Tigercat AD610C CARRIER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL

Tigercat AD610C CARRIER Issue 1.2, DECEMBER 2010 TABLE OF CONTENTS SECTION INTRODUCTION.................................................................................................................iii SAFETY............................................................................................................................... 1 CONTROLS AND OPERATION...............................See separate OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE................................................................................. 3 ELECTRICAL AND COMPUTERS...................................................................................... 6 ENGINE START AND STOP............................................................................................... 7 DRIVE................................................................................................................................. 8 BRAKES AND DIFFERENTIAL LOCKS . ........................................................................... 9 OIL COOLER AND FAN.................................................................................................... 10 STEERING AND CENTER JOINT..................................................................................... 11 CRANE (ATTACHMENT PRESSURE) . ........................................................................... 12 WINCH.............................................................................................................................. 13 DOZER BLADE................................................................................................................. 14

AD610C-SM00-1.0

AD610C Available Literature Operator's Manual, English...........................................................................Part No. 35611A Service Manual, English (This Manual)........................................................ Part No. 35612A Vehicle Moving and Transporting Instructions.......................................Part No. 35761AMUL Parts Catalog, English.................................................................................. Part No. 35609A

Tigercat

®

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

Tigercat AD610C Carrier

Introduction

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Tigercat AD610C Carrier

Introduction

Tigercat AD610C Carrier INTRODUCTION

An Operator's manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the AD610C Carrier.

Serial numbers:6109001 to 6109250 The AD610C Carrier is designed as an aerial device carrier for forestry/utility applications including tree trimming and line clearing as well as general aerial work on and around energized conductors.

The operator's manual will assist the operator with the techniques of proper and safe operation of the AD610C Carrier. The service manual contains safety and servicing procedures and a preventive maintenance schedule to assist in repair and to ensure optimum machine performance. For manual part numbers, see the title page in each manual.

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

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

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

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

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

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

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

Tigercat Industries Inc.

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Tigercat AD610C Carrier

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.

Tigercat Industries Inc.

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Tigercat AD610C Carrier

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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Introduction

vi

Tigercat AD610C Carrier SECTION 1 - SAFETY

june 2010

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

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 ARTICULATION LOCK................................................................................................... 1.28 BATTERY DISCONNECT SWITCH................................................................................. 1.8 BATTERY SAFETY.......................................................................................................... 1.6 CAB EXITS....................................................................................................................... 1.7 CAB SAFETY CABLE.................................................................................................... 1.12 CAB SUPPORT BRACE................................................................................................ 1.12 COOLING SYSTEM....................................................................................................... 1.11 EMERGENCY CAB EXITS............................................................................................... 1.7 EXHAUST FUMES......................................................................................................... 1.14 FIRE PREVENTION................................................................1.20, 1.21, 1.22, 1.23, 1.24 DRY CHEMICAL CLEANUP PROCEDURES............................................................. 1.24 FIRE PREVENTION GUIDELINES............................................................................. 1.20 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED..................................... 1.23 WHAT TO DO TO PREPARE FOR A MACHINE FIRE............................................... 1.21 WHAT TO DO WHEN A MACHINE FIRE OCCURS................................................... 1.22 FIRST AID........................................................................................................................ 1.4 FLUID INJECTION INJURY........................................................................................... 1.15 GREASE INJECTION INJURY....................................................................................... 1.16 HYDRAULIC PRESSURE HAZARD.............................................................................. 1.11 LIGHTNING SAFETY AWARENESS LIGHTNING SAFETY................................................................................................. 1.17 WHAT IS A LIGHTNING STRIKE................................................................................ 1.17 LOOSE CLOTHING HAZARD........................................................................................ 1.12 PARKING THE MACHINE................................................................................................ 1.8 PROTECTIVE CLOTHING............................................................................................... 1.2 SAFETY LABELS...................1.25, 1.26, 1.27, 1.28, 1.29, 1.30, 1.31, 1.32, 1.34, 1.35 SAFETY PRECAUTIONS, GENERAL..............................................1.2, 1.3, 1.4, 1.5, 1.6 SAFETY PRECAUTIONS, OPERATING.......................................................... 1.7, 1.8, 1.9 SAFETY PRECAUTIONS, SERVICING...............1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16 SAFETY SYMBOLS......................................................................................................... 1.2 SIGNAL WORDS.............................................................................................................. 1.2 WELDING, PRIOR TO................................................................................................... 1.10 WORKING WITH OIL....................................................................................................... 1.4

Tigercat AD610C Carrier

Safety

SAFETY SYMBOLS

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

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

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

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

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

Follow the instructions in the safety message.

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

Understanding Signal Words

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

Follow all instructions from safety inspector and supervisors.

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

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

Do not let an untrained person operate the machine.

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

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

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Tigercat AD610C Carrier

Safety

GENERAL SAFETY PRECAUTIONS continued

WARNING

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

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

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

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

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

Prolonged exposure to loud noise can cause permanent hearing loss.

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

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

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

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

Do not jump off the machine at any time.

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

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

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

1.3

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

Tigercat AD610C Carrier

Safety Check all fluid levels.

GENERAL SAFETY PRECAUTIONS continued

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

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

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

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

Machine should be washed completely at every major service.

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

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

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.

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

Check window and door guards for damage.

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

Some advice which should be observed: • • •

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

•

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

• • • • • •

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

Avoid contact with oil, particularly heated oil.

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

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

Don't put oily rags in your pockets.

Oil soiled clothing should be changes as soon as possible.

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

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

Avoid breathing in oil fumes.

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

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

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

1.4

Tigercat AD610C Carrier

Safety 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.

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

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

•

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.

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

Reduce engine speed to LOW IDLE and let run for approximately 5 minutes to allow gradual dissipation of heat and also to reduce turbo speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

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

Install articulation lock whenever the machine is to be transported.

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

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

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.

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

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 attachment manufacturer.

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.

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

1.5

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.

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.

Tigercat AD610C Carrier

Safety

GENERAL SAFETY PRECAUTIONS continued

Avoid Injury from Backover Accidents Before moving machine, be sure all persons are clear of the area.

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

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

Wash hands after handling.

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

To avoid backover accidents:

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

• •

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

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

• •

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

•

CAUTION

•

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

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

1.6

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

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

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

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

Keep windows, mirrors and lights in good condition.

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

Tigercat AD610C Carrier

Safety CAB EXITS

OPERATING SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

Sound the machine horn before starting the machine.

IMPORTANT !

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

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

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

For additional information, refer to EMERGENCY EXITS in SECTION 3 of the OPERATOR'S MANUAL. Secure loose items in cab.

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

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

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

Never use a liquid staring aid to start an engine.

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

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

1.7

Tigercat AD610C Carrier

Safety When parking the machine:

OPERATING SAFETY PRECAUTIONS continued

•

Park on level ground ONLY and engage parking brake

•

Do not park on a hillside or incline.

•

Before leaving the operator's cab, park the attachment, lower the dozer blade onto the ground and engage the parking brake.

•

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

WARNING

1. Fully apply brake foot pedal 25 times or more.

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

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

Use caution when loosening hydraulic connections.

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

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

Never operate the winch from the ground. Control it only from the operator’s seat.

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

Keep the brake properly adjusted at all times.

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

e625c-111

•

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

Do not leave the operator's cab while the winch line is under tension.

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

WARNING

Before leaving the operator's cab, park the attachment, lower the dozer blade to the ground and engage the parking brake.

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

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

1.8

Tigercat AD610C Carrier

Safety

OPERATING SAFETY PRECAUTIONS continued

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.

WARNING

Before moving the machine, park the attachment, raise dozer blade off the ground and keep it 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. Refer to also to TIRE PRESSURES in SECTION 3 of THIS MANUAL.

Never operate the attachment 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.

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.

Use only prearranged and approved signalling practices.

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

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.

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.

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

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

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

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

NEVER travel across a STEEP slope or side hill: •

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

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

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

WARNING Always park the machine on level stable ground and lower the dozer blade to the ground before activating the crane. The lowered dozer blade will increase stability of the carrier when operating the crane.

In addition, always read, understand and follow all operating and safety instructions in attachment manufacturer's instructions before operating the crane attachment.

1.9

Tigercat AD610C Carrier

Safety 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.

SERVICING SAFETY PRECAUTIONS

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

Also, turn off the battery disconnect switch and disconnect the positive (+) battery cable from both batteries.

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

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

IMPORTANT

24 VOLT

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

ELECTRICAL SYSTEM

Install a “DO NOT START ENGINE” sign on the operator’s cab door and in the engine compartment when making repairs to the machine. disconnect the two multi-pin plugs from the engine cpu

DISCONNECT 4 PIN ENGINE POWER CONNECTOR

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

610c-03

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

engine cpu disconnect -left side of engine

disconnect engine ground connection

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

Exercise care when working in this area with the engine running. If the fan control switch is in the AUTOMATIC position, the fan could go into clean mode at any time when the engine is running.

610c-04

engine ground disconnect - right side of engine

Disconnect the engine CPU (Central Processing Unit) by unplugging the four pin engine power connector and the two multipin connectors from the left side of the engine.

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

Also disconnect the engine ground connection at the chassis.

1.10

Tigercat AD610C Carrier

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING

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.

Warning, HOT FLUIDS and hot machine surfaces can cause serious burns!

•

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

•

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

•

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

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. Park attachment, lower dozer blade to the ground and relieve trapped pressure from brake accumulator before performing work on components, or disconnecting any hoses. For the procedure to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

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

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.

1.11

Tigercat AD610C Carrier

Safety

SERVICING SAFETY PRECAUTIONS continued safety cable

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

AD610C-05

cab at full tilt supported by safety cable

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

E620C-17

tilted cab supported by support brace

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

WARNING

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

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

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

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

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.

1.12

Tigercat AD610C Carrier

Safety

SERVICING SAFETY PRECAUTIONS continued

630d-03

BOLT ON ACCESS PANELS

ARTICULATION LOCK in straight locked position

E620C-15a

630d-01

maintenance access doors

ACCESS PANELS LEFT SIDE

ARTICULATION LOCK in articulated locked position

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

door prop

WARNING

E620C-14

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

MAINTENANCE ACCESS DOOR (LEFT SIDE SHOWN)

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

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

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

All handles should be hand tight only at all times.

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

1.13

Tigercat AD610C Carrier

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.

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Tigercat AD610C Carrier

Safety

SERVICING SAFETY PRECAUTIONS continued

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

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

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

• Seek professional medical attention immediately.

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

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

Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

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

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

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

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

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

•

Time becomes critical as tissue damage progresses rapidly. The longer you delay getting professional medical attention, the more damage can occur.

Although fluid injection accidents are rare, the resulting injury has on occasion required the amputation of a finger, a hand or in some cases the entire limb. The longer the delay in getting professional medical aid, the further up the limb the tissue damage can spread. An injury of this type can become very serious or even fatal if not dealt with promptly and properly.

1.15

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

• Place the end of a long piece of wood in the suspected path of any fluid stream. Never use any part of your body.

• Recognize that the source of the leak and the fluid streaming from it may be very small and not easily visible. You may only be able to see the fluid that accumulates as a result of the fluid stream.

When performing any service work • Stop the engine and relieve all diesel fuel or hydraulic pressure before disconnecting any lines or otherwise working on the system.

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

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

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

Tigercat AD610C Carrier

Safety

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

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

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

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

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

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

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

•

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

•

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

•

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

•

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

•

Remove dirt and grease from grease fittings prior to greasing.

•

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

•

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

1.16

Tigercat AD610C Carrier

Safety LIGHTNING SAFETY

LIGHTNING SAFETY AWARENESS

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

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

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

1. Designate a member of your crew to

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

•

Monitor daily weather forecasts

•

Observe local weather conditions

•

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

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

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

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

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

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

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

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

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

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

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

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

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Tigercat AD610C Carrier

Safety What to do if you are outside and see lightning or hear thunder.

LIGHTNING SAFETY AWARENESS

If you can, get inside.

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

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

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

2. If inside a building:

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

•

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

•

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

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

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

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

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

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

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

1.18

•

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

•

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

•

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

•

Do not touch any metallic objects referenced to the outside of the vehicle.

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

•

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

Tigercat AD610C Carrier

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

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

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

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

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

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

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

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

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

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

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

6. Avoid entering any small enclosures or shelters.

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

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

2. Call your local emergency response telephone number immediately.

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

3. If the victim has no pulse, their heart has stopped or they have stopped breathing, start cardiopulmonary resuscitation (CPR) or mouth –to-mouth resuscitation immediately.

Use a portable defibrillator if one is available.

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

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

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

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

11. Do not use the telephone except for emergencies.

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

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Tigercat AD610C Carrier

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

fire prevention

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

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

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

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

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

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

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

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

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

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

Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires. Do not operate the machine until the exhaust leak is repaired.

2. Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine. Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR’S MANUAL. 3. Blow off all forest debris and fine organic material accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently when working in logging conditions where large amounts of combustible forest debris are present. Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If dislodged this smoldering debris can fall into other areas of the machine and thereby spread a fire.

1.20

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

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

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

Tigercat AD610C Carrier

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

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

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

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

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

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

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO LOG, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY or PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL. What to do to prepare for a MACHINE fire

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

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

1.21

•

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

•

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

•

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

•

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

Tigercat AD610C Carrier

Safety WHAT TO DO WHEN A MACHINE FIRE OCCURS

fire prevention •

•

•

•

1. Lower all working attachments to the ground.

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

Ensure that your fire detection system* is in working order. Refer to fire DETECTION system in SECTION 2 of the OPERATOR’S MANUAL.

