXLE ..................................................................... 8.30 OSCILLATION SHIM CHECK AND ADJUSTMENT (FRONT AXLE) ....... 8.32 SERVICE BRAKES (FRONT AXLE ONLY) BRAKE BLEEDING ............................................................................... 8.30 BRAKE LINING INSPECTION .............................................................. 8.29 SERVICING BRAKES ........................................................................... 8.29 HYDRAULIC OIL HEATING PROCEDURE ................................................. 8.11 REAR (BOGIE) AXLE .................................................................................. 8.34 BOGIE HOUSINGS (2 FILLING POINTS) ................................................ 8.35 DIFFERENTIAL (1 FILLING POINT) ......................................................... 8.34 DIFFERENTIAL AND DIFFERENTIAL LOCK ........................................... 8.34 DRAINING AND REFILLING BOGIE AXLE .............................................. 8.34 PLANETARY DRIVES (4 FILLING POINTS) ............................................ 8.35 TEST DRIVE - SAUER PUMP AND REXROTH MOTORS BEGIN OF DISPLACEMENT CONTROL PRESSURE ............................. 8.13 DIFFERENTIAL LOCKS ........................................................................... 8.14 GROUND SPEED ..................................................................................... 8.15 HORSEPOWER ....................................................................................... 8.14 MOTOR PRESSURE OVERRIDE (POR) ................................................. 8.13 STEERING OPERATION ......................................................................... 8.14 TRANSMISSION .......................................................................................... 8.27 TRANSMISSION IDENTIFICATION .................................................. 8.14, 8.17 WHEEL INSTALLATION .............................................................................. 8.36 TAPERED ASSEMBLY STUD .................................................................. 8.36

Tigercat 635 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 635 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 motors through the first connecting hose. The motors then reconverts the hydraulic power back into the mechanical power used to propel the machine. Low pressure hydraulic oil flow then returns from the motors 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

8.2

Tigercat 635 Skidder

Drive

SAUER DRIVE PUMP

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 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

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

'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 8.3

Tigercat 635 Skidder

Drive

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

CHARGE PUMP

CONTROL CYLINDER

M2 TEST PORT

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.

•

DRIVE SHAFT

• •

• •

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 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.

M1 TEST PORT

SWASHPLATE

DRIVE PUMP (SAUER)

AP105-1

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. 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

The speed control valve limits the maximum speed of the vehicle by reducing the flow of pilot oil to the 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

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

CONTROL CYLINDER

DRIVE PUMP SCHEMATIC (SAUER) 8.4

Tigercat 635 Skidder

Drive

or reverse side of the pump swashplate control valve as required. With the drive prevent valve deenergized, 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.

8.5

Tigercat 635 Skidder HYDROSTATIC DRIVE MOTOR

Drive

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 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 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 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 regulation set point" or "pressure override set point".

The MOTOR P.O.R. set point must be correctly set for the system to function properly. Refer to DRIVE MOTOR PRESSURE SETTINGS for REXROTH PUMP AND MOTORS or SAUER PUMP AND REXROTH MOTORS in THIS SECTION .

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 displacement control cylinder thus increasing displacement to maximum.

FROM PUMP AQ010-1

MINIMUM DISPLACEMENT ADJUSTING SCREW

••

DRIVE MOTOR SCHEMATIC

P.O.R. ADJUSTING SCREW

••

••

FROM PUMP

• PORT 'X'

DRIVE SHAFT

BEGIN OF DISPLACEMENT ADJUSTING SCREW

•

PORT 'B'

AQ010-5Y

••

PORT 'A'

'A' AQ010-1

PORT 'M1'

ROTATING GROUP

••

••

FLUSHING VALVE

DRIVE MOTOR ~ REXROTH (160CC SIZE) 8.6

VIEW 'A'

Tigercat 635 Skidder

Drive

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.

8.7

Tigercat 635 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.

8.8

Tigercat 635 Skidder

Drive

DRIVE PREVENT VALVE

DRIVE PREVENT PILOT VALVE

••

317-10A

DRIVE PREVENT VALVE

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 cross-connects the forward and reverse pilot lines to cause pilot pressure to return to tank if the foot control is operated. 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

8.9

Tigercat 635 Skidder SPEED CONTROL LEVER VALVE

Drive

•

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).

SPEED CONTROL LEVER VALVE AW020 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 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.

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 port 2.

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

8.10

Tigercat 635 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 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 317-12A

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 5psi.

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.

8.11

Tigercat 635 Skidder

Drive

DRIVE CIRCUIT - SAUER PUMP AND REXROTH MOTORS 630B-02

8.12

Tigercat 635 Skidder

Drive

DRIVE TEST: LM1

SAUER PUMP & REXTROTH MOTORS

RM1

X

The test drive will verify the following:

•• ••

1. Motor begin of displacement control pressure: 110-120 psi.

••

2. Motor pressure override (P.O.R.): 4300 psi and (half of ‘M2’) - 2150 psi.

3. Steering check; slow and fast.

275-3

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.

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 115 psi at ‘X’.

The foot brakes may have to be applied to create approximately 2000 psi at ‘M2’ on the PUMP. 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 110-120 psi. Both motors (‘LM1’ and 'RM1' gauges) should rise to 1000 psi within the 110-120 psi range on the ‘X’ gauge, if the set-up is correct.

MAIN DRIVE PUMP-SAUER

308-2X

FASTEN GAUGES FOR VIEWING FROM THE OPERATOR'S SEAT

2. 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 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.

8.13

Tigercat 635 Skidder

Drive

C. While doing the above, observe the pressure at ‘M2’. It should read the P.O.R. setting of 4300 psi. Also read the pressure at both 'LM1' and 'RM1' gauges, it should be approximately half of ‘M2’ 2150 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.

5. HORSEPOWER A. To check engine horsepower it is necessary to temporarily reset dozer pressure to 2600 psi.

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

C.

D. Ensure that the hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in this SECTION.

STEERING OPERATION

E. Start the engine, hold down the brake pedal and set the throttle control to IDLE.

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.

F.

H. Turn off engine, remove gauges, reinstall plugs on the test ports.

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 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.

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.

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.

K. While doing the above, observe the engine rpm. The engine should lug down to between 1700 rpm and 1800 rpm and should not stall.

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.

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 2600 psi on the 'P3' gauge.

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.

F.

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

L. IMPORTANT: Dozer pressures must be reset to normal levels after this test. See PRESSURE SETTINGS PROCEDURE in SECTION 14 of the SERVICE MANUAL.

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.

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.

8.14

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

Tigercat 635 Skidder

Drive

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. B. Drive machine FORWARD with the FULL DRIVE PEDAL. Allow the machine to reach top speed.

HOLE PUNCHED TO INDICATE FACTORY INSTALLED TRANSMISSION PART NUMBER

FACTORY INSTALLED TRANSMISSION PART NUMBER 9488B 9491B 11114B

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

REFER TO SERVICE MANUAL FOR CORRECT DRIVE SYSTEM PRESSURE SETTINGS. 18290A R0

TRANSMISSION IDENTIFICATION LABEL INSIDE CAB ASSEMBLY PART NUMBER STAMP LOCATION

(seconds) 9488B

n/a

9491B

n/a

11114B

13.32 - 15.55

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.

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.

630B-08

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

EXAMPLE: Transmission identified as 11114B by: Hole punched on the transmission identification label next to transmission part number 11114B. OR Transmission part number 11114B indicated on transmission at the assembly part number stamp location.

Recorded time: Time recorded as 14.80 seconds.

Test Result: Acceptable time within the range 13.32 - 15.55 seconds. Machine passes the ground speed test.

8.15

TRANSMISSION IDENTIFICATION

Tigercat 635 Skidder

Drive

DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS

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.

SAUER PUMP & REXROTH MOTORS The drive pump P.O.R. settings are different depending on the combination of transmission part number and series of front axle used. Before beginning this procedure, use the illustrations below to help determine the transmission part number and series of front axle 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

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

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.

1. Set parking brake ON, lower grapple and dozer and shut off the engine.

630B-08

WARNING

TRANSMISSION IDENTIFICATION

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.

2. Adjust auxiliary brake set-up caliper to lock the rotating Brake disc. Refer to illustrations to identify your caliper and the proper setting.

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF/FT.

SERIAL NUMBER PLATE LOCATION

250 = 1200 Series 251 = 1400 Series 252 = 1600 Series

•

630B-09

AXLE IDENTIFICATION 336-3AX

TRANSMISSION DRIVE PUMP P.O.R. PART NUMBER FWD & REV (PSI) 9488B n/a 9491B n/a 11114B 6200 – 6250

AUXILIARY BRAKE SET-UP CALIPER

3. Connect a 0-10,000 psi gauge to port ‘M1’ and ‘M2’ on the HYDROSTATIC DRIVE PUMP, FRONT AXLE INSTALLED 1400 Series John Deere and Tigercat 1400 Series John Deere and Tigercat 1400 Series John Deere and Tigercat 8.16

Tigercat 635 Skidder

Drive

and a 0-1000 psi gauge to the tee connection from port ‘M3’ on the HYDROSTATIC DRIVE PUMP. LM1

RM1

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.

CAUTION

•• •• 275-3

The machine should not be able to move while the brake pedal is depressed.

TEST PORT COMPARTMENT

WARNING

4. Disconnect parking brake switch power wire from the switch.

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.

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).

'A' P.O.R.VALVE 5/16" ALLEN KEY 15/16" WRENCH

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.

'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 8.17

Tigercat 635 Skidder

Drive

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.

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.

8.18

Tigercat 635 Skidder DRIVE MOTOR PRESSURE SETTINGS AND ADJUSTMENTS

Drive 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.

MINIMUM DISPLACEMENT ADJUSTING SCREW

BEGIN OF 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

•• ••

275-3

X

••

•• •• (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 16mm. (For different length screws, measure the length and subtract 74mm from this total length. This is the amount of screw that should be exposed above the locknut.) (For example: 100mm screw, minus 74mm will leave 26mm above locknut).

TEST PORT COMPARTMENT

NOTE: Repeat for the other motor.

8.19

Tigercat 635 Skidder B.

Drive

MOTOR BEGIN OF DISPLACEMENT CONTROL PRESSURE ADJUSTMENT

PREPARATION FOR ADJUSTMENT 1. Set parking brake ON, lower grapple and dozer and shut off the engine.

IMPORTANT NOTES: The goal of this procedure is to set motor control pressures 'RM1' and 'LM1' at 2150 psi (50 % of work port pressure, 4300 psi) when a pilot pressure from the foot pedal of 115 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 120 psi at 'X' results in a reading at 'RM1' and 'LM1' of 2200 psi or more.

And applying a pressure of 110 psi at 'X' results in a reading at 'RM1' and 'LM1' of 2100 psi or less.

Then the goal of approximately 2150 psi (50 % of work port pressure, 4300 psi) at 'RM1' and 'LM1' when a pilot pressure of 115 psi is applied at the 'X' port will have been achieved. (The test drive procedure will confirm these settings.)

336-3AX

2. Adjust auxiliary brake set-up caliper to lock the rotating Brake disc. Refer to illustrations to identify your caliper and the proper setting.

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.

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 4250-4300 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.

AUXILIARY BRAKE SET-UP CALIPER

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 (P.O.R.) to achieve a pressure at ‘M2’ of 4250-4300 psi @full throttle.

CAUTION The machine should not be able to move while the brake pedal is depressed.

8.20

Tigercat 635 Skidder

Drive PROCEDURE ONE

PUMP PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.) • 5/16" ALLEN KEY • 15/16" WRENCH

This is the first of two alternative procedures for motor begin of displacement control adjustment.

Perform steps 1 to 8 (PREPARATION FOR ADJUSTMENT) before proceeding to step 9.

•

9. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the speed control lever to give a pressure reading at the ‘X’ test port of 120 psi @full throttle for 15 seconds.

•

CAUTION The machine should not be able to move while the brake pedal is depressed.

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

SAUER DRIVE PUMP P.O.R. VALVE

333-9

10. While maintaining 120 psi at 'X' adjust the motor begin of displacement screw (small screw in pocket, points upwards) to give a reading of 2200 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.

8. Adjust the MOTOR pressure override screw (P.O.R.) 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

BEGIN OF DISPLACEMENT ADJUSTING SCREW

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 2200 psi or more. If not, re-adjust the motor begin of displacement control adjusting screw on the motor that is incorrect.

•• •• •• (SOME HOSES REMOVED FOR CLARITY) 320-23

If the reading is LOW; turn the motor begin of displacement control adjusting screw IN (counter-clockwise).

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

DRIVE MOTOR (R.H. SHOWN)

MINIMUM DISPLACEMENT ADJUSTING SCREW - 6MM ALLEN KEY - 19MM WRENCH DIM. 'X' = 5/8" (16MM) 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'

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) 8.21

PORT 'M1' • 6 ORB 1/4" ALLEN KEY

Tigercat 635 Skidder

Drive

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.

10. While maintaining 110 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.

11. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the speed control lever to give a pressure reading at the ‘X’ test port of 110 psi @full throttle for 15 seconds.

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 800-1000 psi. If not, re-adjust the motor begin of displacement control adjusting screw on the motor that is incorrect.

12. While maintaining 110 psi at 'X' check for a reading of 2100 psi or less @full throttle at 'RM1' and 'LM1' test ports.

If the reading is LOW; turn the motor begin of displacement control adjusting screw IN (counter-clockwise).

13. Alternately apply 120 psi and 110 psi at 'X'.

Confirm that at 120 psi 'RM1' and 'LM1' ports read 2200 psi or more and at 110 psi 'RM1' and 'LM1' ports read 2100 psi or less. Repeat several times to ensure that the setting does not change.

14. If these readings are obtained, then the motor begin of displacement control setpoint is now between 110 and 120 psi.

If not, readjust begin of displacement screw on failing motor and check again for 110 psi (low pressure) and 120 psi (high pressure).

When properly set, this means that the motors will begin to stroke in the pressure range 110120 psi. This is a critical setting for the smooth and efficient drive operation of the machine.

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.

11. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the speed control lever to give a pressure reading at the ‘X’ test port of 120 psi @full throttle for 15 seconds.

12. While maintaining 120 psi at 'X' check for a reading of 2200 psi or more @full throttle at 'RM1' and 'LM1' test ports.

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.

15. 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 8 (PREPARATION FOR ADJUSTMENT) before proceeding to step 9.

9. With the aid of an assistant, hold down the brake pedal and while fully depressing the FORWARD foot pedal, adjust the speed control lever to give a pressure reading at the ‘X’ test port of 110 psi @full throttle for 15 seconds.

13. Alternately apply 110 psi and 120 psi at 'X'.

Confirm that at 110 psi 'RM1' and 'LM1' ports read 800-1000 psi and at 120 psi 'RM1' and 'LM1' ports read 2200 psi or more. Repeat several times to ensure that the setting does not change.

14. If these readings are obtained, then the motor begin of displacement control setpoint is now between 110 and 120 psi.

CAUTION

If not, readjust begin of displacement screw on failing motor and check again for 110 psi (low pressure) and 120 psi (high pressure).

The machine should not be able to move while the brake pedal is depressed.

8.22

Tigercat 635 Skidder

Drive

When properly set, this means that the motors will begin to stroke in the pressure range of 110-120 psi. This is a critical setting for the smooth and efficient drive operation of the machine.

15. The motor pressure override (POR) must be re-adjusted to complete this procedure. Refer to MOTOR PRESSURE OVERRIDE ADJUSTMENT (POR) below.

LM1

RM1

••

••

X

••

TEST PORT COMPARTMENT 275-3 4. To set the motor pressure override adjustment (P.O.R.), it is necessary to temporarily adjust the hydrostatic PUMP pressure override to 4250-4300 psi.

C. MOTOR PRESSURE OVERRIDE ADJUSTMENT (P.O.R.) NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION of the manual.

PUMP PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

Perform this procedure on BOTH MOTORS.

• 5/16" ALLEN KEY • 15/16" WRENCH

••

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, lower grapple and dozer and shut off the engine.

2. Adjust auxiliary brake set-up caliper to lock the rotating Brake disc. Refer to illustrations to identify your caliper and the proper setting.

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

ADJUST AUXILIARY BRAKE SET-UP CALIPER (ADJUSTING NUT) TO 50 LBF/FT.

333-9

SAUER DRIVE PUMP P.O.R. VALVE

5. Disconnect power wire from the parking brake switch terminal.

••

336-3AX

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.

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 ‘M2’ port on the main drive pump.

6. Start the engine, set throttle control to FULL.

8.23

Tigercat 635 Skidder

Drive

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 (P.O.R.) to achieve a pressure at the PUMP ‘Ma’ port of 4250-4300 psi @full throttle.

MINIMUM DISPLACEMENT ADJUSTING SCREW

BEGIN OF DISPLACEMENT ADJUSTING SCREW

• •• ••

CAUTION The machine should not be able to move while the brake pedal is depressed.

(SOME HOSES REMOVED FOR CLARITY)

8. To set the motor pressure override adjustment (P.O.R.), 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.

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. Push the speed control lever FULLY FORWARD.

320-23

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (P.O.R.)

DRIVE MOTOR (R.H. SHOWN)

Reconnect the pilot control lines to the drive pump at X1 and X2 before proceeding to the next step.

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 2125-2175 psi (half of ‘M2’) @ full throttle should register if the motor pressure override adjustment is set correctly. Check both motors.

CAUTION To avoid spraying of hydraulic oil under pressure DO NOT press drive pedals while hoses are disconnected and unplugged.

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 (2125-2175 psi @full throttle, half of ‘M2’) is obtained with the locknut tightened.

Release the FORWARD foot pedal and reapply to ensure that the gauge reading at ‘RM1’ and 'LM1' is 2125-2175psi. If it is not correct re-adjust the motor pressure override adjusting screw.

CAUTION 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 while depressing the FORWARD foot pedal check for 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. Repeat for the REVERSE foot pedal.

If the readings are not correct, 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.

If the reading is HIGH; turn the motor pressure override adjusting screw OUT (counterclockwise) until a correct gauge reading at ‘LM1’ and 'RM1' port (2125-2175 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 2125-2175 psi. If it is not correct readjust the motor pressure override adjusting screw.

• •• REVERSE LIMITING SCREW

FORWARD AND REVERSE DRIVE PEDALS 189-10

8.24

FORWARD LIMITING SCREW

Tigercat 635 Skidder

Drive

This adjustment must be done on both motors.

When properly set the motor pressure override adjustment setpoint will be 4250-4300 psi. Recheck frequently while adjusting by having assistant release and depress pedals.

SUMMARY:

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

The settings must be made in the order shown.

MOTOR MINIMUM DISPLACEMENT ADJUSTMENT:

BEGIN OF DISPLACEMENT ADJUSTMENT: 1. Adjust pump POR to 4250-4300 psi @ full throttle.

11. With the aid of an assistant, hold down the brake pedal, full throttle and while depressing the REVERSE foot pedal, reset the P.O.R. 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 P.O.R. setting.

12. With the aid of an assistant, hold down the brake pedal, full throttle and while depressing the FORWARD foot pedal, reset the P.O.R. 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 P.O.R. 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.

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.

2. Turn both motor POR IN carefully until lightly seated.

3. Adjust speed control lever to an 'X' test port reading of 120 psi @ full throttle.

4. Adjust both motor begin of displacement to 2200 psi or more @ full throttle at 'RM1' and 'LM1'.

5. Adjust speed control lever to an 'X' test port reading of 110 psi @ full throttle.

6. Check for a reading of 2100 psi or less @full throttle at 'RM1' and 'LM1'.

7. Adjust speed control lever to an 'X' test port reading of 120 psi @ full throttle.

8. Check for a reading of 2200 psi or more @full throttle at 'RM1' and 'LM1'.

9. Motor POR must be reset. See below.

P.O.R. ADJUSTMENT: 1. Adjust pump P.O.R. to 4250-4300 psi @ full throttle. (Done in step 1 above) 2. If necessary 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 achieve this reading, then reconnected.

3. Adjust both motor P.O.R. to 2125-2175 psi @ full throttle (half of 'M2'). The motor P.O.R. set point is now 4250-4300 psi.

4. Adjust REVERSE pump P.O.R. 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 P.O.R. setting.

5. Adjust FORWARD pump P.O.R. 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 P.O.R. setting.

8.25

Tigercat 635 Skidder

Drive

8.26

Tigercat 635 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

••

275-3

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.

8.27

Tigercat 635 Skidder

Drive

FRONT AXLE Power from the two drive motors is transmitted to the front axle via a transmission and the front drive shaft.

DIFF. LOCK (BTM.)

BRAKE

The front axle assembly is pivot mounted to the front frame allowing it to oscillate.

The front 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), (6) inboard planetary final drives (1-each side) and axle housing and shaft.

DRAIN

27KSM

The final drive (6) is an inboard mounted planetary gear arrangement which further reduces speed and increases torque to the front axle. 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.

The lubricant in the front axle assembly is hydraulic oil. There are drain lines from the front 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 FRONT AXLE LUBRICATION in THIS SECTION.

1

FRONT AXLE HYDRAULIC CONNECTIONS

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 axle assembly, are hydraulically controlled and can be turned ON or OFF by a switch in the cab. The front and rear differential locks can be operated independently.

Placing front differential lock switch in the ON position, energizes the differential lock control valve solenoid (located on the multifunction valve) and directs pilot oil to the front differential clutch pack assembly pistons to lock the differential.

2 GREASE SEAL

3

GREASE FITTING

4

6

7

OUTER BEARING

5 AXL-3

FRONT AXLE ASSEMBLY CROSS SECTION - EARLIER DESIGN 8.28

GREASE SEAL

Tigercat 635 Skidder

Drive

This condition provides positive drive to both wheels of the axle when tractive conditions might otherwise allow one wheel to spin.

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

SERVICE BRAKES (FRONT AXLE ONLY) 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.

BRAKE DISK

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. 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. Before inspecting the brakes the axle must be drained. Refer to DRAINING THE AXLES in THIS SECTION. •

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.

BACKING PLATE

ANNULAR PISTON

AXL-BRK

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.

1

2 4

6

7

3

5 AXL-4X

FRONT AXLE ASSEMBLY CROSS SECTION - LATER DESIGN 8.29

Tigercat 635 Skidder

Drive

BRAKE BLEEDING

FRONT AXLE LUBRICATION

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.