2. Shut the engine off.

3. Activate the fire suppression system**.

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

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

Ensure that your fire suppression system** is charged and in working order. Refer to fire suppression system in SECTION 2 of the OPERATOR’S MANUAL.

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

•

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

•

Ensure that you follow all national, state / provincial and local regulations dealing with fire fighting in effect in your specific geographic region. Regulations will vary from region to region but most will usually require that:

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

•

1. Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

1. The fire is small and not rapidly spreading.

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

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

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

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

6. If possible a dry chemical fire extinguisher

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

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

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

•

Before deciding to fight the fire, be certain that:

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

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

•

If operating the machine when a fire occurs:

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

1.22

or fire suppression system** should be used first to fight a machine fire.

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

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

Tigercat AD610C Carrier

Safety What to do after a MACHINE fire HAS OCCURRED

fire prevention •

•

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

•

•

Before returning the machine to work.

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

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

Break the plastic seal as the pin is pulled.

2. Ensure that the fire detection system*

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

•

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

•

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

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

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

•

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

*NOTE: Fire detection systems are offered by

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

**NOTE: Dry chemical fire suppression systems

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

20229A

• • •

• •

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

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

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

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

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

Remain with the machine until help arrives.

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Tigercat AD610C Carrier

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

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

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

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

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

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

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

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

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

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

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

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

1.24

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

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

Tigercat AD610C Carrier

Safety NO RIDERS

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

EMERGENCY EXIT HAND TIGHTEN ONLY

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

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

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

Persons riding on the outside of the machine are subject to hazards such as falling off the machine, crush hazards, thrown object hazards and many other hazards which cOULD result in death OR serious injury.

If any person attempts to climb onto the machine during operation, STOP THE MACHINE IMMEDIATELY. Do Not Operate the machine until other personnel are a safe distance away from the machine.

1.25

Tigercat AD610C Carrier

Safety

safety labels

READ OPERATOR'S MANUAL

USE SEAT BELT

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

Pay close attention to WARNINGS and HAZARD identifications.

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

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

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Tigercat AD610C Carrier

Safety REMOVE IGNITION KEY BEFORE SERVICING THE MACHINE!

safety labels OPERATOR'S MANUAL LOCATION

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

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

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Tigercat AD610C Carrier

Safety ARTICULATION LOCK

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

rear chassis AD610C-10

retaining pins

ARTICULATION LOCK stored position

CRUSH HAZARD This label warns of the crush zone in the center joint area. This can occur when the machine steering is used. DO NOT WORK IN THIS AREA until the ARTICULATION LOCK BAR is installed!

630d-03

ARTICULATION LOCK in straight locked position

Before working in the center joint area, install the chassis articulation lock bar between the chassis and center joint to prevent accidental articulation which could result in death or serious injury.

Refer to ARTICULATION LOCK in section 3 of this manual for complete instructions.

630d-01

ARTICULATION LOCK in articulated locked position

43304BUNI R0

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Tigercat AD610C Carrier

Safety ENTANGLEMENT HAZARD

safety labels CRUSH HAZARD

This label warns of the crush zone by a down force when the cab is in the partial tilt position.

DO NOT WORK IN THIS AREA until the CAB TILT SUPPORT LOCK is in PLACE! Before working under the cab when the cab is in the partial tilt position, be sure the CAB TILT SUPPORT LOCK is in place.

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

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

36779BUNI R0

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

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

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

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Tigercat AD610C Carrier

Safety DO NOT LOOSEN CAP UNTIL COOL

safety labels do not use winch for hoisting

43225BUNI R0

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

DO NOT use winch for hoisting.

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

Refer to OPERATING MACHINE ~ OPERATING WINCH and SKIDDING ~ CABLE SKIDDING in SECTION 2 of the OPERATOR'S MANUAL for instructions regarding the safe use and proper operation of the winch.

33952AUNI R0

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

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

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

1.30

Tigercat AD610C Carrier

Safety fluid spray hazard

safety labels STORED ENERGY HAZARD

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

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

Contact with fluid under pressure may cause injury.

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

• STORED ENERGY HAZARD • THE ACCUMULATOR HAS 3000 PSI OF STORED ENERGY. SERVICING THE ACCUMLATOR BEFORE RELEASING PRESSURE COULD RESULT IN DEATH OR SERIOUS INJURY.

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

Refer also to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of THIS MANUAL.

• DO NOT SERVICE THE ACCUMULATOR BEFORE RELEASING PRESSURE BY APPLYING BRAKES 25 TIMES WITH ENGINE OFF. 39945BENG R0

This label warns of a STORED ENERGY HAZARD. This label is located on the right side of the front chassis below the cab.

The machine is equipped with an accumulator (located on the underside of the cab). The accumulator has 207 bar (3000 psi) of stored energy. Servicing the accumulator or any hydraulic components before releasing pressure could result in death or serious injury.

DO NOT SERVICE ACCUMULATOR before releasing pressure by applying brakes 25 times with the engine OFF.

1.31

Tigercat AD610C Carrier

Safety

safety labels EXPLOSION HAZARD

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

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

Using ether could cause an explosion which could result in death or serious injury.

1.32

Tigercat AD610C Carrier

Safety

AD610C-206

CRUSH HAZARD This label is located on the aerial device beside the lower controls.

This label warns of a CRUSH HAZARD that exists when operating the aerial device from the lower controls.

KEEP CLEAR of potential crush zones between the platform and the aerial device as it moves.

NEVER have any part of your body between aerial device moving parts and the platform.

AD610C-205

KEEP CLEAR OF CRUSH ZONES WHEN OPERATING LOWER CONTROLS

Always take care to position your body clear of the crush zone between the steps and the aerial device as it moves. Particular care should be taken when rotating the aerial device close to the steps on the platform. Stop the aerial device and move carefully from one level of the platform to another as required to safely access the controls and avoid placing any part of your body between the aerial device moving parts and the platform.

Failure to keep clear of the crush zones could result in serious injury or death.

1.33

Tigercat AD610C Carrier

Safety PRESSURIZED WATER SYSTEM INSIDE HAND TIGHTEN ONLY

safety labels

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

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

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

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

All handles should be hand tight only at all times.

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

This label also located on the storage compartment on the left side of the dozer blade.

1.34

Tigercat AD610C Carrier

Safety fire extinguisher ACCESS HOLE

safety labels FIRE PREVENTION!

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

Refer also to FIRE PREVENTION in THIS SECTION.

Read understand and follow the FIRE PREVENTION guidelines in this manual.

These guidelines provide all the necessary action required to preventing fires on this machine. DO NOT OPERATE THIS MACHINE until you have read these instructions and have performed any necessary maintenance required that will prevent the potential of a fire from starting on this machine.

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

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

1.35

Tigercat AD610C Carrier

Safety

1.36

Tigercat AD610C Carrier SECTION 3 - LUBRICATION & MAINTENANCE CONTENTS - SECTION 3 AIR CLEANER MAINTENANCE....................................................................3.28 AIR CONDITIONING SYSTEM, CHECKING.................................................3.34 APPROVED HYDRAULIC OILS....................................................................3.13 ARTICULATION LOCK...................................................................................3.31 AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS..........................................................................3.39 AXLE PINION SEAL GREASE FITTING........................................................3.39 CAB SAFETY CABLE....................................................................................3.37 CAB SUPPORT BRACE................................................................................3.37 CENTER JOINT LUBRICATION............................................................................................3.30 MAINTENANCE..........................................................................................3.30 DEPRESSURIZING SUSPENDED MACHINE ELEMENTS..........................3.27 Draining Engine Coolant.....................................................................3.25 DRAINING HYDRAULIC TANK......................................................................3.24 Draining Parking Brake oil.................................................................3.26 DRAINING THE FUEL TANK............................................................... 3.20, 3.21 Draining Transmission oil...................................................................3.26 EMERGENCY EXITS, CHECK MONTHLY......................................................3.7 Filling hydraulic tank..........................................................................3.24 FILTERS CHARGE PRESSURE FILTER...................................................................3.23 FUEL FILTER/WATER SEPARATOR..........................................................3.18 FUEL TANK STRAINER.............................................................................3.18 HYDRAULIC OIL DOUBLE FILTERS.........................................................3.21 SERVICING GUIDELINES FOR OIL FILTERS...........................................3.21 FIRE PREVENTION.........................................................................................3.8 GENERAL MAINTENANCE..................................................................... 3.7, 3.8 HOUR METER ~ MAINTENANCE...................................................................3.3 LUBRICATION AND SERVICE POINTS 6109001 TO 6109020.................................................................................3.15 6109021 TO 6109250.................................................................................3.17 NEW MACHINE MAINTENANCE....................................................................3.3 FIRST 125 HOUR INSPECTION AND SERVICE REPORT.........................3.3 INITIAL PRE-DELIVERY INSPECTION........................................................3.3 OIL LOST FROM LEAKAGE............................................................................3.7 OIL SAMPLE COLLECTION PROCEDURES..................................................3.5 OIL SAMPLING PROGRAM............................................................. 3.4, 3.5, 3.6 PRESSURIZED WATER SYSTEM MAINTENANCE.....................................3.32 SCHEDULED MAINTENANCE 8 HOURS......................................................................................................3.9 48 HOURS....................................................................................................3.9 125 HOURS................................................................................................3.10 250 HOURS................................................................................................3.10 500 HOURS................................................................................................ 3.11 1000 HOURS.............................................................................................. 3.11 2000 HOURS..............................................................................................3.12

DECEMBER 2010

Tigercat AD610C Carrier

Lubrication and Maintenance

SEASONAL.................................................................................................3.12 SERVICE AND LUBRICATION POINTS 6109001 TO 6109020.................................................................................3.15 6109021 TO 6109250.................................................................................3.17 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE............................................................................3.40 TILTING THE CAB.........................................................................................3.36 LOWERING THE CAB................................................................................3.37 RAISING THE CAB.....................................................................................3.36 TIRE PRESSURES........................................................................................3.48 TORQUE, FLUID CONNECTIONS............................................ 3.44, 3.45, 3.46 TORQUE SPECIFICATIONS - GENERAL.....................................................3.43 WEIGHTS OF COMMERCIAL WOOD...........................................................3.47 WHEELS, INSTALLING....................................................................................3.3 WINCH MAINTENANCE................................................................................3.38

3.2

Tigercat AD610C Carrier

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR AD610C Carrier NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBER 5339; "PDI AND 125 HOUR INSPECTION REPORT"

*FIRST 125 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBER 5339; "PDI AND 125 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 125 HOUR TIME FRAME. *IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY, THIS REPORT MUST BE COMPLETED AND RETURNED TO Tigercat Industries Inc. WARRANTY DEPARTMENT.

IMPORTANT!

TIGHTENING POINTS FOR:THE FIRST 125 HOUR INSPECTION REPORT:~

WHEELS:

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

All hydraulic connections Hose clamps Center joint pin securing bolts Transmission securing bolts Engine mounting bolts Axle mounting bolts Wheel retaining bolts Cab securing bolts Pin retainers Any other loose nut, bolt or fitting

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

HOUR METER ~ MAINTENANCE: Check the hour meter on a regular basis to determine your scheduled maintenance times.

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

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

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

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

3.3

Tigercat AD610C Carrier

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM Using the Tigercat Advanced Oil Analysis Program on a regular basis is an excellent preventative maintenance tool.

Studies have shown that it is possible to receive a 10 to 1 payback when looking at the amount saved on repair costs to the amount invested in a scheduled oil analysis program. Some of the benefits of a sampling program include: •

Detect problems early before they become major catastrophic failures.

•

Better ability to schedule downtime and forecast cost of repairs.

•

Monitor maintenance schedules and practices and confirm that the required maintenance is being done on time.

•

Increase used equipment value by providing proof of proper maintenance.

This Program uses the most modern technology available to analyze all oil samples. Most test results are available within 24 hours after receipt of the sample and are supplied in an easy to understand report, which calls for specific action and makes detailed recommendations. This report is available as a mailed or faxed hardcopy, sent via e-mail or can be viewed on the internet.

This program will provide Tigercat machine owners access to an Advanced Oil Analysis Program for all major machine components including Engines, Hydraulic Circuits, Axles, Final Drives, Gearboxes, etc.

600 Series Utility Vehicle Models Location Hydraulic Oil Transmission Axles – Front & Rear

First Sample Follow-up Samples 125 Hours Every 1000 Hours or 6 Months 125 Hours Every Oil Change (500 Hours or 3 Months) 125 Hours Every Oil Change (1000 Hours or 6 Months)

Tigercat Oil Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required followup oil samples.

Refer also to OIL SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain plug locations.

TIGERCAT OIL ANALYSIS KITS Each kit includes a Pre-paid Sample Bottle and Sample Information Form. Pre-printed mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

The same type of sample bottle can be used for all types of oil testing including: Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.

To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on how properly collect, prepare and ship the oil samples.

Contact your Tigercat Dealer Parts Department to order Kits.

3.4

Tigercat AD610C Carrier

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM OIL SAMPLE COLLECTION PROCEDURES Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple oil samples, fill out all of the required SIF forms in their entirety, prior to taking any oil samples. Then, immediately package each completed SIF form together with the matching oil sample in the black outer shipping container as each individual sample is taken. This will reduce the possibility of mixing up or incorrectly identifying the SIF forms and oil samples. Incorrectly identified samples could result in a false warning alarm.

HYDRAULIC SAMPLE VALVE

MAIN HYDRAULIC OIL

The accuracy of the lab analysis results is very dependent on the quality of the oil sample taken. Collection of clean oil samples that are representative of the main body of oil are essential if meaningful lab results are to be obtained.

Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all follow-up samples should be consistently taken from the same location using the same techniques as all previous samples.

•

Ensure that all sample valves and drain plugs are clean and free of debris.

•

Remove the sample bottle cap only when ready to take the sample. Keep the cap clean – do not put it in your pocket or let it get contaminated in any way.

•

Do not allow any airborne dirt, etc. to enter the sample bottle.

•

Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full.

OS MAIN 604 610 620C

Hydraulic Oil Samples:

All samples taken should be immediately forwarded to the lab for processing.

Contact your Tigercat dealer to purchase additional or replacement hydraulic sample valves or drain plugs.

In cases where oil samples must be pumped or otherwise drawn out of a reservoir or housing, a hand operated oil suction pump is also available from your Tigercat dealer.

3.5

•

Hydraulic oil samples should be taken from the circulating oil flow at operating temperature, with no functions actuated, using sample valves that are permanently located on the machine whenever possible.

•

To obtain a representative oil sample, sample valves must be purged before the actual oil sample is taken. Drain a minimum of 3 or 4 ounces of oil into a separate container and discard this oil using approved recycling methods.

•

Replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

Tigercat AD610C Carrier

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM Transmission and Axle Oil Samples: •

These samples can be taken during the oil change process.

•

To obtain a representative oil sample, ensure the oil is warm and has not settled very long (within 30 minutes of shutdown).

•

Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

•

Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

MACHIINES 6109001 TO 6109020

sample location / transmission drain 630c-100

transmission oil

axle level check and fill

axle drain

axle drain 610-01

SAMPLE LOCATION axle drain

REFER ALSO TO AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS IN THIS SECTION FOR MORE INFORMATION.

AXLE DRAIN AND FILL LOCATIONS (REAR axle shown) axle level check and fill (FAR SIDE)

MACHIINES 6109021 TO 6109250

axle level check and fill

SAMPLE LOCATION axle drain

S610-01

AXLE DRAIN AND FILL LOCATIONS 3.6

REFER ALSO TO AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS IN THIS SECTION FOR MORE INFORMATION.

Tigercat AD610C Carrier

Lubrication and Maintenance

GENERAL Inspect the EXHAUST SYSTEM DAILY for any signs of leakage. Check for worn, cracked, broken, or damaged pipes or muffler.

Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

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

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

Plug or cap immediately

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

Clean up spills as soon as possible Always use clean oil and containers Drain dirty oil while still warm Do not exceed recommended fluid levels Service all hydraulic filters after the failure of a pump, motor, cylinder or valve. Failures of this nature could contaminate the entire hydraulic system

Always have a fire extinguisher at hand

Top up diesel fuel at end of each shift to reduce contamination by condensation

For safety; when leaving the cab or leaving machine unattended or during service, always lower dozer blade to the ground

Clean up oil spills on walking surfaces and top of engine enclosure immediately

For safety, always block or support attachment and dozer blade when working under them.

Before welding on machine be sure master switch is disconnected

CHECK EMERGENCY EXITS MONTHLY~

When welding secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings

Alternate exit routes are provided: the sliding windows in the cab doors. These are only to be used if the cab doors cannot be opened.

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires

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

*Oil lost from leakage Lost 0il (LITERS) Lost 0il (GALLONS) per per per per per per Leakage rate day month year day month year One drop In 10 Seconds 0.424 12.72 152.0 0.112 3.36 40.0 One drop In 5 Seconds 0.852 25.6 306.6 0.225 6.75 81.0 One drop per second 4.26 127.76 1533.1 1.125 33.75 405.0 Three Drop per Second 14.2 425.86 5110.31 3.75 112.5 1350.0 Drops Break Into Stream 90.83 2725.5 32706.0 24.00 720.0 8640.0

3.7

Tigercat AD610C Carrier

Lubrication and Maintenance

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

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

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

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

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

4. In case of fire lower the boom system to the ground and 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.

3.8

Tigercat AD610C Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE frequently:~

Check:~ • All engine air intake system components (including charge air cooler) rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair immediately.

• Check engine cooling air intake screens for possible restriction.

Every 8 hours (every shift):~ • Perform "frequently" maintenance check, and in addition:~ • Check engine coolant level

• Charge Air Cooler for damage, wear, cracks, or leaks and repair immediately.

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

• Check engine oil level • Drain secondary fuel filter/water separator

• For loose nuts, bolts and fittings

• Check air intake precleaner, clean as required

• Condition and tension of fan belts.

• Check air cleaner unloader valve

• Exhaust system for leaks.

• Check air intake filter restriction indicator.

• Water pressure (60 psi [4 Bar]) for pressurized water system.

Replace primary filter if indicator is in red zone.

Replace secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

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

• Check hydraulic oil level with crane stowed and dozer blade on the ground

• Conduct an overall visual inspection.

• Check winch sump oil level

• Inspect winch, control valve, and connecting hoses for damage or hydraulic oil leakage.

Check that the wire cable is in good condition.

If any problems are found, they should be corrected before operating the winch.

• Check transmission oil level with dipstick • Lubricate front axle pivot, 2-fittings, purge • Lubricate mid drive shaft 1-fitting, purge Note: Lubrication of mid drive shaft slip joint should be done with machine fully articulated and locked. Refer also to ARTICULATION LOCK ~ ARTICULATED LOCKED POSITION in THIS SECTION.

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

• Lubricate center joint bearings, 2-fittings, purge

every 48 hours

• Lubricate steering cylinder ends, 4-fittings, purge • Lubricate dozer blade cylinders and pivots, 6-fittings, purge Clean:~ • Potentially damaging limbs or sticks from machine • A/C condenser, oil cooler, radiator refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR'S MANUAL.

3.9

• 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.

Tigercat AD610C Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE Every 125 hours:~

Every 250 hours:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

And in addition:~ • Carry out A/C system inspection; Refer to AIR CONDITIONING SYSTEM, CHECKING in THIS SECTION

• Perform 125 hour maintenance And in addition:~ • Replace primary fuel filter and secondary fuel filter/water separator

Check:~ • Check oil level in front and rear axles. Refer to AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION.

• Check parking brake oil level

• Fluid level in batteries unless maintenance free

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

• Engine rpm.

• All hydraulic pressures • Hydraulic pump and motor securing bolts • Check fuel tank filler screen • Torque tightening points as per new machine maintenance • Proper operation of pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. Visually check for damage to:• Front and rear frame • Center joint area • Attachment Make repairs immediately Visually inspect for:• Frayed electrical wiring and hydraulic hose • Wear in any other components • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

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

3.10

Tigercat AD610C Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE Every 500 hours:~

Every 1000 hours:~

• Perform "frequently" maintenance

• Perform "frequently" maintenance

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

• Perform 250 hour maintenance

• Perform 250 hour maintenance

And in addition : ~ • Replace hydraulic oil double element filters (2 elements) † 1 white, high performance element.

1 blue, water absorbing element.

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

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

• 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.

• Lubricate door hinges, 12-fittings, purge

• Replace oil in winch sump.

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

• Replace oil in parking brake.

• Replace charge pressure filter † • Replace oil in transmission.

• Lubricate front drive shaft 1-fitting, purge

• Drain and refill front and rear axles. Refer to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils.

Refer also to AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION. • Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION. • Lubricate front axle pinion grease seal (if equipped (6109021 to 9109250) • Lubricate rear axle pinion grease seal (if equipped (6109021 to 9109250) • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

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

3.11

Tigercat AD610C Carrier

Lubrication and Maintenance

SCHEDULED MAINTENANCE 2000 hours:~ • Replace all air intake rubber components such as elbows and connectors - High temperatures in this area can cause the rubber to harden.

See AIR INTAKE MAINTENANCE in THIS SECTION • Check all air intake tubing, rubber couplings and band clamps for signs of wear and leakage • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

SEASONAL:~ • Drain and refill hydraulic oil tank with recommended hydraulic oil. Refer to approved hydraulic oils in THIS SECTION. Fill tank with crane stowed and the dozer blade on the ground until hydraulic oil level reaches the sight gauge full mark. Note that the oil level will drop 2 to 3 in (2 to 7.5 cm) when all cylinders are extended.

Check to ensure that the hydraulic oil type selected in the computer program matches the oil type being used. Adjust oil type if needed.

This will allow the program to optimize the cooling and s functions to best suite the oil being used.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge. Operating outside the recommended operating range will shorten hydraulic component life. Refer to COMPUTER ~ ADJUSTMENT MENU - SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in SECTION 2 of the OPERATOR'S MANUAL or SECTION 6 of the SERVICE MANUAL, for hydraulic oil grade selection settings information.

• Drain and refill front and rear axles. Refer to LUBRICATION AND SERVICE CHART in THIS SECTION for recommended gear oils.

Refer also to AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS in THIS SECTION. • Drain and refill pressurized water system.

Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in THIS SECTION.

3.12

Tigercat AD610C Carrier

Lubrication and Maintenance

APPROVED HYDRAULIC OILS Use only one of the following oils to fill or replenish the MAIN HYDRAULIC SYSTEM.

3.13

Tigercat AD610C Carrier

Lubrication and Maintenance

machines 6109001 to 61009020

3.14

Tigercat AD610C Carrier

Lubrication and Maintenance

machines 6109001 to 61009020 Tigercat® Model AD610C SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

CHK

2

ENGINE OIL/FILTER CUMMINS QSB SERIES

CHK

3 3A

•

PRIMARY FUEL FILTER SECONDARY FUEL FILTER/WATER SEPARATOR

DRN

34.4

9.1

•

•

qTY

2000 6

1000 6

500 6

CHANGE COOLANT EVERY 2 YEARS

DESCRIPTION USG

COOLING SYSTEM

CAPACITY LITERS

1

250 6

86

ITEM

125 6

SERVICE POINT NO.

SERVICE EVERY

60/40 ANTIFREEZE *

• SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS

REP

1

REP

1

4

FUEL TANK FILLER SCREEN

5

AIR INTAKE PRECLEANER/INLET HOOD

CHK

1

CLEAN AS REQUIRED

AIR INTAKE PRIMARY ELEMENT

CHK

1 1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENCE FOR DETAILS.

1

REFER TO SECTION 3 IN MANUAL

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

1

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

6

CHK

1

AIR INTAKE SAFETY ELEMENT

CHK

7

AIR CLEANER UNLOADER VALVE

CHK

8

AIR INTAKE CONNECTIONS

CHK

9

HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10

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

REP †

2

*NOTE: MUST USE: 1 BLUE FILTER ELEMENT 1 WHITE FILTER ELEMENT

11

CHARGE PRESSURE FILTER

REP †

1

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

12

WINCH: DP

CHK

13

PRESSURIZED WATER SYSTEM

CHK

14

TRANSMISSION

CHK

15

AXLES: FRONT REAR

16

CAST

AXLE-PIVOT (FRONT ONLY)

REP REP

89

TEST

MID DRIVE SHAFT

1.89

0.5

REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL

D/R

52

13.7

SEASONAL DRAIN AND REFILL

6

1.6

1

36 36

9.5 9.5

1 1

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

PURGE

2

LITHIUM BASE EP2 GREASE u

PURGE

1

LITHIUM BASE EP2 GREASE u

PURGE

2

LITHIUM BASE EP2 GREASE u

D/R ***

LUB

FRONT DRIVE SHAFT 17

D/R

D/R

CHK

23.5

LUB LUB **

REAR DRIVE SHAFT

LUB

CENTER JOINT

LUB

CENTER JOINT BEARING PRELOAD

CHK 48 6

19

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE u

20

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE u

21

AERIAL DEVICE

18

22

PARKING BRAKE

Lubechart-46651BENG R0A.pdf

REFER TO SECTION 3 OF THE MANUAL FOR DETAILS

CHK

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

CHK

3.15

D/R

0.5

0.1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

Tigercat AD610C Carrier

Lubrication and Maintenance

machines 6109021 to 61009250 DOOR HINGES

MID DRIVE SHAFT

4 FTG/500

12

1 FTG/8

REAR DRIVE SHAFT

1 FTG/500

12

AXLE-PIVOT, FRONT 2 FTG/8 17 DOOR HINGES

STEER CYLINDERS 20 4 FTG/8

2

1

13

8 FTG/500

4

22

3

3A

11

10

23

18

18

9

10 11

6 7

1

5

8

19

15 AXLE PINION

1 FTG/1000

16

18

CENTER JOINT

2 FTG/8

14

FRONT DRIVE SHAFT

1 FTG/500

16

AXLE PINION

1 FTG/1000

DOZER

6 FTG/8

15

21

LEGEND

* ANTIFREEZE SOLUTION MUST MEET GM 6038M SPECIFICATIONS - SEE MANUFACTURERS MAINTENANCE MANUAL ** STEER MACHINE FULLY BEFORE GREASING MID DRIVE SHAFT SLIP YOKE. *** MAY USE UP TO BUT NOT MORE THAN 1 LITER OF LUBRIZOL 6178, DSL-178, OR EQUA-TORQUE 2411 OR 2414 (FRONT AXLE ONLY, BRAKE NOISE REDUCTION).

LUBRICATION POINT WITH A DESIGNATED NUMBER OF FITTINGS (2FTG) AND HOURS BETWEEN SERVICING (125 ). JOINT TO BE PURGED.

2 FTG/125 

USE LITHIUM BASED GREASE CONTAINING MOLYBDENUM DISULFIDE. USE OF FILTERS OTHER THAN GENUINE Tigercat REPLACEMENT FILTERS IS NOT RECOMMENDED. ®

3.16

CHK REP DRN D/R LUB

..... ..... ..... ..... ..... .....