DIFFERENTIAL LUBRICATION The front axle is allowed to completely fill with oil to the top of the differential case. This hydraulic oil buildup inside the differential case is due to normal internal leakage from the differential locks and is used as lubricant for the differential. The excess oil drains back to the hydraulic tank via the axle drain line.

BLEED SCREWS SINGLE BRAKE LINE ACTUATES BOTH BRAKES

DRAINING THE FRONT AXLE Care should be taken when draining the hydraulic oil from the front axle, not to also drain the oil from the hydraulic tank. To prevent oil from siphoning from the tank, first remove the hydraulic drain line from the top of the axle to allow air to vent into the axle when the bottom drain plug is removed and oil drains out. The line that is removed must be capped to prevent draining from the hydraulic tank.

SINGLE BRAKE PEDAL

• •

• • • FRONT AXLE ASSEMBLY AXL-BRK1

The time to schedule an oil change in the front axle is when doing the seasonal oil change on the hydraulic oil tank, as they are part of the overall system and use the same oil.

DUAL BRAKES (FRONT AXLE)

PROCEDURE 1. Place parking brake ON. 2. Place a clear plastic tube over bleed screw with other end in a container.

IMPORTANT Care should be taken to refill the axle(s) before moving the machine after draining.

3. Start engine and run at IDLE 4. Loosen bleed screw

FILLING THE FRONT AXLE

5. With the aid of an assistant push and hold brake pedal down until brake bleeding procedure is complete (no air bubbles in clear plastic tube).

The front axle is filled by pumping oil in through the case drain plug port on the top right of the front axle. A vent plug also at the top of the axle should be removed to allow air to vent out and to allow oil to exit when the axle is full of oil.

6. Tighten bleed screw when oil is free of air.

7. Release brake foot pedal.

8. Repeat above procedure for each bleed screw.

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 front axle was drained and not the entire hydraulic system, the port from which the drainline was removed will provide the vent and oil will exit from this port when the axle is full of oil.

The drainline should remain capped until it is reinstalled.

Care must be taken to ensure that the front axle is completely full of oil and that all plugs, fittings and lines are tight.

CAPACITY For front axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in SECTION 3 of THIS MANUAL.

8.30

Tigercat 635 Skidder

Drive 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.

• •• CASE DRAIN PLUG

VENT PLUG

635-P06

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.

FRONT AXLE (RIGHT SIDE OF MACHINE)

ALTERNATIVE METHOD FOR FILLING FRONT AXLE The following alternative method of filling the front axle is suitable for refilling the drained axle only. If you have done major service, a rebuild, replaced any major component or drained the machine of hydraulic oil refer to STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE in THIS SECTION. 1. Ensure the articulation lock pin is installed.

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

3. Turn front differential lock ON and run engine at IDLE for 30 minutes to purge air and fill front axle with oil (axle fills with leakage from diff. lock). If wheels have been removed, operate forward and reverse pedals very slowly to fill front axle with oil.

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

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

6.

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

8.31

Tigercat 635 Skidder

Drive

FRONT AXLE OSCILLATION SHIM CHECK AND ADJUSTMENT

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

8.32

Tigercat 635 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

••

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

7. Read the dial indicator. Axle movement should be .004” to .014”. Check the reading twice by repeating steps 4 through 7.

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.

THRUST WASHER

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.

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.

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.

8.33

Tigercat 635 Skidder REAR (BOGIE) AXLE

Drive REAR (BOGIE) AXLE

Power from the two drive motors is transmitted to the rear (bogie) axle via a transmission and the rear drive shaft.

The bogie axle has 7 separate oil reservoirs. Each reservoir must be filled separately to get the proper level of lubrication in the bogie axle.

The rear (bogie) axle assembly is bolted directly to the rear frame.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

REAR ( BOGIE) AXLE

DRAINING AND REFILLING BOGIE AXLE

Each axle assembly consists of (1) input yoke, (2) differential gear set, (3) hydraulic differential lock, (4) outer planetary final drives (2-each side), (5) bogie housing (1- each side) and (6) axle housing and shaft.

The gear oil in the planetary final drives, differential and bogie housings are separated within the axle by internal seals. This results in the need to individually drain and fill the 7 separate oil reservoirs. Refer also to REAR (BOGIE) AXLE LUBRICATION in THIS SECTION. DIFFERENTIAL AND DIFFERENTIAL LOCKS The differential (2) distributes the power to each side of the axle while allowing the wheels to turn at different speeds. The differential lock (3), in the rear (bogie) axle assembly, is hydraulically controlled and can be independently turned ON or OFF by a switch in the cab. The front and rear differential locks can be operated independently.

Placing and holding the rear differential lock switch in the ON position, energizes the differential lock control valve solenoid (located on the multifunction valve) and directs pilot oil to the rear differential clutch pack assembly pistons to lock the differential(s). Note that the rear differential lock is operated by a momentary switch . Note also that on early machines (6350101 to 6350134) the rear (bogie) differential lock cannot be engaged while the machine is in motion. Refer to DIFFERENTIAL LOCK in SECTION 2 of the OPERATOR'S MANUAL for complete operating instructions.

This condition provides positive drive to all wheels of the axle when tractive conditions might otherwise allow one wheel to spin.

•

Park the machine on level ground.

•

Stop the engine and place the parking brake in the ON position.

•

The bogie axle must be level in order to drain and refill it properly.

•

Note that it will be necessary to reposition the wheel hubs when draining and refilling the planetary drives.

•

The oil must be warm before draining and refilling.

•

Clean around all fill, level and drain plugs before removing them.

DIFFERENTIAL (1 FILLING POINT) Note: The volume of oil required for the differential case has been increased from the previously recommended level. Checking the increased fill level requires the installation of a dipstick kit per PSB 1373. Refer to SERVICE AND LUBRICATION POINTS CHART in THIS SECTION for correct volume.

1. Remove the DIPSTICK from the TOP BREATHER PORT. 2. Remove the DIFFERENTIAL DRAIN PLUG and drain the oil into a suitable container for disposal.

3. Clean any filings from the magnet on the oil drain plug.

4. Re-install the DIFFERENTIAL DRAIN PLUG. 5. Refill the differential with new oil until the level reaches the first flat section at the end of the DIPSTICK. Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

6. Re-install the DIPSTICK in the TOP BREATHER PORT.

8.34

Tigercat 635 Skidder

Drive

PLANETARY DRIVES (4 FILLING POINTS)

BOGIE HOUSINGS (2 FILLING POINTS)

7. Position the wheel hub for draining the planetary, with the drain plug in the lowest possible position as shown.

13. Note that the bogie housing must be level to drain and refill it properly.

14. Before draining the oil from the bogie housings, the axle should sit for at least 30 minutes so that contaminants in the oil can settle in the oil pan.

8. Remove the PLANETARY FILL PLUG. 9. Remove the PLANETARY DRAIN/LEVEL PLUG and drain the oil into a suitable container for disposal.

15. Remove the BOGIE HOUSING FILL PLUG.

10. Reposition the wheel hub for filling the planetary, with the PLANETARY DRAIN/LEVEL PLUG at 9 o’clock and the fill plug at 1 o’clock as shown.

11. Refill the planetary with new oil until the level reaches the bottom of the PLANETARY DRAIN/LEVEL PLUG. (Note: To get a correct filling level the wheel hub must be in the planetary fill position as shown.)

16. A portion of the oil drained from the housing can be reused. To drain the reusable oil remove the BOGIE HOUSING DRAIN PLUGS (2 per housing – upper plugs) and drain the oil into a clean container, as this part of the oil can be reused.

17. Set aside the reusable oil.

18. The remaining oil is contaminated and must be discarded. To drain the contaminated oil remove the BOGIE HOUSING CONTAMINATED OIL DRAIN PLUGS (2 per housing – lower plugs) and drain the remaining oil into a second container for disposal.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

12. Repeat steps 7 to 11 for each of the four planetary drives.

19. Clean any fillings from the four drain plugs.

20. Re-install the four drain plugs.

21. Remove the BOGIE HOUSING LEVEL PLUGS (2 per housing).

Continued on page 36

DIFFERENTIAL DRAIN PLUG (1 PLACE)

BOGIE HOUSING LEVEL PLUG (4 PLACES)

•

TOP BREATHER PORT (DIPSTICK 1 PLACE)

•

•

•

•• BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS 8.35

•

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

BM041

BOGIE HOUSING FILL PLUG (2 PLACES)

Tigercat 635 Skidder

Drive

Continued from page 35

WHEEL INSTALLATION

22. Refill the housing through the BOGIE HOUSING FILL PLUG, using first the reusable portion of the oil drained from the bogie housing and then new oil, until the oil level reaches the bottom of the BOGIE HOUSING OIL FILL PLUG.

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.

Refer to LUBRICATION CHART in THIS SECTION for oil capacity. Refer to Bogie Axle Service and Repair Manual for recommended gear oils.

23. Re-install the BOGIE HOUSING FILL PLUG and BOGIE HOUSING LEVEL PLUGS.

2.17" MIN. FULL THREAD

24. Repeat steps 12 to 23 for the second bogie housing.

.79" .406" DRILL

.06" X 45° 3/4" - 10 UNC THREAD OR 7/8" - 14 UNF THREAD

AFTER DRAINING AND REFILLING 25. Check all drain, fill and level plugs for leaks.

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" - UNF 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.

8.36

Tigercat 635 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 .............................................. 9.11 BRAKE PILOT VALVE ................................................................................ 9.2 PARKING BRAKE ....................................................................................... 9.5 CHARGING VALVE, ACCUMULATOR .......................................................... 9.3 CIRCUIT DIAGRAM (6350101 TO 6350134) ............................................................................... 9.6 (6350135 TO 6350499) ............................................................................... 9.7 DIFFERENTIAL LOCKS ADJUSTING DIFFERENTIAL LOCK VALVES .......................................... 9.10 CIRCUIT DESCRIPTION .......................................................................... 9.10 MAIN PUMP ................................................................................................... 9.4 MULTIFUNCTION VALVE ADJUSTING HIGH PRESS RELIEF ........................................................... 9.8 DESCRIPTION ........................................................................................... 9.8 HIGH PRESSURE RELIEF ......................................................................... 9.8 PARKING BRAKE .......................................................................................... 9.5

Tigercat 635 Skidder

Brakes

BRAKE PILOT VALVE

ACCUMULATOR

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 and release 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

BLADDER P

T

POPPET (Seats against oil port after oil evacuation)

HYDRAULIC CONNECTION ACCU-1

T

ACCUMULATOR (BLADDER TYPE)

CHECKING THE GAS PRE-CHARGE PRESSURE

A P

Bleed off the system pressure as stated earlier.

MO-02

After the accumulator has been put in service, the pre-charge pressure should be checked with an accumulator charging and testing device.

CROSS SECTION OF VALVE BODY MO-01

Install the charging and testing device onto the gas valve. While depressing the button on the charging device, observe gas pressure reading on gauge.

BRAKE VALVE

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 635 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 635 Skidder

Brakes

MAIN PUMP

••

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 635 Skidder

Brakes

PARKING BRAKE

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.

•

320-8

ADJUSTING KNOB

PARKING BRAKE LEVER

9.5

Tigercat 635 Skidder

635-11

Brakes

BRAKE/DIFFERENTIAL LOCK CIRCUIT (6350101 TO 6350134) 9.6

Tigercat 635 Skidder

635-12

Brakes

BRAKE/DIFFERENTIAL LOCK CIRCUIT (6350135 TO 6350499) 9.7

Tigercat 635 Skidder

Brakes

MULTIFUNCTION VALVE

P3 TEST PORT

THE MULTIFUNCTION VALVE PROVIDES THE FOLLOWING:

RP1 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

275-3

2. On later machines the two solenoid pilot valves direct pressure from the main pump to operate the differential locks.

On earlier machines the two solenoid pilot valves direct pressure from the main pump to operate the front differential lock (C2) and the winch freespool function (C1, if equipped).

PRESSURE REDUCING VALVE

HIGH PRESSURE RELIEF VALVE

SEQUENCE VALVE

3. Supplies system pressure oil for the emergency braking system (accumulator and brakes in front axle).

•

4. It also serves as a distribution point for oil to the steering, grapple, dozer and winch functions.

••

•

HOSES REMOVED FOR CLARITY

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.

MULTIFUNCTION VALVE

321-2A

•

MAIN PUMP P.O.R. ADJUSTING SCREW

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).

HOSES REMOVED FOR CLARITY

630-PH2

TO ADJUST HIGH PRESSURE RELIEF VALVE AND MAIN PUMP PRESSURE:

MAIN PUMP DOZER VALVE INLET RELIEF

1. Parking brake ON, grapple down, dozer down and shut off the engine.

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

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.

DOZER VALVE INLET RELIEF 630-D42

9.8

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF.

Tigercat 635 Skidder

Brakes

5. Start the engine, hold down the brake pedal and set the throttle to IDLE.

b. Turn the main pump POR to 3850-3900 psi on 'P3' gauge using the pressure 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. a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

7. 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.

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.

For machines without a dozer inlet relief valve set the multifunction to 3500-3600 psi .

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 coverplate.

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 9.9

3 REDUCING VALVE

Tigercat 635 Skidder

Brakes

2. DIFFERENTIAL LOCKS

P3 TEST PORT

The differential locks in both front and rear axles are controlled by two switches located on the joystick control lever in the cab.

RP1 TEST PORT

• ••

On later machines the differential lock 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 all wheels on the axle.

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

275-3

On earlier machines the front axle differential lock switch controls the solenoid pilot valve in port 'C2' of the multifunction valve manifold. The winch freespool switch controls the solenoid pilot valve in port 'C1' of the multifunction valve, refer to SECTION 13 of THIS MANUAL for winch function information. Placing the front differential lock switch in the ON position energizes solenoid pilot valve 'C2' which directs pilot oil to the differential lock clutch packs in the front axle to lock the differentials and provide drive torque to both front wheels. (Note: The rear axle differential lock switch controls the rear differential lock solenoid pilot valve, which is supplied by the pilot manifold.)

HIGH PRESSURE RELIEF VALVE

PRESSURE REDUCING VALVE

SEQUENCE VALVE

•• ••

•

HOSES REMOVED FOR CLARITY 321-2A

MULTIFUNCTION VALVE

6. Adjust the pressure reducing valve (beside sequence valve) to get 750-760 psi on 'RP1' gauge.

The pressure reducing valve supplies oil through the directional valve and the solenoid valve(s) 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 lock(s), preventing problems due to high pressures.

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.

TO ADJUST DIFFERENTIAL LOCK VALVES:

8. Re-adjust the pressure reducing valve OUT to get 625-635 psi at 'RP1'gauge. Lock it at this point.

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.

9. Engine off, remove gauge and install cap on 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. Turn OFF the Differential Locks.

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.

9.10

Tigercat 635 Skidder 3.

EMERGENCY BRAKING SYSTEM (ACCUMULATOR AND BRAKES IN FRONT AXLE) 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.

The accumulator is installed to ensure that the brake control remains responsive at all times by maintaining an optimum pilot pressure of 3000psi to the brake pilot valve.

This oil from the accumulator side of the check valve is sent, through an orifice at port 'B' to the brake pilot valve.

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.

Brakes 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.

Refer to BRAKE PILOT VALVE and ACCUMULATOR in THIS SECTION for further information on this brake valve and the accumulator.

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 9.11

Tigercat 635 Skidder

Brakes

9.12

Tigercat 635 Skidder SECTION 10-OIL COOLER/RADIATOR AND CROSS-FLOW FAN DECEMBER 2002

CONTENTS - SECTION 10 CROSS-FLOW FAN-FDC (6350136 TO 6350499) .................................................... 10.12 CIRCUIT DESCRIPTION ........................................................................................ 10.16 CIRCUIT DIAGRAM ................................................................................................ 10.17 ELECTRONIC FAN DRIVE CONTROL (FDC) CHECK FOR TEMPERATURE SENSOR FAILURE ........................................... 10.21 CHECK MINIMUM FAN SPEED WITH A/C "ON" AND NO A/C D ...................... 10.21 CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY ENGINE .............. 10.22 CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY HYDRAU ............. 10.23 FAN CONTROLLER RELAY ASSEMBLY ............................................................... 10.14 FAN DRIVE MOTOR .............................................................................................. 10.15 FAN DRIVE PUMP ................................................................................................. 10.12 FAN DRIVE PUMP PRESSURE, CHECK ............................................................... 10.20 FAN PUMP FORWARD AND REVERSE MAX. DISPLACEMENT SET ................. 10.18 FAN SPEED, MAX. FORWARD AND REVERSE ................................................... 10.18 FDC CONTROL ...................................................................................................... 10.14 TROUBLE-SHOOTING GUIDE FDC. OPERATION .............................................................................................. 10.24 OVERHEATING PROBLEMS ............................................................................. 10.24 CROSS-FLOW FAN-LEVER OPERATED (6350101 TO 6350135) ............................. 10.6 CIRCUIT DESCRIPTION AND OPERATION ........................................................... 10.8 CIRCUIT DIAGRAM .................................................................................................. 10.9 FAN DRIVE MOTOR ................................................................................................ 10.7 FAN DRIVE PUMP ................................................................................................... 10.6 FAN DRIVE PUMP PRESSURE VERIFICATION ................................................... 10.11 FAN SPEED VERIFICATION / ADJUSTMENT ....................................................... 10.10 OIL COOLER ............................................................................................................... 10.2 OIL COOLER AND RADIATOR INSTALLATION ......................................................... 10.3 OIL COOLER CIRCUIT DESCRIPTION ...................................................................... 10.4 OIL COOLER CIRCUIT DIAGRAM .............................................................................. 10.5

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

OIL COOLER/RADIATOR

OIL COOLER

The hydraulic oil cooler and engine radiator are mounted side by side as an assembly. The assembly is mounted longitudinally in the front chassis to provide cross flow ventilation. The A/C condenser core is mounted in front of these two units and on hinges to facilitate cleaning. The cooling fan is mounted behind the oil cooler/ radiator assembly and draws air from the right side of the machine. The air passes through the oil cooler/radiator and A/C condenser core and exhausts on the left side of the machine.

RADIATOR

A/C CONDENSER

••

The fan drive system is reversible to facilitate cleaning by blowing air in the opposite direction through the cooling assembly This cooling assembly must be checked daily for accumulation of debris.

302-19

••

••

OIL COOLER / RADIATOR

The complete oil cooler/radiator/A-C condenser/ fan drive assembly is rubber isolation mounted to reduce the transmission of noise and to isolate the components from vibration.

For detailed cleaning procedures, refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 630-D36

10.2

CROSS FLOW FAN

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

A/C CONDENSER PLENUM OIL COOLER RADIATOR

•

•

OIL COOLER 'OUT' CONNECTION TO DOUBLE FILTER

• COOLER TANK

•

•

• •

FAN SHROUD FAN FINGER GUARD

•• • •

RADIATOR AND OIL COOLER MOUNTS

•

RADIATOR TOP HOSE

• •

FAN MOTOR RADIATOR BOTTOM HOSE

7638BIL2

OIL COOLER AND RADIATOR INSTALLATION 10.3

FAN DRIVE SUPPORT

NOTE: REGULARLY CHECK FOR DEBRIS ACCUMULATION BETWEEN RADIATOR/ OIL COOLER AND A/C CONDENSER

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

OIL COOLER CIRCUIT DESCRIPTION

FROM OIL COOLER

Oil for the entire hydraulic system first passes through the oil cooler. The oil cooler is situated down stream from the cooling pump.

DOUBLE ELEMENT FILTERS

RESERVOIR

••

The cooling pump draws oil from the reservoir and sends it to the oil cooler via the cooler bypass manifold. The cooler bypass manifold ensures that the differential pressure between the oil cooler inlet and outlet does not exceed 100 psi.

Pressure increases within the oil cooler can occur in cold weather when oil temperatures at start-up are very low.

BLUE ELEMENT

••

•• •

••

COOLING PUMP SUCTION LINE

••

CHARGE PRESSURE OUTLET FILTER

••

Cooling of the oil occurs as air is drawn over the oil cooler cooling fins. Cooled oil then passes through the double element filter and on to the distribution manifold located on the right hand inside wall of the front chassis.

TO DISTRIBUTION MANIFOLD

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 return to the reservoir.

•• COOLING PUMP

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.

630B-11

The three tank ports in the distribution manifold collect return oil from the front chassis pilot return manifold, the drive pump and 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. 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.

Refer also to HYDRAULIC OIL RESERVOIR in SECTION 2 of the OPERATOR'S MANUAL for more information about the hydraulic reservoir.

Refer to HYDRAULIC HAND FILL PUMP in SECTION 2 of the OPERATOR'S MANUAL.

10.4

•• COOLING PUMP TO OIL COOLER CONNECTION

PUMPS

Tigercat 635 Skidder

630B-03

Oil Cooler and Cross-flow Fan

OIL COOLER CIRCUIT 10.5

Tigercat 635 Skidder CROSS-FLOW FAN - Lever operated

Oil Cooler and Cross-flow Fan FAN DRIVE PUMP

(EARLIER DESIGN 6350101 TO 6350135)

•

'M1' TEST PORT (FORWARD RELIEF)

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

• •• •• 290-11

CROSS FLOW FAN

REVERSE MAXIMUM DISPLACEMENT ADJUSTING SCREW

The cross-flow fan is hydraulically driven by the fan drive pump and fan drive motor in a dedicated closed loop circuit. The fan control lever is located adjacent to the left arm rest in the cab and is used to control fan speed and direction. Fan speed is infinitely adjustable.

When operated in the "forward" direction the cross-flow fan provides normal cooling operation.

The cross-flow fan draws air from the right side of the machine through the door screen, the A/C condenser, the oil cooler and the engine radiator blowing it out the left side of the machine.

When operated in the "reverse" direction the cross-flow fan provides flow for cleaning debris from the cooling system. By reversing the direction of air flow dust and debris are forced out of the radiator, oil cooler, A/C condenser and air intake screens.

For additional information regarding the operation of the cross flow fan refer to FAN CONTROL LEVER and CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of THE OPERATOR'S MANUAL.

'M2' TEST PORT (REVERSE RELIEF)

SOME HOSES REMOVED FOR CLARITY 333-7

FAN DRIVE PUMP

The fan drive pump is located at the rear of the engine, just in front of the cooling system assembly. The fan drive pump is accessed from the left hand rear engine access panels. A splined adapter connects the input driveshaft of the pump directly to the engine.