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

Tigercat AD610C Carrier

Lubrication and Maintenance

machines 6109021 to 61009250 Tigercat® Model AD610C SERVICE AND LUBRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

CHK

2

ENGINE OIL/FILTER CUMMINS QSB SERIES

CHK

3

PRIMARY FUEL FILTER

3A

•

34.4

9.1

•

•

REP

SECONDARY FUEL FILTER/WATER SEPARATOR

DRN

qTY

2000

1000

500

CHANGE COOLANT EVERY 2 YEARS

DESCRIPTION USG

COOLING SYSTEM

CAPACITY LITERS

1

250

8

ITEM

125

SERVICE POINT NO.

SERVICE EVERY

60/40 ANTIFREEZE *

• SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS 1

REP

1

4

FUEL TANK FILLER SCREEN

5

AIR INTAKE PRECLEANER/INLET HOOD

CHK

1

CLEAN AS REQUIRED

AIR INTAKE PRIMARY ELEMENT

CHK

1

6

CHK

AIR INTAKE SAFETY ELEMENT

CHK

7

AIR CLEANER UNLOADER VALVE

CHK

8

AIR INTAKE CONNECTIONS

CHK

9

HYDRAULIC RESERVOIR (GAUGE ON TANK)

CHK

10

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

11

CHARGE PRESSURE FILTER

12

WINCH: DP

CHK

13

PRESSURIZED WATER SYSTEM

CHK

14

TRANSMISSION

CAST

15

AXLES: FRONT REAR

16

PINION GREASE SEAL - FRONT AND REAR AXLE

17

AXLE-PIVOT (FRONT ONLY)

1

MID DRIVE SHAFT

1

REFER TO SECTION 3 IN MANUAL

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

1

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

REP †

2

*NOTE: MUST USE: 1 BLUE FILTER ELEMENT 1 WHITE FILTER ELEMENT

REP †

1

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

REP REP

89

TEST

CHK

1.89

0.5

D/R

52

13.7

D/R ***

CHK

23.5

D/R

D/R

LUB LUB

FRONT DRIVE SHAFT 18

1

CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENCE FOR DETAILS.

REFER TO WINCH MAINTENANCE IN SECTION 3 OF MANUAL. SEE ALSO WINCH MANUFACTURER'S MANUAL SEASONAL DRAIN AND REFILL

6

1.6

1

24.6 26.5

6.5 7.0

1 1

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

PURGE

2

ONE FITTING PER AXLE LITHIUM BASE EP2 GREASE

PURGE

2

LITHIUM BASE EP2 GREASE

PURGE

1

LITHIUM BASE EP2 GREASE

PURGE

2

LUB LUB **

REAR DRIVE SHAFT

LUB

CENTER JOINT

LUB

CENTER JOINT BEARING PRELOAD

CHK 48

20

STEERING CYLINDERS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE

21

DOZER BLADE CYLINDER & PIVOTS

LUB

PURGE

6

LITHIUM BASE EP2 GREASE

22

AERIAL DEVICE

19

23

PARKING BRAKE

Lubechart-49232BENG R0.pdf

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

CHK

SEE MANUFACTURER'S MAINTENANCE SCHEDULE

CHK

3.17

D/R

0.5

0.1

FILL WITH MIL-L-2105C OR API-GL-5 LUBRICANT GRADE/WEATHER TEMPERATURE: BELOW -10°F(-23°C) USE 75W-90 UP TO 100°F(38°C) USE 80W-90 ABOVE 100°F(38°C) USE 85W-140

Tigercat AD610C Carrier

Lubrication and Maintenance

FILTERS

WARNING

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.

The fuel pump high-pressure fuel lines and fuel rail contain very high pressure fuel.

Never loosen any fittings while the engine is running. Personal injury and property damage can result.

Changing the primary fuel filter:

primary FUEL FILTER and secondary fuel filter/water separator (cummins qsb engine) This machine is equipped with two fuel filters.

The secondary fuel filter is a combination unit, with a replaceable fuel filter with drain valve and a reusable water in fuel sensor. For service and replacement intervals see SERVICE AND LUBRICATION POINTS in THIS SECTION. Refer also to engine manufacturer's manual for more detailed information. primary fuel FILTER

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

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. Dispose of any fuel and the fuel filter properly.

5. Check the seating area for the o-ring on the filter head and wipe clean.

6. Lubricate the o-ring on top of the new filter with clean engine oil. DO NOT PRE-FILL the new filter.

7. Screw the new filter on to the filter head as specified by the filter manufacturer. Note: Mechanical overtightening can damage the filter element.

secondary fuel FILTER/ water separator

8. Prime the fuel system using the hand primer on the secondary fuel filter/water separator before starting the engine.

610C-12

Loosen the plug on the top of the secondary fuel filter. Pump the hand primer until fuel begins to seep out around the loosened plug, continue to pump until no air bubbles are visible (approximately 30 pumps). Tighten the plug. Pump the hand primer 30 more times.

fuel water separator

WARNING Drain fuel filter into a container and dispose of all fluids properly.

9. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL.

3.18

Tigercat AD610C Carrier

Lubrication and Maintenance

Changing the secondary fuel filter/water separator: 1. Park machine on level ground, install articulation lock bar, lower dozer to the ground, stop engine, engage parking brake and block wheels.

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

3. Use filter drain to drain fuel out of the filter for approximately 5 seconds. This will prevent fuel from running over the top of the filter when it is removed.

4. Disconnect the water in fuel sensor from the wiring harness.

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

6. Wearing face protection (in case of a fuel spray) unscrew the old filter. Dispose of any fuel properly .

8. Install the water in fuel sensor in the new filter.

(Inspect water in fuel sensor for damage and replace as required.)

9. Check the seating area for the o-ring on the filter head and wipe clean.

10. Lubricate the o-ring on top of the new filter with clean engine oil. DO NOT PRE-FILL the new filter.

11. Screw the new filter on to the filter head as specified by the filter manufacturer. Note: Mechanical overtightening can damage the filter element.

12. Connect water in fuel sensor to the wiring harness.

13. Prime the fuel system using the hand primer on the secondary fuel filter/water separator before starting the engine.

Loosen the plug on the top of the secondary fuel filter. Pump the hand primer until fuel begins to seep out around the loosened plug, continue to pump until no air bubbles are visible (approximately 30 pumps). Tighten the plug. Pump the hand primer 30 more times.

7. Remove the water in fuel sensor from the fuel filter. Dispose of the fuel filter properly. primary fuel FILTER

14. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2 of the OPERATOR'S MANUAL.

OUTLET CONNECTION

plug hand primer secondary fuel FILTER/ water separator

610C-12

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.

WARNING Drain fuel filter into a container and dispose of all fluids properly.

fuel water separator

drain valve water in fuel sensor

610c-15

secondary fuel filter/ water separator

3.19

Tigercat AD610C Carrier

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.

COVER

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 to the ground , stop engine, engage parking brake and block wheels.

2. Drain the fuel tank. Refer to DRAINING THE FUEL TANK in THIS SECTION.

AD610C-07

fuel tank

DRAINING THE FUEL TANK 1. The fuel system is equipped with two standard saddle tanks. A siphon should be used to drain the fuel tanks.

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.

2. Use the fuel gauge on the computer display or the dipstick to estimate the container capacity required to properly drain the fuel.

Refer to FUEL TANK in SECTION 2 of the OPERATOR'S MANUAL for tank capacities.

REAR COVER

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.

RIGHT HAND TANK

LEFT HAND TANK

3. To access the fuel tanks, remove the cover.

Remove the fuel tank filler cap and filler screen on the right hand fuel tank.

Remove the rear cover on the left hand fuel tank. Care should be taken to avoid damaging the fuel level sender mounted on this cover.

Siphon fuel from both the left and right hand tanks into the container.

Once fluid has been drained replace the filler cap, filler screen and cover.

3.20

Tigercat AD610C Carrier

Lubrication and Maintenance

HYDRAULIC OIL DOUBLE ELEMENT FILTERS hydraulic tank

double element filter

HYDRAULIC FILTER SERVICING GUIDELINES

breather

NEVER PRE-FILL HYDRAULIC FILTERS

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 prefill 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.

BLUE ELEMENT sight gauge

hydraulic hand fill pump CHARGE PRESSURE FILTER

610C-11

WARNING

hydraulic tank, filters and sight gauge

The hydraulic oil cooling circuit contains a double filter head with a built in 25 psi (1.7 Bar) 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. It is recommended that all machines use two different filter elements:

Warning, HOT FLUIDS and hot machine surfaces can cause serious burns!

•

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

•

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

•

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

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

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

Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs.

Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in SECTION 3 of THIS MANUAL. Use of hydraulic filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

3.21

Tigercat AD610C Carrier

Lubrication and Maintenance

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

hydraulic tank

double element filter

breather

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

BLUE ELEMENT

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

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

sight gauge

5. The new Tigercat spin-on filter is supplied with two gaskets. The round ('O' ring style) section gasket is used for all return filters. Discard the square section gasket.

FILTER HEAD

hydraulic hand fill pump CHARGE PRESSURE FILTER

GASKET 610C-11

FILTER ELEMENT FILTR_SEALS 2

'O' Ring Gasket INSTALLATION

Remove used gasket and clean gasket seat in head.

Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

Screw on new filter until gasket makes contact.

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

3.22

hydraulic tank, filters and sight gauge

Tigercat AD610C Carrier

Lubrication and Maintenance

CHARGE PRESSURE FILTER The charge circuit contains a single element, full flow Tigercat hydraulic filter with a 50 psi (3.5 Bar) third port bypass valve. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the charge circuit.

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

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

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

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

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. 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.

9. Hand tighten filter an additional 1/2 turn only.

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.

3.23

Tigercat AD610C Carrier

Lubrication and Maintenance

DRAINING HYDRAULIC TANK to tank via filters

CAUTION Perform the hydraulic tank drain when the hydraulic oil temperature is below 100°F (38°C), but warm enough to be viscous.

1. The hydraulic tank is equipped with a hose that routes from the bottom of the tank to the bottom of the front chassis belly pan.

hand fill pump

shut-off valve in off position

2. The hose is plugged at the end and can be accessed by removing the belly pan door.

3. The drain hose for the hydraulic tank can be lowered from the belly of the chassis and positioned in a drip pan.

quick connect to suction hose (stored in step Compartment below left hand cab door)

4. Remove the plug in the hose end to drain tank.

5. Once fluid has been drained, replace the drain plug in the drain hose.

Filling hydraulic tank

610C-11

Refer to approved hydraulic oils in THIS SECTION. Refer to SERVICE AND LUBRICATION POINTS chart in THIS SECTION for hydraulic tank capacity.

hydraulic HAND FILL PUMP

IMPORTANT !

Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs.

Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in SECTION 3 of THIS MANUAL.

1. Park machine on level ground, lower dozer blade onto the ground.

2. Open right rear engine compartment access panels.

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

3. Get the hydraulic oil fill suction hose from its storage location in the step compartment below the left cab door. Clean the suction hose, connect to hydraulic hand pump and remove cap.

4. Open oil fill shut-off valve, insert end of suction tube into supply drum and operate pump. The oil is pumped directly into the hydraulic tank via the double element filter.

The pump should always be operated at a medium speed with a steady motion. Refer also to HYDRAULIC HAND FILL PUMP in SECTION 2 of the OPERATOR'S MANUAL. Fill tank with crane stowed and the dozer blade on the ground until hydraulic oil level reaches the sight gauge full mark. Note that the oil level will drop 2 to 3 in (2 to 7.5 cm) when all cylinders are extended.

5. Close shut-off valve after filling. Replace cap on suction tube, wipe dry, disconnect and store. Swing pump handle up and lock.

Replace all access covers.

3.24

Tigercat AD610C Carrier

Lubrication and Maintenance

Draining Engine Coolant

CAUTION DO NOT remove the coolant filler cap from a hot engine. Wait until coolant temp is below 122°F (50°C) before removing cap.

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

1. The radiator is equipped with a hose to drain the contents of the radiator system fluid into a storage container.

filler cap 33952AUNI R0

2. Remove the front nose belly pan in the front chassis.

3. Remove the radiator pressure cap.

4. The radiator is located on the right hand side of the heat exchanger.

engine coolant filler cap

620c-36

A/C CONDENSER

DRAIN HOSE

630D-06

SHUT-OFF VALVE

CHARGE AIR COOLER (CAC)

RADIATOR

LOWER RADIATOR TUBE SPUD AND SHUT-OFF VALVE

The lower radiator tube is equipped with a spud and shut-off valve. The drain hose is attached to the shut off valve.

5. Place the free end of the drain hose in a storage container and remove the gear clamp and bolt from the end of the hose.

6. Slowly open the shut-off valve to drain the radiator fluid.

7. Once fluid has been drained, close the shut-off valve and replace the gear clamp and bolt on the drain hose.

3.25

610-03

COOLING ASSEMBLY

HYDRAULIC OIL COOLER

Tigercat AD610C Carrier

Lubrication and Maintenance

Draining Parking Brake oil

Draining Transmission oil

1. The parking brake is equipped with a hose to drain the oil contents of the parking brake into a storage container.

1. The transmission is equipped with a plug to drain the contents of the transmission into a storage container.

2. Remove the belly pan in the rear chassis closest to the articulation joint.

2. Remove the belly pan in the front chassis closest to the articulation joint.

3. The hose is plugged at the end. Place the free end of the drain hose in a storage container and remove the plug.

3. Remove the drain plug on the hydraulic motor side of the transmission (pic).

4. Once fluid has been drained, replace the drain plug in the drain hose.

4. Once fluid has been drained, replace the drain plug in the transmission housing once draining has completed.

drain hose

transmission drain 630d-001

parking brake

630c-100

3.26

transmission oil

Tigercat AD610C Carrier

Lubrication and Maintenance

DEPRESSURIZING SUSPENDED MACHINE ELEMENTS

LET DOWN AUXILLIARY POWER CONTROL

When operator controls cannot be used to lower suspended machine elements due to an engine stall or other machine malfunction, suspended elements can be lowered manually using this procedure.