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

The primary pump is a variable displacement, swashplate axial piston pump. 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 destroked the flow smoothly decreases until there is no flow at an angle of zero(0°). Continuing to angle the swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

The secondary pump is a fixed displacement internal gear pump which provides charge oil (make-up oil) for the fan drive pump and motor in the closed loop fan drive circuit. Charge flow also provides cooling for the circuit and pressure for the pump control system.

10.6

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

The fan control lever is connected to the fan control cable which operates the manual displacement control on the fan drive pump.

FAN DRIVE MOTOR

The fan drive pump is equipped with two high pressure relief valves. These relief valves are factory set and non-adjustable.

The fan drive charge pump is equipped with a charge pressure relief valve to maintain the charge pressure. The charge pressure relief valve is adjustable.

Refer to FAN DRIVE PUMP PRESSURE VERIFICATION AND ADJUSTMENT in THIS SECTION. Refer to FILTERS- REMOVE AND REPLACE: CHARGE PRESSURE FILTER - FAN DRIVE PUMP in SECTION 3 of THIS MANUAL for information regarding charge pressure filter replacement.

FAN DRIVE MOTOR

324-10

The fan drive motor is fixed displacement inline swashplate axial piston motor. The fan drive motor is driven by hydraulic pressure from the fan drive pump and in turn it directly drives the crossflow fan.

ASSEMBLY NOTE: Before re-installing a fan drive motor, pack spline area of fan hub and motor shaft with multi-purpose lithium grease.

See Fig. 630B-10

FILL HATCHED AREA WITH AN EP MOLY-GRAPH GREASE AS SHOWN PRIOR TO INSTALLING MOTOR DO NOT FILL THIS AREA WITH GREASE

• •

• •

•

•

•

•

•

•

• MOTOR

BOLT

WASHER

RETAINING RING

FAN

•

FAN SHAFT BEARINGS

FAN SUPPORT

630B-10

FAN DRIVE MOTOR INSTALLATION

10.7

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

CROSS-FLOW FAN CIRCUIT DESCRIPTION AND OPERATION The cross-flow fan circuit is a closed loop system.

The circuit consists of the fan drive pump and fan drive motor 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 motor through the first connecting hose the motor then reconverts the hydraulic power back into mechanical power to rotate the cross-flow fan. Low pressure hydraulic oil then returns from the motor to the pump through the other connecting hose. This completes the circuit.

The charge pump provides make up oil to the circuit to compensate for internal leakage in the closed loop and provide a cooling effect. All make up hydraulic oil entering the closed loop first passes through the charge pressure filter to ensure that no debris enters the closed loop.

Fan speed and direction is controlled by the manual control lever on the fan drive pump. This lever is operated by the fan control lever in the cab of the machine.

10.8

Tigercat 635 Skidder

630B-04

Oil Cooler and Cross-flow Fan

CROSS-FLOW FAN CIRCUIT - EARLIER DESIGN SERIAL NUMBER 6350101 TO 6350135 10.9

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

FAN SPEED VERIFICATION / ADJUSTMENT Note: A calibrated "electronic photo tachometer" is required for this procedure.

1. Park the machine on level ground. Parking brake ON, grapple and dozer down and engine off.

9. With the aid of an assistant use a photo tachometer to check the REVERSE fan speed. REVERSE fan speed should be 1700-1800 rpm.

10. If adjustment is required: a. Set the fan speed control to neutral.

2. Place a piece of reflecting tape on the fan hub.

b. Adjust the REVERSE maximum displacement adjusting bolt.

3. Start the engine. Leave the parking brake ON.

c. Recheck the REVERSE fan speed as in step 9 above.

4. Adjust the throttle control until the engine is running at 2200 rpm.

5. Shift the fan control friction lever to the full FORWARD position.

LEVER SHOWN IN NEUTRAL POSITION

•

290-19

FAN CONTROL LEVER

11. When forward and reverse fan speeds are correct tighten maximum displacement adjusting screws.

12. Re-check the fan speed settings to make sure that they have not changed.

••

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

REVERSE MAXIMUM DISPLACEMENT ADJUSTING SCREW

6. With the aid of an assistant use a photo tachometer to check the FORWARD fan speed. FORWARD fan speed should be 2100-2200 rpm.

•• •

••

'M1' TEST PORT (FORWARD RELIEF) 'M2' TEST PORT (REVERSE RELIEF)

7. If adjustment is required: a. Set the fan speed control to neutral.

CAUTION Do not adjust displacement limiter screws while the fan is running. Always position the fan control lever in neutral during fan speed adjustments. Failure to do so may result in component damage.

FAN DRIVE PUMP CONTROL LEVER

SOME HOSES REMOVED FOR CLARITY

• FAN DRIVE PUMP

630B-12

CHARGE PRESSURE RELIEF ADJUSTING SCREW

b. Adjust the FORWARD maximum displacement adjusting bolt. DO NOT ALLOW THE FAN TO REVOLVE FASTER THAN THE ENGINE.

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

FORWARD MAXIMUM DISPLACEMENT ADJUSTING SCREW

•

CAUTION Do not let the fan revolve faster than the engine. c. Recheck the FORWARD fan speed as in step 6 above.

SHOWN WITH HOSES REMOVED FOR CLARITY

8. Shift the fan control friction lever to the full REVERSE position.

346-1

10.10

••

••

FAN DRIVE PUMP - REAR VIEW

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

FAN DRIVE PUMP PRESSURE VERIFICATION DISCONNECT MAIN HOSES AND PLUG WITH 12 ORS PLUGS.

1. Park the machine on level ground. Parking brake ON, grapple and dozer down and engine off.

2. Install two 0-5000 psi gauges on 'M1' and 'M2' test ports. Install one 0-500 psi gauge on 'M3' test port.

••

3. Disconnect the main hoses going into the fan motor and plug using two 12ORS plugs.

••

4. Disconnect the fan control cable from the ball link on the fan drive pump control lever (at the pump).

324-10

WARNING Monitor hydraulic oil temperature closely when the fan motor is disconnected. Do not allow the hydraulic oil to overheat 5. Start the engine. Keep the parking brake ON. Adjust engine speed to 2200 rpm.

6. Verify that the fan drive charge pump pressure, 'M3' gauge, reads 200-210 psi.

7. If necessary adjust the charge pump pressure using the charge pressure adjusting screw.

CAUTION Capped hoses will move when shifting the fan drive pump control lever out of neutral.

8. Adjust engine speed to 1000 rpm. Manually shift the fan drive pump control lever fully toward the front of the machine (forward).

FAN DRIVE MOTOR

lever shifted fully, this is acceptable.

10. Manually shift the fan drive pump control lever fully to toward the rear of the machine (reverse).

11. Verify that the 'M2' gauge reading is 3700-3900 psi. Note the pressure has a tendency to drop slightly while holding the lever shifted fully, this is acceptable.

12. If 'M1' and 'M2' gauge readings are incorrect contact Tigercat Customer Service for more information.

13. Return the fan drive pump control lever to the neutral position and turn off the engine.

14. Reconnect the fan control cable and the fan motor hoses.

15. Check for hydraulic leaks.

9. Verify that the 'M1' gauge reading is 3700-3900 psi. Note the pressure has a tendency to drop slightly while holding the

10.11

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan 333-7

•

•

FAN DRIVE PUMP

CHARGE OIL FROM PRESSURE FILTER

DRAIN LINE TO PUMP PORT 'L2'

SYSTEM PRESSURE PORT 'A'

••

•• • • •• •

SYSTEM PRESSURE PORT 'B'

FAN DRIVE MOTOR

DRAIN FROM CHARGE PRESSURE FILTER

630-D48

LEFT SIDE OF MACHINE

FAN DRIVE

CROSS-FLOW FAN WITH ELECTRONIC FAN DRIVE CONTROL (FDC) - Switch operated

• 'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

(LATER DESIGN 6350136 TO 6350499) The cross-flow fan is driven by a dedicated closed loop hydraulic system consisting of a variable displacement drive pump and a fixed displacement fan drive motor. The cooling fan is mounted behind the oil cooler/radiator assembly and draws air from the right side of the machine.

The air passes through the oil cooler/radiator and A/C condenser core and exhausts on the left side of the machine.

•• •• ••

By reversing the direction of air flow (PURGE) dust and debris are forced out of the radiator, oil cooler, A/C condenser cores. The fan drive is controlled electronically by the FDC system.

For additional information regarding the operation of the cross flow fan refer to FAN CONTROLSWITCH and CLEANING A/C CONDENSER AND OIL COOLER/RADIATOR in SECTION 2 of THE OPERATOR'S MANUAL.

'M1' TEST PORT (FORWARD RELIEF)

'M2' TEST PORT (REVERSE RELIEF)

REVERSE MAXIMUM DISPLACEMENT ADJUSTING SCREW

SOME HOSES REMOVED FOR CLARITY

FAN DRIVE PUMP FAN DRIVE PUMP The fan drive pump is located to the rear of the engine, just in front of the cooling system assembly. The fan drive pump is accessed from the left hand rear engine access panels. A splined adapter connects the input driveshaft of the pump directly to the engine.

10.12

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan SWASHPLATE

DRIVE SHAFT

PISTON(S)

•

VALVE PLATE

••

••

• AP117-1

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

The primary pump is a variable displacement, swashplate axial piston pump. 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 destroked the flow smoothly decreases until there is no flow at an angle of zero(0°). Continuing to angle the swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

CHARGE PUMP

FAN DRIVE PUMP The fan drive charge pump is equipped with a charge pressure relief valve to maintain the charge pressure. The charge pressure relief valve is adjustable.

Refer to FAN DRIVE PUMP PRESSURE VERIFICATION AND ADJUSTMENT in THIS SECTION. Refer to FILTERS - CHARGE PRESSURE FILTER - FAN DRIVE PUMP in SECTION 3 of THIS MANUAL for information regarding charge pressure filter replacement.

The fan drive pump is equipped with two high pressure relief valves. These relief valves are factory set and non-adjustable.

The fan drive pump is equipped with an electronic displacement controller to control the movement of the swashplate when it receives signals from the electronic fan drive control module (FDC).

For additional information on the FDC module, refer to FDC CONTROL in THIS SECTION. The secondary pump is the fan drive charge pump, a fixed displacement internal gear pump, which provides charge oil (make-up oil) for the fan drive pump and motor in the closed loop fan drive circuit. Charge flow also provides cooling for the circuit and pressure for the pump control system.

10.13

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

FDC CONTROL RELAY #13 (FWD COIL NEGATIVE)

RELAY #10 (POWER)

RELAY #11 (A/C ON)

FDC PROCESSING MODULE

FAN DRIVE CONTROLLER RELAY ASSEMBLY

••

FAN CONTROLLER RELAY ASSEMBLY

RELAY #12 (A/C OFF)

ACCESSORY POWER TO FORWARD COIL 'A' TO FORWARD COIL 'B' POWER, RELAY #10 POWER, RELAY #11 POWER, MOMENTARY PURGE NEGATIVE, OIL SENSOR POSITIVE, OIL SENSOR NEGATIVE, WATER SENSOR POSITIVE, WATER SENSOR A/C TEMP SWITCH SIGNAL POWER, A/C ON RELAY GROUND

••

62 68/68A 89 63 80A 64 93 92 91 90 84 84A 68A SPARE 67B SPARE 67 G25

TERMINAL STRIP

FAN CONTROLLER RELAY ASSEMBLY LATER MACHINES WITH FDC ONLY 630-D47

This control consists of an electronic processing module (FDC), a three position FAN switch in the operator's cab FULL ON/AUTOMATIC/PURGE, and two temperature sensors, one to sense engine coolant temperature and the other to sense hydraulic oil temperature.

FAN CONTROL SWITCH

•

630-D36X

FAN CONTROL - SWITCH

15228B R0

When the switch is in the AUTOMATIC position, the fan will operate completely in an automatic mode. It will start, speed up, slow down or stop all based on the temperature of the engine coolant and/or the temperature of the hydraulic oil. The fan does not automatically purge.

When the engine coolant temperature reaches 191°F the sensor on the engine, in conjunction with the FDC module, will send a signal to the controller on the pump to move the swashplate and start to turn the fan very slowly. The fan speed is infinitely variable from zero up to a maximum of 2200 rpm fan speed @2200 rpm engine speed. As the temperature of the coolant increases so does the speed of the fan up to the maximum 2200 rpm fan speed @2200 rpm engine speed. At this point the engine coolant temperature will be 201°F, or higher.

The temperature sensor in the hydraulic tank operates in a similar manner to the engine coolant temperature sensor but independently and with a different temperature range of 130°F-160°F. This sensor will turn the fan ON at 130°F. As the temperature of the hydraulic oil increases, the speed of the fan will also increase to a maximum 2200 rpm fan speed @2200 rpm engine speed, at this point the temperature of the hydraulic oil will be 160°F, or higher.

10.14

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan FAN DRIVE MOTOR

CAUTION Before placing the fan switch in the PURGE position make sure that there are no personnel on the right side of the machine in the area where the fan will expel debris When the switch is in the AUTOMATIC position and the fan is stopped due to low engine coolant or hydraulic oil temperatures, turning ON the A/C will immediately turn the cooling fan to run at approximately half engine speed. This is to ensure that sufficient air flow is available for the cab A/C even while the machine is still warming up.

The fan drive motor is a fixed displacement inline swashplate axial piston motor. The fan drive motor is driven by hydraulic pressure from the fan drive pump and in turn it directly drives the crossflow fan.

ASSEMBLY NOTE: Before re-installing a fan drive motor, pack spline area of fan hub and motor shaft with EP Moly-Graph grease. See Fig. 630B-10

When the switch is in the FULL ON position, the FDC system is overridden and the fan will run at FULL speed for cooling regardless of coolant or oil temperatures.

When the switch is in the PURGE position, the FDC system will signal the controller on the pump to move the pump swashplate in the opposite direction, reversing the flow of oil in the hydrostatic closed loop and turn the fan in reverse. The FDC module will also turn the air conditioning system OFF for as long as the fan switch is in the PURGE position. The amount of time that the switch is held in the PURGE position need not be more than 20 - 30 seconds.

FAN DRIVE MOTOR

324-10

FILL HATCHED AREA WITH AN EP MOLY-GRAPH GREASE AS SHOWN PRIOR TO INSTALLING MOTOR DO NOT FILL THIS AREA WITH GREASE

• •

• •

•

•

•

•

•

•

• MOTOR

BOLT

WASHER

RETAINING RING

FAN

•

FAN SHAFT BEARINGS

FAN SUPPORT

630B-10

FAN DRIVE MOTOR INSTALLATION

10.15

Tigercat 635 Skidder FAN COOLING CIRCUIT DESCRIPTION WITH ELECTRONIC FAN DRIVE CONTROL (FDC) - Switch operated (LATER DESIGN 6350136 TO 6350499) The fan "cooling" circuit is a closed loop hydraulic system consisting of a variable displacement pump, a fixed displacement motor and a pressure filter.

The fan drive pump includes an integral charge pump which provides charge oil (make-up oil) for closed loop system. Charge flow also provides cooling for the circuit and pressure for the pump control system.

Charge oil is filtered prior to entering the loop by the charge pressure filter. The accumulation of excess oil in the pump and motor cases, caused by controlled internal leakage is returned to the hydraulic tank via the pump tank port 'L2'.

The fan drive pump is equipped with an electronic controller which receives signals from the electronic fan drive control module (FDC) to control the operation of the pump.

With the fan switch in the AUTOMATIC position, current flows through RELAY '10' to the FDC module BATTERY (+) terminal to power the FDC module. In this mode the FDC module has full control over the operation of the cooling fan.

The fan will start, speed up, slow down or stop all based on the temperature of the engine coolant and/or the temperature of the hydraulic oil.

In addition if the cab air conditioning system is turned ON before the engine coolant or hydraulic oil has reached operating temperature, current will flow to energize RELAY (11) and connect the (+) and (-) A/C terminals on the FDC module. This will run the cooling fan at half engine speed.

When the temperature of the engine coolant reaches 191°F the sensor on the engine will send a signal to the FDC module. The FDC module will then send current to the FORWARD coil in the pump controller to move the pump swashplate and start to turn the fan very slowly. As the temperature increases so does the speed of the fan up to a maximum of 2200 rpm fan speed

Oil Cooler and Cross-flow Fan @2200 rpm engine speed. At this point the engine coolant temperature will be 201°F, or higher.

Hydraulic oil temperature is also monitored in the same way and will engage the fan independently of the engine cooling sensor if the hydraulic oil temperature reaches 130°F. first. This sensor will turn the fan ON at 130°F, as the temperature of the hydraulic oil increases, the speed of the fan will also increase to a maximum of 2200 rpm fan speed @2200 rpm engine speed, at this point the temperature of the hydraulic oil will be 160°F, or higher.

With the switch in the FULL ON position, the FDC system is overridden and the fan will run at FULL speed for cooling regardless of coolant or oil temperatures.

Current flows through the fan switch to energize the coil of RELAY (10) this will disconnect the FDC (battery +) terminal and shut down the FDC module. Current will flow via a 75 ohm resistor to the FORWARD coil in the pump controller to move the pump swashplate and start to turn the fan forward at FULL speed, 2200 rpm fan speed @2200 rpm engine speed. Current also flows to energize the coil of RELAY (13). This will connect the 'C' side of the pump controller FORWARD coil to ground and at the same time disconnect the pump controller FORWARD coil from the FDC FWD "-" terminal.

When the switch is in the PURGE position, current flows through terminals 30 and 87A of the FDC RELAY (10) to the BATTERY (+) to power the FDC module. Current also flows through a 47 ohm resistor via the fan switch to the REVERSE coil in the pump controller to move the pump swashplate in the opposite direction and run the fan in reverse and at FULL speed. Current also flows to energize the coil of RELAY (12) and remove current from the A/C BINARY switch to turn off the air conditioning while the fan is running in REVERSE.

10.16

Tigercat 635 Skidder

630B-17

Oil Cooler and Cross-flow Fan

CROSS-FLOW FAN CIRCUIT - LATER DESIGN SERIAL NUMBER 6350136 TO 6350499 10.17

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

FAN WITH ELECTRONIC FAN DRIVE CONTROL (FDC) - Switch operated (LATER DESIGN 6350136 TO 6350499)

CHECK MAXIMUM FAN SPEED FORWARD AND REVERSE PUMP FORWARD AND REVERSE MAXIMUM DISPLACEMENT SETTINGS "X"

NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1. Park the machine on level ground. Parking brake ON, grapple and dozer on the ground and engine OFF. 2. Check that the forward displacement limiter adjusting screw (bottom) is set to 0.435" and the reverse displacement limiter adjusting screw (top) is set to 0.370", (dimension 'X').

If adjustment is required: 3. Place a piece of reflecting tape on the fan hub.

DIM X

DISPLACEMENT LIMITER ADJUSTING SCREW "X" DIMENSION

••

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

REVERSE MAXIMUM DISPLACEMENT ADJUSTING SCREW

5. Adjust the throttle control until the engine is running at 2200 rpm.

•• •

••

'M1' TEST PORT (FORWARD RELIEF) 'M2' TEST PORT (REVERSE RELIEF)

FAN DRIVE PUMP CONTROL LEVER

SOME HOSES REMOVED FOR CLARITY

• FAN DRIVE PUMP

630B-12

4. Start the engine. Leave the parking brake ON.

MANUAL SHIFT LEVER ON PUMP CONTROLLER SHOWN IN FULL FORWARD POSITION 724D-D43 6. Using the manual shift lever on the pump controller, shift the pump to full forward (UP) and measure the fan speed with the electronic photo tachometer, it should be 2200 rpm.

CHARGE PRESSURE RELIEF ADJUSTING SCREW

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

SHOWN WITH HOSES REMOVED FOR CLARITY 346-1

FORWARD MAXIMUM DISPLACEMENT ADJUSTING SCREW

•

••

••

FAN DRIVE PUMP - REAR VIEW

724D-D42

MANUAL SHIFT LEVER ON PUMP CONTROLLER SHOWN IN FULL REVERSE POSITION

7. Using the manual shift lever on the pump controller, shift the pump to full reverse (down) and measure the fan speed, it should be 1700-1800 rpm.

10.18

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

8. If adjustment is required due to incorrect readings: a. Stop engine. The engine should not be running when adjustments are being made to the fan drive pump.

CAUTION Do not adjust displacement limiter screws while the fan is running. Always stop the engine during fan speed adjustments.

Failure to do so may result in component damage. b. Adjust the forward maximum displacement adjusting screw; Loosen jamnut and turn screw counterclockwise to increase speed and clockwise to decrease fan speed. Set to 2100-2200 rpm.

NOTE: Always start with adjusting screw turned in to less than 'X' dimension and then start to unscrew in one 1/2 turn increments. One full turn of the adjusting screw will raise/lower the fan speed by 315 rpm. c. Adjust the reverse maximum displacement adjusting screw; Loosen jamnut and turn screw counterclockwise to increase speed and clockwise to decrease fan speed. Set to 1700-1800 rpm. See NOTE in (b). d. Tighten jamnut (s) and re-check the forward and reverse fan speed as in steps 4 - 8 above. e. Continue with step 8 until correct forward and reverse fan speeds are obtained.

10.19

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

CHECK FAN DRIVE PUMP PRESSURE: 1. Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of the THIS MANUAL. 2. Park the machine on level ground. Parking brake ON, grapple and dozer down and engine OFF. 3. Install two 0-5000 psi gauges on 'M1' and 'M2' test ports. Install one 0-500 psi gauge on fan charge pressure 'M3' test port.

••

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

WARNING Monitor hydraulic oil temperature closely when the fan motor is disconnected. Do not allow the hydraulic oil to overheat 5. Start the engine. Leave the parking brake ON. 6. Adjust the throttle control until the engine is running at 2200 rpm.