CRANE - aerial device The aerial device is equipped with a Let Down Auxilliary Power Control. Refer also to aerial device attachment manufacturer's manual.

1. Press and hold the Let Down Auxilliary Power Control to operate the auxilliary pump.

2. Refer to manufacturer's operator's manual for further instructions.

ad610c-14

DOZER 1. When suspended the dozer blade will tend to extend the hydraulic cylinders supporting them due to gravity.

2. Remove the function valve cover in the rear chassis.

Use caution and follow all safety warnings when working in this area. Never stand under an object supported with hydraulics. Always use safety stands or a locking device.

3. Refer to the label in the valve compartment or this manual to locate valve section for the element you wish to lower. Locate the spool limiting set screw at the end of the spool section of interest.

4. Use a wrench to loosen the jam nut that secures the spool limiting set screw. Use an allen wrench to slowly turn the set screw clockwise (IN). Continue until the set screw starts to contact the spool inside the valve.

5. At this point the spool will allow pressurized oil on the rod side of the cylinder to travel to the valve tank port and thus lower the implement.

6. Restore spool limiting set screws to their factory setting and secure jam nuts prior to operating the machine.

Factory settings are dozer section 6mm.

aerial device - let down auxilliary power control

auxilliary pump

ad610c-15

SPOOL LIMITING SET SCREW

620D-09

MAIN VALVE SPOOL LIMITING SET SCREWS

a

b DOZER

WINCH

WARNING

ATTACHMENT PRESSURE

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

DO NOT perform work on valves or piping until all suspended elements are are lowered and engine is shut off.

AD610C-02

3.27

MAIN VALVE

Tigercat AD610C Carrier

Lubrication and Maintenance

air cleaner maintenance

IMPORTANT !

For peak engine performance and maximum fuel economy, please ensure that the air precleaner is regularly checked and cleaned as required. All intake air tubes and clamps should be thoroughly inspected on a regular basis and any damaged or missing components should be replaced immediately.

engine air precleaner air cleaner

610C-08

3

3

air cleaner unloader valve

4

engine air cleaner

2

air precleaner

1

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. The air precleaner should be checked every 8 hours to make sure that foreign materials have not plugged the intake area or the discharge louver area. Clean as required. important !

The air precleaner must be check every 8 hours and cleaned as required.

If the inlet/precleaner is plugged causing a restriction to airflow, reduced engine performance and increased fuel consumption may result.

If a plugged inlet/precleaner is left too long excessive air intake restriction may damage the rubber air intake tube. A damaged air intake tube will lead to ingestion of dirt into the engine which may result in engine failure.

5

630c-19

centri® precleaner operation

OPERATION: 1. Air enters the precleaner.

2. Specially designed vanes move dirty air toward the impeller.

3. The spinning impeller spins the air creating centrifugal force to separate contaminants from the clean air.

4. Contaminants are blown out the discharge louver.

5. Clean air enters the intake to the air cleaner.

Note that the air filter restriction indicator may not function properly if the air intake tube is damaged.

Engine failures due to improper maintenance are not covered by Tigercat or Engine Manufacturer’s Warranty and any such claim will be denied.

3.28

Tigercat AD610C Carrier

Lubrication and Maintenance FILTER RESTRICTION INDICATOR

filter restriction indicator

A filter restriction indicator is connected to the outlet side of the air filter. Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

filter restriction switch (if equipped)

NOTE: Replace the safety element every third primary filter change. air cleaner 610C-10

INTAKE TUBING AND JOINTS

ENGINE AIR PRECLEANER

Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

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.

Replace all air intake rubber components such as elbows and connectors every 2000 hours - High temperatures in this area can cause the rubber to harden.

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

A filter restriction indicator is mounted to the output side of the filter, this should show green when the engine is running under load. Service is required if the indicator shows red. Later machines may be equipped with a switch used to send a signal to the computer control system in the event of a filter restriction.

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.

This valve should be replaced every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. Check and clean the valve.

A good valve should be soft and flexible. If it is plugged, be sure to check the filter elements as they may need replacing as well. Reattach the valve to the tube.

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

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

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

NOTE: This does not apply to oil filters.

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.

Continued on next page

3.29

Tigercat AD610C Carrier

Lubrication and Maintenance center joint

outlet tube

maintenance of center joint Maintenance in this area is usually limited to:

primary element

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. safety element

aircleaner

air filter elements

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.

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

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.

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

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

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.

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

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

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

rear chassis

6. Inspect the new filter for damage.

check for movement in this joint area

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

8. Inspect connections and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points and replace as needed. Leaks in these locations send dust directly to the engine.

dig-003

3.30

front chassis

center joint pre-load check

Tigercat AD610C Carrier

Lubrication and Maintenance

ARTICULATION LOCK ~ straight locked position

ARTICULATION LOCK ~ articulated locked position

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

1. Position machine on level ground and steer machine into a fully articulated position to the right.

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

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

ARTICULATION LOCK

rear chassis AD610C-10

ARTICULATION LOCK

retaining pins

ARTICULATION LOCK stored position

rear chassis AD610C-10

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

ARTICULATION LOCK stored position

3. Remove both retaining pins from the articulation lock. Relocate articulation lock between front and rear chassis. Line up holes on the articulation lock with holes in chassis’ as shown and secure in place with both retaining pins.

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

630d-03

retaining pins

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

ARTICULATION LOCK in straight locked position

630d-01

3.31

ARTICULATION LOCK in articulated locked position

Tigercat AD610C Carrier

Lubrication and Maintenance

pressurized water system maintenance water tank

water control valve

System test This system should be tested once every month by turning the shut-off valve ON and expelling water from the hose end nozzle. A very forceful discharge of water should be obtained. If the water does not come out with force (with pressure gauge reading 60 psi [4 Bar]) the system needs to be PURGED. Refer to PURGING PRESSURIZED WATER SYSTEM in THIS SECTION.

dozer blade

After testing, the tank must be refilled and pressurized to 60 psi (4 Bar). Refer to the following FILL AND CHARGE procedure. This FILL AND CHARGE procedure should be carried out yearly.

hose storage compartment shut-off valve in closed position

620c-41

FILL & CHARGE PRESSURIZED WATER SYSTEM

pressurized water system

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

A water tank is incorporated into the dozer blade and is pressurized to 60 psi (4 Bar). A valve controls the flow of water from the tank to a hose located in the hose storage compartment on the dozer blade.

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

The pressure gauge on the valve should read 60 psi (4 Bar) check system pressure daily. The pressurized water system should be drained and refilled every 1000 hours as per the maintenance schedule.

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. dozer blade

fill plug

water tank

pressure gauge

outlet connection

E625C-104

air charge valve water shut-off valve (shown closed) 620c-42

pressurized water system

3. Close water shut off valve.

4. Fill tank with clean water.

water control valve

When temperatures below 32°F (0°C) are anticipated, use a 60/40 solution of Nontoxic R. V. Antifreeze or other suitable antifreeze.

Antifreeze solution must meet GM 6038M specifications.

Refer also to FIRE PREVENTION in SECTION 1 of THIS MANUAL. 3.32

Tigercat AD610C Carrier 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 (4 Bar).

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 (4 Bar) as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

7. Open the water shut off valve.

8. Discharge about 1/2 US gal (2 L) 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 US gal (8 L) of clean water to the tank.

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

Do not substitute.

10. Close the water shut-off valve.

11. Release pressure and fluid from the hose.

12. Pressurize the system to 60 psi (4 Bar) as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

5. Pressurize the system to 60 psi (4 Bar) as indicated on pressure gauge by connecting an air hose to air charge valve beside the pressure gauge.

13. Return the hose to the hose compartment.

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

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

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

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

9. After the purging operation, fill and charge the system as described in FILL & CHARGE PRESSURIZED WATER SYSTEM in THIS SECTION. 3.33

Tigercat AD610C Carrier

Lubrication and Maintenance

checking the AIR CONDITIONING SYSTEM

CAUTION

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

Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

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

Always use personal protective equipment to guard against flying debris.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT

PAG OIL (polyalkylene glycol)

1.76 kg (3 lbs 14 oz)

0.25 kg (9.0 oz)

CAUTION Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

The compressor and charge valves are accessed from the left side engine compartment. The receiver dryer is mounted in the compartment behind the right cab door, on the outside of the cab.

IMPORTANT !

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

Perform following inspection along with 125 HOURS inspection outlined in SCHEDULED MAINTENANCE in THIS SECTION. a. Check re-circulating and fresh air filters in operator's cab. Refer to SECTION 2 of the OPERATOR'S MANUAL.

b. Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR'S MANUAL. c. Check for dirt and debris; on the evaporator coil located inside the A/C-heater unit and also the inside of the A/C-heater unit. Clean as required. d. Check and adjust compressor drive belt tension. e. Check all A/C hoses for kinks.* f.

check a/c condenser core

g. Check air temperature exiting vents in cab. h. Listen to compressor and blower motor for abnormal noises.* i.

610-03

Run air conditioning system for 3 - 5 minutes.

check a/c condenser core 3.34

Check to see that compressor clutch will engage.*

Tigercat AD610C Carrier

Lubrication and Maintenance

SIGHT GLASS INDICATES CONDITION OF CHARGE

BINARY SWITCH, SYSTEM PROTECTION

MOISTURE INDICATOR BLUE - OK. PINK - REPLACE DRYER, RECHARGE SYSTEM

BACK WALL OF CAB A/C RECEIVER/DRYER

870-D43

j.

A/C RECEIVER/DRYER

Inspect sight glass on receiver dryer with A/C ON. A constant stream of bubbles indicates system requires charging.* Check colour in moisture indicator; BLUE is OK. PINK indicates desiccant material in dryer is saturated with moisture. In this situation replace receiver/dryer, evacuate system and recharge system with both refrigerant and PAG oil.* * Indicates that these repairs must only be carried out by a certified A/C technician.

For additional SERVICE information refer to the Tigercat A/C SERVICE MANUAL part number 18795A, available from Tigercat parts department.

3.35

Tigercat AD610C Carrier TILTING THE CAB WARNING

Before tilting the cab, ensure that the machine is parked on level ground. Lower the dozer blade to the ground. Engage the parking brake and turn the ignition switch off.

NOTE: The cab tilt circuit is closed and does not normally require scheduled maintenance other than lubrication of cylinders and pivot points.

Tigercat recommends the use of DEXTRON III TYPE transmission fluid in this circuit (total circuit capacity 1 L [0.25 US gal]). The fill port is located on the pump.

Lubrication and Maintenance RAISING THE CAB 1. Position the machine on level ground.

2. Lower the dozer to the ground.

3. Engage parking brake and turn ignition off.

4. Remove the sweep mounting bolts at the cab.

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

cab sweep bolts

pump

LOCATED in the right hand step compartment below the cab door

pump lever shown in "raise" position 630D-11 AD610C-03

pump control lever in raise cab position

7. Turn the lever on the pump manifold to RAISE (pointing IN, toward of the machine).

8. Insert handle into pump and pump in a steady manner to raise the cab to the tilt position. The pump handle is stored in brackets inside the cab.

CAUTION 630d-12

pump handle storage 311-2

cab locking pins 630d-13

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.

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 the machine is on level ground.

3.36

Tigercat AD610C Carrier

Lubrication and Maintenance LOWERING THE CAB

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.

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.

LOCATED in the right hand step compartment below the cab door

pump handle

pump

pump lever shown in "lower" position

cab locking pin

safety cable

cab support brace (3291b).

MUST USE CAB & CHASSIS LUGS SHOWN

AD610C-04

3. Turn the lever on the pump manifold to LOWER (pointing OUT, away the machine).

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

cab locking pin

partial tilt with cab support brace

E620C-17

cab safety cable (3361B)

pump control lever in lower cab position

4. Pump the handle in a steady motion to lower the cab.

5. Watch closely for pinching of hydraulic lines 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 to point IN toward the machine and store the pump handle inside the cab.

8. Reinstall the access panel.

9. Replace the Cab Sweep Bolts. (2 bolts)

AD610C-05

cab at full tilt supported by safety cable cab support brace

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

AD610C-203

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.

cab support brace STORED UNDER PLATFORM 3.37

Tigercat AD610C Carrier

Lubrication and Maintenance

winch MAINTENANCE - dp The recovery winch is located in the rear of the carrier.

The winch is controlled through the winch select switch and the winch control lever. The winch select switch is used to activate/deactivate the winch control lever and to activate the winch freespool function. The winch control lever when activated is used to spool the winch cable in/out.

Refer to CAB CONTROLS~WINCH CONTROL LEVER , CAB CONTROLS~WINCH SELECT SWITCH in SECTION 2 of the OPERATOR'S MANUAL. Refer also to OPERATING WINCH in SECTION 2 of the OPERATOR'S MANUAL. Refer to SECTION 13 of the SERVICE MANUAL and the winch manufacturer's service manual for additional service information.