7. Verify that the fan drive charge pump pressure, 'M3' gauge, reads 200-210 psi.

8. If necessary adjust the charge pump pressure using the charge pressure adjusting screw.

CHARGE PRESSURE RELIEF ADJUSTING SCREW

REVERSE MAXIMUM DISPLACEMENT ADJUSTING SCREW

'M3' TEST PORT (CHARGE PRESSURE) REMOTE MOUNTED

•• •

630B-12

•

'M1' TEST PORT (FORWARD RELIEF)

••

SOME HOSES REMOVED FOR CLARITY

FORWARD MAXIMUM DISPLACMENT ADJUSTING SCREW

'M2' TEST PORT (REVERSE RELIEF)

SHOWN WITH HOSES REMOVED FOR CLARITY

FAN DRIVE PUMP CONTROL LEVER

•

346-1

FAN DRIVE PUMP

4. Disconnect the main hoses going into the fan motor and plug using two 12 ORS plugs.

DISCONNECT MAIN HOSES AND PLUG WITH 12 ORS PLUGS.

••

••

••

••

FAN DRIVE PUMP - REAR VIEW

9. Adjust engine speed to 1000 rpm.

10. Shift the pump to full forward using the hand lever on the pump. Verify that the 'M1' gauge reading is 3700-3900 psi. Note the pressure has a tendency to drop slightly while holding the lever shifted fully, this is acceptable.

11. Shift the pump to full reverse using the hand lever on the pump. Verify that the 'M2' gauge reading is 3700-3900 psi. Note the pressure has a tendency to drop slightly while holding the lever shifted fully, this is acceptable.

12. If 'M1' and 'M2' gauge readings are incorrect contact Tigercat Customer Service for more information as the relief valves are not adjustable.

13. Reconnect hoses to fan motor.

324-10

FAN DRIVE MOTOR

14. Check for hydraulic oil leaks. Stop the engine and remove gauges from test port connections.

10.20

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

ELECTRONIC FAN DRIVE CONTROL (FDC)

If the readings taken compare favourably with the reading shown in the chart then the sensor is OK.

CHECK FOR TEMPERATURE SENSOR FAILURE: An Ohms meter and an infrared temperature probe (heat gun) are required for this test.

Both the engine coolant and hydraulic oil temperature sensors may be checked for faulty operation by performing a "resistance" check.

This involves checking the resistance value of the sensor across the sensor terminals with the coolant or hydraulic oil at a specific temperature level.

10. If the temperature sensor is faulty the resistance reading on the Ohms meter will most likely be zero.

11. Replace sensor and/or reconnect wires.

12. Perform the same test with the Hydraulic oil temperature sensor using the same chart.

SOME WIRES REMOVED FOR CLARITY

The check may be performed without removing the sensor. Use the chart below as a guide for temperature to resistance values.

SENSOR RESISTANCE CHECK TEMP. OHMS 120°F (49°C) 796 ± 5% 140°F (60°C) 561 ± 5% 160°F (71°C) 395 ± 8% 180°F (82°C) 279 ± 8% 200°F (93°C) 196 ± 8% 220°F (104°C) 138 ± 8% FDC ENGINE COOLANT TEMPERATURE SENSOR

••

630-D49

ENGINE COOLANT TEMPERATURE SENSOR (FDC)

1. Disconnect wires from FDC engine coolant temperature sensor.

2. Start the engine. Leave the parking brake ON. 3. Set throttle control to IDLE (1000 rpm).

4. Place A/C switch in OFF position.

5. Place FAN switch in AUTOMATIC position.

8. Stop engine when engine coolant temperature gauge in cab reads close to a value shown in the above chart.

7. Aim the heat gun at the coolant pipe close to the temperature sensor and take a temperature reading, note the reading.

8. Connect the Ohms meter to the two terminals on the temperature sensor and note resistance value.

FDC HYDRAULIC OIL TEMPERATURE SENSOR

•

630-D50

HYDRAULIC OIL TEMPERATURE SENSOR (FDC)

CHECK MINIMUM FAN SPEED WITH A/C "ON" AND NO A/C DURING PURGE MODE NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1. Ensure that engine coolant and hydraulic oil temperatures are well below the normal operating temperatures of 191°F coolant and 130°F hydraulic oil throughout entire test or fan will rotate and test will be invalid.

2. Place a piece of reflecting tape on the fan hub.

3. Start the engine. Leave the parking brake ON. 4. Set throttle control to 2200 rpm.

5. Place FAN switch in AUTOMATIC position.

6. Place A/C switch in ON position.

7. Use a photo-tachometer to measure the speed of rotation of the fan blade, it should be 1140-1200 rpm.

8. With the help of an assistant press and hold the fan switch in the PURGE position and visually check clutch on A/C compressor. It should be disengaged and compressor not running.

9. When the PURGE switch is released the clutch on the A/C compressor should engage and the compressor should be running.

9. Use the SENSOR RESISTANCE CHECK chart and compare readings.

10.21

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan 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.

CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY ENGINE COOLANT TEMPERATURE: NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1. Complete TEMPERATURE SENSOR FAILURE VERIFICATION test.

2. Place a piece of reflecting tape on the fan hub.

3. Place A/C switch in OFF position.

4. Cover only the radiator portion of the cooling assembly with cardboard.

5. Disconnect wire from the FDC hydraulic oil temperature sensor and install a spare sensor of the same type on the sensor wires.

Suspend the spare sensor in a cooler location so that it is not in contact with any hot engine parts. This is necessary to prevent the engine hydraulic oil temperature sensor from interfering with this engine coolant temperature sensor test.

6. Start engine. Leave parking brake ON. 7. Set throttle control to 2200 rpm and raise engine coolant temperature to 170°F-180°F on gauge.

IMPORTANT NOTE: Monitor hydraulic oil temperature closely throughout test and place the fan switch in the FULL ON position if necessary. The hydraulic oil temperature should not be allowed to climb above 130°F. Operator should be instructed to activate functions for 5 seconds and then release for 5 seconds to avoid overheating of valve by hydraulic oil as it passes over the reliefs during the following procedures.

9. Observe the engine coolant temperature gauge during this process, when the gauge settles down and reads a steady temperature and then begins to rise, the fan should begin to slowly rotate. The engine coolant temperature should be approximately 191°F. 10. Continue with step (7) to increase the engine coolant temperature to 201°F while at the same time verifying that the rpm of the fan increases proportionally with the increase in temperature of the engine coolant.

11. Use the photo-tachometer to measure the rpm of the fan at this temperature of 201°F, it should be 2100-2200 rpm.

12. Remove the cardboard from the radiator.

13. The engine coolant temperature will start to decrease. Verify that the fan speed decreases relative to the decrease in the engine coolant temperature. NOTE, This will happen quickly and can be verified visually without the use of the photo-tachometer.

14. The fan speed should slow down and settle at 800-840 rpm with engine speed of 2200 rpm and engine coolant temperature steady at 195°F, with a 195°F thermostat.

15. If the test was successful, remove the spare hydraulic oil temperature sensor and reconnect the sensor wires to the FDC hydraulic oil temperature sensor.

16. Replace FDC processing module if this test fails.

8. Operate the ARCH OUT function and hold position for 5 seconds and then release for 5 seconds (see IMPORTANT NOTE) This will impose a load on the engine and cause the engine coolant temperature to rise.

SINGLE ARCH ONLY POSITION GRAPPLE TO OPERATE ARCH OUT FUNCTION SAFELY

NOTE - SINGLE ARCH ONLY: 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 308-19

10.22

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY HYDRAULIC OIL TEMPERATURE:

SINGLE ARCH ONLY POSITION GRAPPLE TO OPERATE ARCH OUT FUNCTION SAFELY

NOTE: A calibrated "electronic photo tachometer" is required for this procedure.

1. Complete the TEMPERATURE SENSOR FAILURE VERIFICATION test.

2. Place a piece of reflecting tape on the fan hub.

3. Disconnect wire from the FDC engine coolant temperature sensor and install a spare sensor of the same type on the sensor wires. Suspend the spare sensor in a cooler location so that it is not in contact with any hot engine parts. This is necessary to prevent the engine coolant temperature sensor from interfering with this hydraulic oil temperature sensor test.

4. Place A/C switch in OFF position.

5. Cover only the oil cooler portion of the cooling assembly with cardboard.

6. Start engine. Leave paring brake ON. 7. Set throttle control to 2200 rpm and raise hydraulic oil temperature to 130°F on gauge.

308-19

Take care to avoid damaging hydraulic hoses while positioning the grapple.

9. Observe the hydraulic oil temperature gauge during this process, when the gauge settles down and reads a steady temperature and then begins to rise, the fan should begin to slowly rotate. The hydraulic oil temperature should be approximately 130°F. 10. Continue with step (8) to increase the hydraulic oil temperature to 160°F while at the same time verifying that the rpm of the fan increases proportionally with the increase in temperature of the hydraulic oil.

IMPORTANT NOTE: Monitor engine coolant temperature closely throughout test. Abort test if engine coolant temperature climbs above 200°F.

11. Use the photo-tachometer to measure the rpm of the fan at this temperature of 160°F, it should be 2200 rpm. with an engine speed of 2200 rpm

Operator should be instructed to activate functions for 5 seconds and then release for 5 seconds to avoid overheating of valve by hydraulic oil as it passes over the reliefs during the following procedures.

12. Remove the cardboard from the oil cooler.

8. Operate the ARCH OUT function and hold position for 5 seconds and then release for 5 seconds (see IMPORTANT NOTE) This will impose a load on the engine and cause the engine coolant temperature to rise.

13. The hydraulic oil temperature will start to decrease. Verify that the fan speed decreases relative to the decrease in the hydraulic oil temperature. NOTE, This will happen quickly and can be verified visually without the use of the photo-tachometer.

14. The fan should stop rotating at approximately 130°F.

NOTE - SINGLE ARCH ONLY: 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.

15. If the test was successful, remove the spare engine coolant sensor and re-connect the sensor wires to the FDC sensor in the hydraulic tank

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.

16. Replace FDC processing module if this test failed.

10.23

Tigercat 635 Skidder

Oil Cooler and Cross-flow Fan

TROUBLE-SHOOTING GUIDE FOR FDC OPERATION

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TROUBLESHOOTING.DOC/PDF

TROUBLE-SHOOTING GUIDE FOR OVERHEATING PROBLEMS The following is a list of problems that would cause a skidder to overheat. All items are equally important and each must be considered.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Dirty Radiator Low Coolant Level Low Oil Level Dirty Air Filter Improper Grade of Fuel Faulty Thermostats Faulty Coolant Pump Coolant Gauge Malfunction Defective Water Pump (Belt)

10.

11.

12.

13.

14.

15.

16.

17.

10.24

Air Recirculation Gaps between Radiator & Shroud Fan Engagement into Shroud Corroded Coolant Passages Excess Fuel Delivery from Injection Pump Incorrect lnjection Pump Timing Internal Failure of Deaeration System Operator Induced Problem

Tigercat 635 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 635 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 work port 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 work port, 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 635 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 635 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.

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.

T

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

Back flow 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 635 Skidder

STEER1

Steering and Center Joint

SYSTEM DIAGRAM 11.5

Tigercat 635 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 635 Skidder

630B-19

Steering and Center Joint

STEER CIRCUIT 11.7

Tigercat 635 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 PRE-LOAD CHECK

11.8

Tigercat 635 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 635 Skidder

Steering and Center Joint

CHECKING THE CENTER JOINT PRELOAD Check the center joint preload with a dial indicator every 1000 hours. Refer to SCHEDULED MAINTENANCE in SECTION 3 of THIS MANUAL.

FRONT CHASSIS

B ••

DIAL INDICATOR PLUNGER

•

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.