WINCH SPECIFICATIONS DP recovery WINCH MODEL 35 Maximum rated line pull bare drum ............................35000 lbs (15876 kg) full drum................................18180 lbs (8246 kg) Maximum cable size.............3/4 in (19.1 mm) Drum Size and Capacities Barrel Diameter....................6.13 in (156 mm) Barrel Width..........................12.12 in (308 mm) Cable Capacity 9/16 in (14.3 mm).................289 ft (80 m) 5/8 in (15.9 mm)...................271 ft (82.6 m) 3/4 in (19.1 mm) ..................188 ft (57.3 m) Winch Ratio DPW-35............40.96:1 Dry Weight . .........................645 lbs (293 kg) Oil supply maximum pressure...............................2750 psi (190 bar) Oil supply maximum flow......30 USgpm(114 L/min)

fill/level plug

ad610c-06

drain plug

recovery winch

The winch should be operated once every 30 days to ensure that the cable will freespool and that the winch will pull the machine in the event that it is needed to recover the machine from an unexpected accident or equipment failure.

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

The sump holds 0.5 US gal (1.9 L).

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

Oil should be changed every 1000 hrs, depending on use.

Refer to manufacturer's manual for recommended oil. Use these oils or the equivalent.

The oil level should be up to the oil fill/level plug on the right side of the winch.

In addition fairlead rollers require lubrication on a weekly basis. Refer to manufacturer's service manual.

MAINTENANCE Maintenance of the winch is limited to the hydraulic system maintenance of the machine itself.

Periodically check the winch, control valve, and connecting hoses for damage or hydraulic oil leakage. If any problems are found, they should be corrected before operating the winch.

3.38

Tigercat AD610C Carrier

Lubrication and Maintenance

AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS It may be necessary to remove axle covers to access the axle level check and fill plugs.

Refer to LUBRICATION AND SERVICE CHART and SCHEDULED MAINTENANCE in THIS SECTION for service intervals and recommended gear oils.

exceed the maximum recommended amount of additive as this may cause a loss of differential lock slipping torque and brake holding torque. Refer to LUBRICATION AND SERVICE CHART for additive recommendation details.

CAUTION

NOTE: Warranty coverage of powertrain components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period. Refer to OIL SAMPLING PROGRAM in THIS SECTION for details.

Fluid spray hazard. Contact with fluid under pressure may cause injury.

Pressure may build up inside axle due to temperature changes. Use caution when removing drain and fill plugs, slowly loosen plug to relieve pressure before removing completely.

rEAR AXLE - limited slip additives Rear axles are equipped with brakes. It is permissible to use a limited slip additive in the rear axle to reduce brake chatter noise. Do not MACHIINES 6109001 TO 6109020

axle level check and fill

axle drain

axle drain 610-01

SAMPLE LOCATION axle drain

REFER ALSO TO AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS IN THIS SECTION FOR MORE INFORMATION.

AXLE DRAIN AND FILL LOCATIONS (REAR axle shown)

MACHIINES 6109021 TO 6109250

axle level check and fill (FAR SIDE)

PINION SEAL GREASE FITTING

axle level check and fill

SAMPLE LOCATION axle drain

S610-01

AXLE DRAIN AND FILL LOCATIONS 3.39

REFER ALSO TO AXLE LEVEL CHECK, FILL AND DRAIN LOCATIONS IN THIS SECTION FOR MORE INFORMATION.

Tigercat AD610C Carrier

Lubrication and Maintenance

STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE

•

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.

•

Loosen the plug on the top of the left hand drive motor.

•

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

•

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

•

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

This procedure should be followed: •

after major service or a rebuild.

•

whenever the machine has been drained of hydraulic oil.

•

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

PRE-STARTUP AND FILLING 1. Ensure all filters are in place. Refer to FILTERS in THIS SECTION. 2. Check oil levels in the engine, transmission, main hydraulic tank, winch (if equipped), axles and cab tilt system.

MACHINE STARTUP Before beginning this procedure, perform the PRE-STARTUP and filling steps.

3. Check coolant level in the radiator.

1. Ensure the articulation lock bar is installed.

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

CAUTION

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

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

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

Pre-fill the cases of the hydrostatic drive pump, main pump and any other components that have been drained of oil with clean, filtered hydraulic oil.

case drain make-up line

4 PIN ENGINE POWER CONNECTOR

tee connector

610C-03

oil fill line

620c-46

right hand drive motor disconnect case drain line

•

Disconnect the case drain make-up line from the tee connection on the right hand drive motor and pre-fill the right hand drive motor with clean, filtered hydraulic oil.

•

Watch for oil leaking from tee connection and reconnect case drain line when oil leaks out.

Engine 4 pin power connector

2. Disconnect 4 pin engine power connector on engine (prevents engine starting).

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

3.40

Tigercat AD610C Carrier 4

Lubrication and Maintenance

Check hydraulic oil levels in the main hydraulic tank and add hydraulic oil as required.

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

5. Reconnect 4 pin engine power connector on engine.

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

6. Start engine.

11. Top up the radiator with clean coolant.

7. Check for leaks.

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

connectors drive pump

610C-17

disconnect two connectors on drive pump prior to bleeding brakes

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.

8. Bleed brakes (rear axle) if required.

Prior to bleeding brakes disconnect the two connectors on the drive pump. This is a safety precaution to prevent the machine from travelling while brake bleeding is being performed.

With engine at IDLE, engage parking brake, hold foot brake down, bleed brakes in rear axle (both sides). Refer also to AXLES ~ SERVICE BRAKES ~ BRAKE BLEEDING in SECTION 8 of the SERVICE MANUAL. Reconnect two connectors on drive pump.

3.41

Tigercat AD610C Carrier

Lubrication and Maintenance

TORqUE CHART LOCATION

DIAMETER

Cylinders Piston nut, steer cylinder (38087B) Piston nut, dozer cylinder (3267D) Gland, steer cylinder (36597B) Keeper plate bolts Keeper plate bolts

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

1260 762 550 282 159

1708 1033 745 382 215

Cab pin keeper plate bolts

3/4" UNC

282

393

Center joint bearing Bearing retaining bolts Pin retaining bolts

1/2" UNC 3/4" UNC

80 282

108 382

Engine mounting To Chassis To Engine

7/8" UNC M12

364 73

493 99

Pump Mounting Drive pump to flywheel adapter plate Flywheel adapter plate to flywheel housing Torsional drive coupler to flywheel Main pump to adapter plate Coolant pump to main pump

3/4" UNC M10 3/8" UNF 5/8" UNC M12

282 40 37 159 73

382 54 50 215 99

5/8" UNF 5/8" UNC

170 159

230 215

1/2" UNF

90

122

1/2" UNF

90

122

3/8" UNC

37

50

Axle mounting bolts Front Rear

3/4" UNC 7/8" UNC

226 364

306 493

Wheel bolts

7/8" UNF

501

679

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

5/8"UNC 7/8" UNC

159 364

215 493

Drive shafts Yoke retaining bolt, park brake Parking brake retaining bolts Rear drive shaft universal joint bolts Mid. drive shaft universal joint bolts Front drive shaft universal joint bolts

TORqUE (LUBRICATED) lbf-ft Nm

Torque values pertaining to the engine and attachment are provided in the appropriate manuals. ad610cTORQUECHART.XLS 06/10

3.42

Tigercat AD610C Carrier

Lubrication and Maintenance

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

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

IMPERIAL GRADE 8 BOLTS

GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS LUBRICATED DRY LUBRICATED COARSE lbf-ft Nm lbf-ft Nm lbf-ft Nm THREAD 8 - 10 11 - 13 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 20 - 28 27 - 38 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 33 - 36 45 - 49 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 52 - 57 71 - 77 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 80 - 88 109 - 119 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 115 - 127 156 - 172 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 159 - 175 216 - 237 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 282 - 310 393 - 420 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 455 - 501 617 - 679 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 682 - 750 925 - 1016 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 966 - 1062 1310 - 1441 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1360 - 1496 1844 - 2027 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED LUBRICATED lbf-ft Nm lbf-ft Nm lbf-ft Nm THREAD 10 - 13 14 - 17 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 18 - 25 25 - 33 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 37 - 41 50 - 55 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 58 - 64 79 - 86 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 90 - 99 122 - 134 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 128 - 141 174 - 191 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 180 - 198 244 - 268 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 315 - 347 427 - 470 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 501 - 550 679 - 745 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 746 - 821 1012 - 1113 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1083 - 1191 1469 - 1613 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1509 - 1660 2046 - 2250 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387 4.8

METRIC

8.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

10

5

10

5

5

12.9

10

12.9

12.9

12

12

DRY lbf-ft Nm 11 - 12 15 - 16 26 - 30 35 - 40 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

10

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

10

12

METRIC BOLT TORQUE SPECIFICATIONS CLASS 4.8 SIZE LUBRICATED DRY Nm lbf-ft Nm lbf-ft

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

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

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

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0 700.0 1,200.0 875.0 1,350.0 1,000.0 1,700.0 1,250.0 1,600.0 1,150.0 2,000.0 1,500.0 950.0 1,650.0 1,200.0 1,850.0 1,350.0 2,300.0 1,700.0 2,150.0 1,600.0 2,700.0 2,000.0

675.0 1,150.0 850.0 1,750.0 1,300.0 2,200.0 1,650.0 2,500.0 1,850.0 3,150.0 2,350.0 2,900.0 2,150.0 3,700.0 2,750.0 850.0 1,450.0 1,075.0 2,250.0 1,650.0 2,850.0 2,100.0 3,200.0 2,350.0 4,050.0 3,000.0 3,750.0 2,750.0 4,750.0 3,500.0

TORQUECHARTGENERAL.XLS

3.43

Tigercat AD610C Carrier

Lubrication and Maintenance

Parker

Assembly Torque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts. The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head on to the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

The 4-Bolt Split Flange consists of four main components: • A body (flange head) • An O-ring • One “captive” or two “split” flange clamps

• Four bolts and washer

WASHERS BOLTS FLANGE CLAMP

Flange Port Assembly

FLANGE HEAD

The steps to properly assemble the flange port clamping bolts are: 1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

2. Lubricate the O-ring.

3. Position flange and clamp halves.

4. Place lock washers on bolts and insert through clamp halves.

5. Hand tighten bolts.

6. Torque bolts in diagonal sequence (see Fig. T9) in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

o-RING TAPPED HOLES

FLANGE.JPG

Fig. T8 - 4 Bolt Split Flange Components

FLANGE2.jpg

Fig. T9 - Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

17 +/- 2 25 +/- 3.5 31 +/- 4.5 41 +/- 5 52 +/- 6 60 +/- 6 85 +/- 9 144 +/- 15 125 +/- 8 125 +/- 8 125 +/- 8

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

8 12 16 20 24 32

1/2 3/4 1 1 1/4 1 1/2 2

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

17 +/- 2 30 +/- 4.5 46 +/- 4.5 69 +/- 6 125 +/- 8 208 +/- 20

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

* Does not meet ISO 6162 specification.

Table T7 - Code 62 Flange Recommended Bolt Torque

* Does not meet ISO 6162 specification.

Table T6 - Code 61 Flange Recommended Bolt Torque

3.44

Tigercat AD610C Carrier

Lubrication and Maintenance

Parker

Assembly Torque

JIC 37 Degree Flare SAE Dash Size

Tube Connection Swivel or Hose Connection FFWR FFWR

Thread Size

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

NPTF

5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 3-12

NA NA 2 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 1 1 1

SAE Dash Size

NA NA 2 2 1 1/4 1 1 1 1 1 1 1 1 1

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size 1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

Thread Size NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok SAE Dash Size

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

SAE Dash Size

NA NA 1/2 TO 3/4 NA 1/2 TO 3/4 1/2 TO 3/4 1/2 TO 3/4 1/3 TO 1/2 NA 1/3 TO 1/2 1/3 TO 1/2 1/3 TO 1/2 NA NA

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size 1/8-28 NA 1/4-19 NA 3/8-19 1/2-14 NA 3/4-14 NA 1-11 1 1/4-11 1 1/2-11 2-11 NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE = 10 % -0 SAE DASH SIZE

2 3 4 5 6 8 10 12 14 16 20 24 32

NON-ADJUSTABLE THREAD SIZE

SEAL-LOK

FT.LBS.( IN.LBS) 5/16-24 (310) 3/8-24 (310) 7/16-20 (310) 1/2-20 (360) 9/16-18 (420) 3/4-16 60 7/8-14 100 1 1/16-12 135 1 3/16-12 175 1 5/16-12 200 1 5/8-12 250 1 7/8-12 305 2 1/2-12 375

N-M 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS FT.LBS.( N-M IN.LBS) (85) 10 (155) 18 (260) 29 (280) 32 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

ADJUSTABLE SEAL-LOK FT.LBS.( IN.LBS) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.45

N-M 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS FT.LBS.( N-M IN.LBS) (60) 7 (100) 11 (180) 20 (250) 28 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

PLUGS HOLLOW HEX

HEX HEAD

HP5ON-S

P5ON-S

FT.LBS.( IN.LBS) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

N-M 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

FT.LBS.( IN.LBS) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

N-M 10 18 29 32 40 70 115 183 237 271 339 414 509

Tigercat AD610C Carrier

Lubrication and Maintenance

EATON Aeroquip

Assembly Torque

Recommended Parallel Connection Assembly torque

Eaton recommends that a Torque wrench be used to assure proper fitting assembly of these connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514)

Straight Thread O-Ring Boss High Pressure with ORS (J1453)

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32

The values listed are for steel connections. Contact Teaton for torque values for other materials.

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-9 12-13 13-15 18-20 14-15 19-21 23-24 32-33 40-43 55-57 43-48 59-64 68-75 93-101 83-90 113-122 112-123 152-166 146-161 198-218 154-170 209-230 218-240 296-325

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24

ORS

Dash Size -04 -06 -08 -10 -12 -16 -20 -24

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-10 11-16 14-16 20-22 18-20 24-27 24-26 33-35 50-60 68-78 72-80 98-110 125-135 170-183 160-180 215-245 200-220 270-300 210-280 285-380 270-360 370-490

SAE 37º (JIC) Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

10-12 18-20 32-35 46-50 65-70 92-100 125-140 150-165

Swivel Nut Torque Newton Meters 14-16 24-27 43-47 62-68 88-95 125-136 170-190 204-224

Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -32

Metric Thread Size mm M10x1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2

Thread Size (inches) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Swivel Nut Torque lb.-ft.

11-12 15-16 18-20 38-42 57-62 79-87 108-113 127-133 158-167 245-258

Swivel Nut Torque Newton Meters 15-16 20-22 24-28 52-58 77-85 108-119 148-154 173-182 216-227 334-352

BSPP Straight Adapter or Locknut Torque lb.-ft.

Newton Meters 13-15 18-20 15-19 20-25 19-23 25-30 33-40 45-55 37-44 50-60 52-66 70-90 55-70 75-95 81-96 110-130 96-111 130-150 162-184 220-250 170-192 230-260 258-347 350-470

Nominal Thread Size Straight Adapter or Locknut Torque inches** lb.-ft.

Newton Meters G1/8-28 13-15 18-20 G1/4-19 19-23 25-30 G3/8-19 33-40 45-55 G1/2-14 55-70 75-95 G3/4-14 103-118 140-160 G1-11 162-184 220-250 G1 1/4-11 170-192 230-260 G1 1/2-11 258-347 350-470 ** "G" denotes parallel threads, other than ISO 6149 (Port connection only)

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.46

Tigercat AD610C Carrier

Lubrication and Maintenance

Weights of Commercial Wood

Species

kg/m3

lb/ft3

Species

kg/m3

lb/ft3

Alder, Red Ash, White Aspen, Quaking Bald Cypress Basswood, American Beech, American Birch, Paper Birch, Yellow Cedar, Alaska Cedar, Incense Cedar, Northern White Cedar, Port-Orford Cedar, Western Red Cherry, Black Cottonwood, Eastern Douglas Fir, Coast Douglas Fir, Inland North Elm, American Fir, Alpine Fir, Balsam Fir, Nobel Fir, Red Fir, Silver Fir, White Gum, Black Gum, Blue Gum, Red Gum, Tupelo Hemlock, Eastern Hemlock, Western Hickory, Pecan Hickory, True Larch, Western Locust, Black Magnolia, Cucumber

737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

Maple, Big Leaf Maple, Black Maple, Red Maple, Silver Maple, Sugar Oak, Black Oak, Chestnut Oak, Red Oak, Red, Swamp Oak, Swamp Chestnut Oak, White Oak, White, Swamp Pine, Jack Pine, Loblolly Pine, Lodgepole Pine, Long Leaf Pine, Norway, Red Pine, Short Leaf Pine, Slash Pine, Sugar Pine, Western Yellow Pine, White-Western Pine, White-Eastern Poplar, Yellow Redwood Spruce, Black Spruce, Engleman Spruce, Red Spruce, Sitka Spruce, White Sweetgum Sycamore, American Tamarack Walnut, Black Willow, Black

753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Note: The values shown here are green weights.

3.47

Tigercat AD610C Carrier

Lubrication and Maintenance

TIRE PRESSURES Tigercat Part # BP111 BP112 BP022 BP113 BP114 BP100 BP066 BP039

Manufacturer Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone Bridgestone/Firestone GPX Tire (Primex) Nokian Nokian

Size 30.5L-32 20PR LS2 (FS) 30.5L-32 26PR SS LS2 DH (FS) 73x44-32 16PR HF3 DH (FS) 35.5L-32 20PR LS2 DH (FS) 35.5L-32 24PR LS2 DH (FS) 66/4300-26 20PR HF4 DW (GPX) 750/55-26.5 20PR F (N) 750/55-26.5 20PR TRS (N)

Inflation Pressure (w/o tracks) psi kPa 35 240 45 310 30 210 35 240 40 275 50 345 72 500 72 500

Inflation Pressure (w/tracks) psi kPa n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 80 550 80 550

630d 635d TIRE PRESSURES r1 12/09

COMMON CONVERSIONS To Convert Bar cc °C Kg KW Liters mm Nm N

Into PSI Cu. in. °F lbs.

HP Gallons Inches lb.-ft. lbs.

To Convert

Multiply By

Cu. in. °F Gallons HP Inches lbs. lb.-ft.

PSI In. of HG In. of H2O lbs.

14.5 0.06102 (°C x 9/5) + 32 2.205 1.341 0.2642 0.03937 0.7375 0.22481

3.48

Into

cc °C Liters KW mm Kg Nm Bar PSI PSI N

Multiply By

16.39 (°F - 32) /1.8 3.785 0.7457 25.4 0.4535 1.356 0.06896 . 4912 . 03613 4.4482

Tigercat AD610C Carrier SECTION 6 - electrical AND computers

DECEMBER 2009

CONTENTS - SECTION 6 ALARMS AND GAUGES............................................................................................... 6.99 CHANNELS................................................................................................................... 6.34 INPUTS DIGITAL IN (DIN).................................................................................................... 6.34 FREQUENCY IN (FIN)........................................................................................... 6.34 VOLTAGE IN (VIN)................................................................................................. 6.34 OUTPUTS CURRENT OUT (COUT)........................................................................................ 6.34 DIGITAL OUT (DOUT)............................................................................................ 6.34 PWM OUT (PULSE WIDTH MODULATION)......................................................... 6.34 COMPUTER.................................................................................................................. 6.15 ADJUSTMENT MENU EXAMPLE ~ ADJUSTMENT MENU NAVIGATION................................................ 6.24 ADJUSTMENT MENU - ENGINE SETTINGS........................................................... 6.21 Auto RPM............................................................................................................ 6.21 Cold Idle Speed............................................................................................... 6.21 Engine High Idle Adjust................................................................................ 6.21 ADJUSTMENT MENU - FAN SETTINGS (IF EQUIPPED)........................................ 6.22 Clean Duration................................................................................................ 6.22 Clean Frequency............................................................................................ 6.22 Fan Auto Clean................................................................................................. 6.22 ADJUSTMENT MENU - SERVICE SETTINGS......................................................... 6.23 Front Tire Size................................................................................................. 6.23 Hydraulic Oil Grade...................................................................................... 6.23 Program Mode................................................................................................. 6.23 COMPUTER CONTROL SYSTEM.............................................................................. 6.6 COMPUTER CONTROL SYSTEM COMPONENTS................................................... 6.6 ENGINE COOLANT TEMPERATURE GAUGE......................................................... 6.19 ENGINE MENU.......................................................................................................... 6.17 ENGINE MENU - ENGINE FUNCTIONS................................................................... 6.18 Boost................................................................................................................... 6.19 Charge Air Temperature............................................................................. 6.19 Coolant Temperature.................................................................................. 6.19 Engine Hours.................................................................................................... 6.19 Engine Speed.................................................................................................... 6.18 Engine Voltage................................................................................................ 6.19 Eng % Torque................................................................................................... 6.18 Oil Pressure..................................................................................................... 6.19 ENGINE MENU - FUEL INFORMATION................................................................... 6.20 Fuel Rate............................................................................................................ 6.20 Total Fuel Used............................................................................................... 6.20 Trip Average Fuel Rate................................................................................. 6.20 Trip Fuel Used.................................................................................................. 6.20 ENGINE TACHOMETER GAUGE............................................................................. 6.18 FUEL GAUGE............................................................................................................ 6.20 HYDRAULIC OIL TEMPERATURE GAUGE.............................................................. 6.27

Tigercat AD610C Carrier

Electrical and Computers

INFORMATION MODE MENU...................................................................................

Drive Motor Speed.........................................................................................

Drive Pressure Forward............................................................................

Drive Pressure Reverse.............................................................................

Hydraulic Oil Temperature........................................................................

Hydrostatic Circuit Temperature...........................................................

Machine Hours.................................................................................................

Machine Voltage.............................................................................................

Travel Speed....................................................................................................

MAIN MENU..............................................................................................................

MAIN MENU PAGE....................................................................................................

MAIN MENU PAGE - ADJUST MENU.......................................................................

MAIN MENU PAGE - INFO MENU............................................................................

LOGS.....................................................................................................................

MODULES..............................................................................................................

MAIN MENU PAGE - MEASURE MENU...................................................................

EXAMPLE ~ MEASURE MENU.............................................................................

INPUT AND OUTPUT CHANNELS........................................................................

MAIN MENU PAGE - PREFERENCES MENU..........................................................

DATE/TIME ADJUSTMENT...................................................................................

DISPLAY ADJUSTMENT.......................................................................................

LANGUAGE ADJUSTMENT..................................................................................

MD3 COMPUTER......................................................................................................

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY........................................

MD3 COMPUTER MAIN MENU................................................................................

MESSAGES AND WARNINGS..................................................................................

ALERT MESSAGES (YELLOW)............................................................................

CRITICAL MESSAGES (red)..............................................................................

ERROR MESSAGES (RED)..................................................................................

INFORMATION MESSAGES (BLUE)....................................................................

MESSAGES AND WARNINGS - ALERT Drive Charge Filter Bypassed...................................................................

Drive Charge System Pressure Low......................................................

Drive Motor Speed Sensor No motor speed.......................................

Engine Air Intake Filter Restricted........................................................

ENGINE FAULT CODE MESSAGES - ALERT.......................................................

Engine Voltage High......................................................................................

Engine Voltage Low.......................................................................................

Fuel Level low.................................................................................................

Fuel - Water In Fuel........................................................................................ hardware failure - cout............................................................................. hardware failure - din................................................................................. hardware failure - dout............................................................................. hardware failure - vin.................................................................................

Hardware Fault - MD3....................................................................................

Hardware Fault - XA2.....................................................................................

Hardware Fault - XS2.....................................................................................

Machine Voltage High...................................................................................

Machine Voltage Low....................................................................................

MODULE HIGH SUPPLY VOLTAGE - ALERT.......................................................

MODULE HIGH TEMPERATURE - ALERT............................................................

MODULE LOW SUPPLY VOLTAGE - ALERT........................................................

Service Brake Pressure Low....................................................................

6.2

6.26 6.27 6.27 6.27 6.27 6.27 6.27 6.28 6.28 6.16 6.29 6.30 6.40 6.41 6.41 6.31 6.35 6.32 6.36 6.38 6.37 6.40 6.15 6.15 6.16 6.42 6.60 6.43 6.52 6.75 6.63 6.65 6.64 6.62 6.71 6.70 6.70 6.62 6.66 6.69 6.68 6.69 6.68 6.66 6.67 6.67 6.64 6.63 6.73 6.72 6.74 6.65

Tigercat AD610C Carrier

Electrical and Computers

MESSAGES AND WARNINGS - CRITICAL.............................................................. 6.44 Drive Motor Overspeed............................................................................... 6.44 Engine Coolant Level low.......................................................................... 6.49 Engine Coolant Temperature High......................................................... 6.49 ENGINE FAULT CODE MESSAGES - CRITICAL.................................................. 6.51 Engine Oil Pressure Low............................................................................. 6.50 ENGINE STOP....................................................................................................... 6.46 Hardware Fault - Engine.............................................................................. 6.47 Hardware Fault - MD3.................................................................................... 6.47 Hardware Fault - XA2..................................................................................... 6.48 Hardware Fault - XS2..................................................................................... 6.48 Hydraulic Oil Level Low............................................................................... 6.44 Hydraulic Oil Temperature High.............................................................. 6.45 Intake Manifold Temperature High......................................................... 6.50 Interlock System....................................................................... 6.46, 6.75, 6.78 MESSAGES AND WARNINGS - ERROR................................................................. 6.53 CURRENT OUTPUT ERROR (COUT).................................................................. 6.54 DIGITAL INPUT ERROR (DIN).............................................................................. 6.54 DIGITAL OUTPUT ERROR (DOUT)...................................................................... 6.54 MODULE NO CONTACT ERROR......................................................................... 6.55 MD3 MODULE BLANK SCREEN....................................................................... 6.56 Xa2-A0 MODULE no contact ERROR....................................................... 6.58 XS2-A0 MODULE NO CONTACT ERROR....................................................... 6.57 MODULE VREF ERROR....................................................................................... 6.53 VOLTAGE INPUT ERROR (VIN)............................................................................ 6.54 MESSAGES AND WARNINGS - INFORMATION Interlock System-crane not stowed-machine drive disabled... 6.78 Interlock System-crane not stowed-machine hydraulics disabled Interlock System PARK BRAKE ON............................................................. 6.79 SETUP MODE - DRIVE MOTOR SETUP MODE.................................................. 6.76 SETUP MODE - DRIVE PUMP POR SETUP MODE............................................. 6.76 SETUP MODE - ENGINE HP TEST MODE........................................................... 6.76 SETUP MODE - FUNCTION VALVE SETUP MODE............................................. 6.76 CONNECT TO THE MD3 WITH IQANrun 2............................................................... 6.87 diagnostic breakout harnesses.................................................................... 6.34 DOWNLOADING APPLICATIONS FROM DEALER WEBSITE.................................... 6.84 ELECTRICAL KIT - SERVICE AND DIAGNOSTICS..................................................... 6.81 ELECTRICAL SYSTEM SCHEMATIC DIAGRAMS..................................................... 6.101 ENGINE FAULT CODE MESSAGES - ALERT.............................................................. 6.71 ENGINE FAULT CODE MESSAGES - CRITICAL......................................................... 6.51 FUSE AND RELAY PANELS CAB........................................................................................................................... 6.97 ELECTRICAL BOX.................................................................................................... 6.98 GAUGES AND ALARMS............................................................................................... 6.99 ID-TAG........................................................................................................................... 6.14 INPUT AND OUTPUT CHANNELS............................................................................... 6.32 IQAN MODULES MD3 DISPLAY AND MASTER MODULE..................................................................... 6.8 ELECTRICAL SCHEMATIC..................................................................................... 6.9 XA2-A0 FRONT CHASSIS MODULE........................................................................ 6.12

6.3

6.78

Tigercat AD610C Carrier

Electrical and Computers

ELECTRICAL SCHEMATIC...................................................................................