DIAL INDICATOR

REAR CHASSIS

1. Park the machine on level ground. Set parking brake ON, grapple and dozer blade UP and shut off engine.

DIAL INDICATOR BASE

2. Torque the top and bottom retainer bolts (items 1 and 2) to 282 - 310 lbf-ft.

•

A

Later style pin retainers use 4 bolts each.

1

CHECK PRELOAD

DIG-06

Earlier style pin retainers use 6 bolts each.

•

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 635 Skidder

Steering and Center Joint

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.

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.

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 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 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 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

PRELOAD RANGE LOWER

UPPER

LATER BEARINGS (AA164)

0.021"

0.023 "

EARLIER BEARINGS (AA003)

0.016 "

0.018 "

CENTER JOINT PRELOAD ADJUSTMENT Before making any adjustments to the center joint, please follow CHECKING THE CENTER JOINT PRELOAD procedure in THIS SECTION. 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).

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.

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; •

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.

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.

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 635 Skidder

Steering and Center Joint

11.12

Tigercat 635 Skidder SECTION 12 - GRAPPLE, ARCH AND BOOM DECEMBER 2002

CONTENTS - SECTION 12 CIRCUIT DESCRIPTION ARCH ....................................................................................................... 12.7 ARCH/BOOM .......................................................................................... 12.13 GRAPPLE OPEN/CLOSE ....................................................................... 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 635 Skidder

Grapple, Arch and Boom

12.2

Tigercat 635 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 635 Skidder

Grapple, Arch and Boom

GRAPPLE CONTROL VALVE

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 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 635 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 CLOCKWISE ROTATION PORT

•

• OUTLET SECTION

AT093IL2

GRAPPLE COUNTERCLOCKWISE ROTATION PORT RELIEF POWER BEYOND PLUG

GRAPPLE CONTROL VALVE (single function arch) 12.5

GRAPPLE COUNTERCLOCKWISE ROTATION PORT

Tigercat 635 Skidder

630B-18

Grapple, Arch and Boom

SINGLE ARCH CIRCUIT 12.6

Tigercat 635 Skidder

Grapple, Arch and Boom

SINGLE 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 635 Skidder

Grapple, Arch and Boom

SINGLE ARCH PRESSURE SETTINGS

P3 TEST PORT

•

WARNING 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.

275-3

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

*Refer to RELIEF VALVE ADJUSTING PROCEDURE in THIS SECTION.

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.

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

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

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.

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.

POSITION GRAPPLE FOR ARCH IN/OUT PRESSURE SETTINGS

HOSES REMOVED FOR CLARITY

HIGH PRESSURE RELIEF VALVE

PRESSURE REDUCING VALVE

•• •

••

SEQUENCE VALVE

321-2A

MULTIFUNCTION VALVE

308-19

3. Set parking brake ON, dozer blade DOWN and shut off the engine.

12.8

Tigercat 635 Skidder

Grapple, Arch and Boom

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

DOZER VALVE INLET RELIEF

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.

••

7. It is necessary to temporarily increase the pressure of the main pump to 3850-3900 psi.

DOZER VALVE INLET RELIEF

a. Turn the multifunction high pressure relief valve IN all the way (clockwise) until lightly seated.

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF.

630-D42

••

Turn the dozer inlet relief valve (if equipped) IN all the way (clockwise) until lightly seated.

MAIN PUMP POR ADJUSTING SCREW

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.

9. With the aid of an assistant, operate the arch OUT control and hold pressure.

16. Turn off the engine, remove gauge, reinstall plugs on test ports and replace the cover plates.

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 635 Skidder

Grapple, Arch and Boom

GRAPPLE CONTROL VALVE

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 635 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

ARCH IN PORT RELIEF

•

•

GRAPPLE CLOSE PORT RELIEF

GRAPPLE COUNTERCLOCKWISE ROTATION PORT RELIEF

•

A

•

•

GRAPPLE COUNTERCLOCKWISE ROTATION PORT

BOOM UP PORT RELIEF VALVE OUTLET SECTION

AT095IL2

•

•

GRAPPLE CONTROL VALVE (dual function arch) 12.11

POWER BEYOND PLUG

BOOM DOWN PORT RELIEF VALVE

Tigercat 635 Skidder

630B-22

Grapple, Arch and Boom

ARCH/BOOM CIRCUIT 12.12

Tigercat 635 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 635 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.

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.

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR *Refer to RELIEF VALVE ADJUSTING PROCEDURE in this section.

275-3

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. Set parking brake ON, grapple and dozer DOWN and shut off engine.

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.

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

MULTIFUNCTION VALVE

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 635 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.

10. Adjust the arch OUT, port relief valve to give a reading of 2500-2600 psi on the 'P3' gauge.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

11. Reset the multifunction valve high pressure relief (reading on the 'P3' gauge).

4. Start the engine, hold down the brake pedal and set the throttle to IDLE.

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

•• DOZER VALVE INLET RELIEF 630-D42

•

NOTE: EARLIER MACHINES WERE NOT FACTORY EQUIPPED WITH THIS RELIEF. MAIN PUMP POR ADJUSTING SCREW

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).

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.

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 635 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 635 Skidder

Grapple, Arch and Boom

GRAPPLE CONTROL VALVE

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 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 635 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

•

OUTLET SECTION

AT093IL3

GRAPPLE COUNTERCLOCKWISE ROTATION PORT

• POWER BEYOND PLUG

GRAPPLE CONTROL VALVE (grapple) 12.18

Tigercat 635 Skidder

635-10

Grapple, Arch and Boom

GRAPPLE CIRCUIT 12.19

Tigercat 635 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 removable 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)

• •

•

DRAIN LINE GRAPPLE ROTARY MANIFOLD

••

Later machines (Danfoss Motor) The grapple rotate motor (Danfoss) is a hydraulic gerotor motor and has an adjustable double acting cross-line relief valve for protection. If external rotational pressure is applied to the head, this valve bypasses 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 635 Skidder

Grapple, Arch and Boom

GRAPPLE OPEN/CLOSE CIRCUIT CIRCUIT DESCRIPTION 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 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. For machines equipped with Tigercat dual cylinder grapples oil passes through a flow divider which divides the flow to ensure that the grapple tongs open and close at the same rate. 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.

12.21

Tigercat 635 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

• 308-15

275-3

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR 12.22

POSITION GRAPPLE ON GROUND TO PREVENT ROTATION

Tigercat 635 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)

• ••

•

DRAIN LINE

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 635 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 635 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 635 Skidder ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting nut ADJUSTING NUT

•

JAMNUT

Grapple, Arch and Boom ANTI-CAVITATION RELIEF VALVE ADJUSTING PROCEDURE For relief valve with adjusting screw ADJUSTING SCREW

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.

5.

Re-check relief setting.

Lock jamnut against relief valve body, making sure the adjusting screw does not turn.

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 635 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.

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.

P

STEP 2

T

Step 3.

SEATING POPPET

T

P

STEP 3

T VALVE POPPET

Step 4.

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.

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 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.

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 635 Skidder

Grapple, Arch and Boom

12.28

Tigercat 635 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 .......................................................................... 13.6 CIRCUIT DIAGRAM (6350101 TO 6350134) ............................................ 13.7 CIRCUIT DIAGRAM (6350135 TO 6350499) ........................................... 13.9 WINCH ..................................................................................................... 13.6 WINCH MOTOR ....................................................................................... 13.6 PRESSURE SETTINGS WINCH IN PORT RELIEF ADJUSTMENT ............................................. 13.10 WITHOUT WINCH IN PORT RELIEF, NON- ADJUSTABLE .................. 13.10

Tigercat 635 Skidder

Winch

13.2

Tigercat 635 Skidder

Winch

WINCH CONTROL LEVER VALVE

OPERATING DESCRIPTION

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.

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.

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

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

In the neutral position the control lever is held centered by return spring (4).

WORK PORTS 1, 2

SPOOL ARRANGEMENT

AU013-2

AU014-1

13.3

WINCH CONTROL LEVER VALVE

Tigercat 635 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 635 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

•

•

POWER BEYOND PLUG

OUTLET SECTION

AT093IL4

GRAPPLE CONTROL VALVE (WINCH) (single function arch) 13.5

GRAPPLE COUNTERCLOCKWISE ROTATION PORT RELIEF GRAPPLE COUNTERCLOCKWISE ROTATION PORT

Tigercat 635 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 solenoid valve to the 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 and 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 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.

348-22

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 in THIS MANUAL. Refer to manufacturer's service manual for more information about 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 WINCH - MODEL 40 13.6

Tigercat 635 Skidder

635-13

Winch

WINCH CIRCUIT - LANTEC WINCH SERIAL NUMBERS 6350101 TO 6350134 13.7

Tigercat 635 Skidder

Winch

13.8

Tigercat 635 Skidder

630B-26

Winch

WINCH CIRCUIT - LANTEC WINCH SERIAL NUMBERS 6350135 TO 6350499 13.9

Tigercat 635 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.

275-3

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR

*Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 12 of THIS MANUAL.

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.

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

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.

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.

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.

HOSES REMOVED FOR CLARITY

HIGH PRESSURE RELIEF VALVE

1. Set parking brake ON, grapple dozer blade DOWN and shut off the engine.

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 13.10

Tigercat 635 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.

13.11

MAIN PUMP

HOSES REMOVED FOR CLARITY

Tigercat 635 Skidder

Winch

13.12

Tigercat 635 Skidder SECTION 14 - DOZER BLADE DECEMBER 2002

CONTENTS - SECTION 14 CIRCUIT DESCRIPTION ............................................................................. 14.6 CIRCUIT DIAGRAM ..................................................................................... 14.7 CONTROL LEVER PILOT VALVE ............................................................... 14.3 DOZER CONTROL VALVE .......................................................................... 14.4 OPERATING DESCRIPTION ................................................................... 14.5 PRESSURE SETTINGS .............................................................................. 14.8

Tigercat 635 Skidder

Dozer blade

14.2

Tigercat 635 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

•

1

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.

•

•

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 635 Skidder

Dozer blade

DOZER CONTROL VALVE

the dozer cylinders and from the multifunction valve. Return oil is directed back to tank via the distribution manifold.

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 MULTIFUCTION VALVE

• DOZER

A

B

•• DOZER UP PORT RELIEF

•

•

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 635 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 635 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 which 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-strokes to a zero angle.

The spool section in this control valve is pilot operated. Pilot oil to either 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 635 Skidder

630B-27

Dozer blade

DOZER CIRCUIT 14.7

Tigercat 635 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.

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.

TEST PORT COMPARTMENT BELOW CAB LEFT DOOR *Refer to RELIEF VALVE ADJUSTING PROCEDURE in SECTION 12 of THIS MANUAL. 275-3

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

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.

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.

••

1. Set parking brake ON, grapple UP, dozer DOWN and shut off the engine.

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

WARNING

MAIN PUMP P.O.R. ADJUSTING SCREW

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.

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.

630-PH2

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).

MAIN PUMP - DOZER, STEER & GRAPPLE

14.8

Tigercat 635 Skidder

Dozer blade

6. Make sure that the area is clear and the engine front door is closed.

HOSES REMOVED FOR CLARITY

CAUTION Do not operate machine with front door open.

Dozer blade will damage the door if operated with the front door open.

HIGH PRESSURE RELIEF VALVE

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 635 Skidder

Dozer blade

14.10