XS2-A0 CAB MODULE..............................................................................................

ELECTRICAL SCHEMATIC...................................................................................

IQANrun 2...................................................................................................................

ADJUST.....................................................................................................................

CONNECT TO THE MD3 WITH IQANrun 2............................................................

IQANrun 2 QUICK SUMMARY................................................................................

ADJUST.................................................................................................................

CONNECT TO THE MD3 WITH IQANrun2.........................................................

GET CLONE...........................................................................................................

GET SETTINGS.....................................................................................................

LOGIN....................................................................................................................

LOGS.....................................................................................................................

MEASURE (GRAPH).............................................................................................

SEND CLONE........................................................................................................

SEND SETTINGS..................................................................................................

SYSTEM.................................................................................................................

UPDATE.................................................................................................................

LOGIN........................................................................................................................

LOGS.........................................................................................................................

MEASURE/ GRAPH..................................................................................................

REQUIRED EQUIPMENT & INFORMATION............................................................

SERVICING THE MD3 WITH IQANrun 2................................................................

SYSTEM....................................................................................................................

UPDATE APPLICATION............................................................................................

GET CLONE FILE..................................................................................................

GET settings FILE............................................................................................ update APPLICATION TO MD3..........................................................................

IQAN SOFTWARE........................................................................................................ application PROGRAM UPDATES for product service bulletins...............................................................

DOWNLOADING APPLICATIONS FROM DEALER WEBSITE................................

SERVICING THE MD3 WITH IQANrun 2................................................................

6.13 6.10 6.11 6.85 6.93 6.87 6.85 6.86 6.85 6.85 6.85 6.85 6.86 6.86 6.85 6.85 6.86 6.85 6.88 6.95 6.94 6.85 6.85 6.96 6.89 6.89 6.90 6.91 6.83 6.84 6.84 6.85

SERVICING THE MD3 WITH IQANrun 2................................................................... 6.85 SWITCH AND SENSOR LOCATIONS........................................................................ 6.100 TEMPORARY FIX for ENGINE RPM CONTROL PROBLEMS CAUSED BY J1939 CONNECTION ERRORS.......................................................... 6.80 TROUBLESHOOTING diagnostic breakout harnesses............................... 6.34 UPDATE APPLICATION................................................................................................ 6.89 WIRE COLOUR CODE CHART.................................................................................. 6.101

6.4

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Electrical and Computers

6.5

Tigercat AD610C Carrier

Electrical and Computers

COMPUTER CONTROL SYSTEM

MD3 COMPUTER USB PLUG

Machine operation is controlled electronically by the IQAN computer control system. During operation of the electronic joysticks foot pedals, winch lever, dozer lever or control switches, the computer system provides integrated control of the engine, hydrostatic drive and all of the proportional valve functions.

alarm MD3 COMPUTER LIGHT

master alarm

IQAN SYSTEM COMPONENTS •

MD3 Computer and Display Module

•

XS2 Expansion Module (Cab)

•

XA2 Expansion Module (Front Chassis)

•

Engine Electronic Control Module

•

Various controls, switches, sensors and valves not shown.

INSTRUMENT PANEL

The MD3 computer is the main controller in the system. The MD3 computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

The MD3 module is connected in series to the CAN 1 terminal on the cab module. The cab module is connected via the CAN 2 terminal to front chassis module. The engine electronic control module provides electronic information to the MD3 computer via the J1939 CAN BUS link. This information is displayed on the computer display.

MD3 COMPUTER MODULE

XS2 EXPANSION MODULE CAB

9 pin ENGINE diagnostic connector E625C-01

XA2 EXPANSION MODULE FRONT CHASSIS

ENGINE ELECTRONIC CONTROL MODULE

COMPUTER CONTROL SYSTEM COMPONENTS 6.6

Tigercat AD610C Carrier

Electrical and Computers

The computer monitors and analyzes engine and transmission inputs and produces outputs (as defined in its program) to control the engine and drive functions.

The computer also monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine proportional valve functions.

Proportional valve functions are: • • • • • •

LOCATED IN CAB BEHIND LEFT KICK PANEL

Winch Dozer Crane Differential locks Fan (if equipped with variable pitch fan option) Parking brake

630D-14

xs2-a0 module - cab

LOCATED UNDER CAB, right rear - remove cover to access module

Inputs: The computer monitors analogue, digital, and frequency inputs and CAN Bus inputs. CAN Bus is a data bus system that allows several input signals to be sent to the MD3 through a reduced number of wires.

Outputs: The computer directs a proportional output to the solenoids on the control valve (winch, dozer, crane), multifunction manifold, drive pump and drive motors. The computer controls engine RPM by sending appropriate signals to the engine’s control computer.

635D-152

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

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

6.7

xa2-a0 module - front chassis

Tigercat AD610C Carrier

Electrical and Computers

MD3 DISPLAY AND MASTER MODULE 1

2

3

4

MD3-BACK

REAR OF MD3 MODULE The back of the MD3 Module consists of the following.

1. Tag with serial number and part number.

2. CAN bus connector C2 (VIN inputs, USB communication and alarm output).

R8.0 max

3. CAN bus connector C1 (voltage supply, CAN communication J1939 and expansion modules).

4. Membrane valve for condensation prevention inside unit.

MD3 MODULE WIRING PIN ASSIGNMENT MD3 MODULE REPLACEMENT 1. Turn battery disconnect switch OFF. 6

DIN-A / VIN-A DIN-B / VIN-B DIN-C / VIN-C DIN-D / VIN-D -VREF USB-D-

USB-D+ +VREF DIN-E / VIN-E DIN-F / VIN-F DIN-G / VIN-G DOUT-A

5 8

1

12

7 8 9 10 11 12

1 2 3 4 12 11 10 9

4 9 1 2 3 12 11 10

1

1 2 3 4 5 6

C1

5 8

C2

7 6 7

7 6 7

6

1 2 3 4 5 6

-BAT CAN-A-L CAN-B-L CAN-C-L/Diag RS232 DATA IN Reserved

12

7 8 9 10 11 12

+RTC RS232 DATA OUT CAN-C-H/Diag CAN-B-H CAN-A-H +BAT

NOTE: Refer to the MD3 MODULE SCHEMATIC and ELECTRICAL SCHEMATIC in THIS SECTION for detailed pin and wiring assignment.

2. Remove the 6 screws holding the instrument panel assembly in place and carefully remove the assembly.

3. Remove 4 screws holding MD3 in place as shown in the illustration.

3. Lift the module out of the instrument panel carefully.

4. Disconnect the wiring harness at the module C1 and C2 connectors.

5. Install module in reverse order as removed.

NOTE: Refer to IQANRUN 2 ~ APPLICATION UPDATE in THIS SECTION for procedure to update the application in an MD3 module.

When replacing a MD3 module the machine serial number information will need to be reset. Refer to IQANRUN 2 ~ SYSTEM for more information regarding access and maintenance of logs using IQANrun 2.

6.8

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635D-02

Electrical and Computers

MD3 DISPLAY MODULE SCHEMATIC 6.9

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Electrical and Computers

Xs2-A0 cab MODULE

•

Three red primary flashes in a row and two yellow secondary flashes in a row indicates that the fault is related to the address.

•

Four red primary flashes in a row and one yellow secondary flash indicates a memory error.

•

Continuous red primary flashing indicates a fatal error.

B A

XS2 MODULE LED INDICATORS

Internal diagnostics in the master (MD3) can be used to get more information about the XS2 module. The following values are supervised: •

Internal temperature (°C)

Xs2 MODULE LED INDICATORS

•

Power supply (V)

If there is an error detected, the master (MD3) will present a message on the display. The XS2 module also indicates error status through the red blinking LED.This gives an immediate diagnosis as to the nature of the error that has occurred.

•

Reference voltage (V)

•

CAN address voltage (V)

A. Supply Voltage LED (green).

LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

B. Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: •

One red primary flash and one secondary yellow flash indicates an error controlled by the master (MD3).

•

Two red primary flashes in a row and one yellow secondary flash indicates an error controlled by the master (MD3).

•

Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN-bus.

LED indicator showing different XS2 and XA2 modes Status

Flash

Normal operation (yel.)

Error code

Error

1:n

See note a

2:n

See note a

3:1

CAN error

3:2

Address error

4:1

Memory errorb

FE

Fatal error

Primary Flash (red) Error category

ADDR-H DOUT-G DOUT-H DOUT-I DOUT-J DOUT-K DOUT-L DOUT-A DOUT-B VIN-A/DIN-A VIN-B/DIN-B VIN-C/DIN-C VIN-D/DIN-D ADDR-L

42 28 14

29 15 1

15 16 17 18 19 20 21 22 23 24 25 26 27 28

-BAT DIN-I DIN-K DIN-M DIN-O DIN-Q DIN-S DOUT-C DOUT-D VIN-E/DIN-E VIN-F/DIN-F CAN2-H CAN-H +BAT(+12V, +24V)

29 30 31 32 33 34 35 36 37 38 39 40 41 42

-VREF DIN-J DIN-L DIN-N DIN-P DIN-R DIN-T DOUT-E DOUT-F VIN-G/DIN-G VIN-H/DIN-H CAN2-L CAN-L +VREF

XS2 MODULE WIRING PIN ASSIGNMENT Note that the XS2 module is equipped with eight voltage inputs (VIN-A to VIN-H) which may be configured as digital inputs (DIN-A to DIN-H). The function of these inputs determined by the machine program.

NOTE: Refer to the XS2-A0 CAB MODULE SCHEMATIC and ELECTRICAL SCHEMATIC in THIS SECTION for detailed pin and wiring assignment.

Secondary Flash (yellow) Error description

a. Error groups 1:n and 2:n are controlled by the master. b. FRAM memory error.

6.10

Tigercat AD610C Carrier

AD610C-03

Electrical and Computers

XS2-a0 CAB MODULE SCHEMATIC 6.11

Tigercat AD610C Carrier

Electrical and Computers

Xa2-A0 front chassis MODULE

•

Three red primary flashes in a row and two yellow secondary flashes in a row indicates that the fault is related to the address.

•

Four red primary flashes in a row and one yellow secondary flash indicates a memory error.

•

Continuous red primary flashing indicates a fatal error.

B A

XA2 MODULE LED INDICATORS

Internal diagnostics in the master (MD3) can be used to get more information about the XA2 module. The following values are supervised: •

Internal temperature (°C)

Xa2 MODULE LED INDICATORS

•

Power supply (V)

If there is an error detected, the master (MD3) will present a message on the display. The XA2 module also indicates error status through the red blinking LED.This gives an immediate diagnosis as to the nature of the error that has occurred.

•

Reference voltage (V)

•

CAN address voltage (V)

XA2 MODULE WIRING PIN ASSIGNMENT

A. Supply Voltage LED (green).

LED with green light ON indicates supply voltage is ON.

42 28 14

LED OFF indicates supply voltage is OFF. B. Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: •

One red primary flash and one secondary yellow flash indicates an error controlled by the master (MD3).

•

Two red primary flashes in a row and one yellow secondary flash indicates an error controlled by the master (MD3).

•

Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN-bus.

LED indicator showing different XS2 and XA2 modes Status

Flash

Normal operation (yel.)

Error code

Error

1:n

See note a

2:n

See note a

3:1

CAN error

3:2

Address error

4:1

Memory errorb

FE

Fatal error

Primary Flash (red) Error category

Secondary Flash (yellow) Error description

1 2 3 4 5 6 7 8 9 10

ADDR-H COUT-A/DOUT-G COUT-B/DOUT-H COUT-C/DOUT-I COUT-D/DOUT-J COUT-E/DOUT-K COUT-F/DOUT-L DOUT-A DOUT-B VIN-A/DIN-A

15 16 17 18 19 20 21 22 23 24

11 12 13 14

VIN-B/DIN-B VIN-C/DIN-C VIN-D/DIN-D ADDR-L

25 26 27 28

29 15 1

-BAT CRET-A+/DIN-I CRET-B+/DIN-K CRET-C+/DIN-M CRET-D+/DIN-O CRET-E+/DIN-Q CRET-F+/DIN-S DOUT-C DOUT-D VIN-E/DIN-E/FIN-A DFIN-A+ VIN-F/DIN-F/DFIN-ACAN2-H CAN-H +BAT(+12V, +24V)

29 30 31 32 33 34 35 36 37 38 39 40 41 42

-VREF CRET-A-/DIN-J CRET-B-/DIN-L CRET-C-DIN-N CRET-D-/DIN-P CRET-E-/DIN-R CRET-F-/DIN-T DOUT-E DOUT-F VIN-G/DIN-G/FIN-B DFIN-B+ VIN-H/DIN-H/DFIN-BCAN2-L CAN-L +VREF

XA2-WIREASSIGN

Note that the XA2 module is equipped with eight voltage inputs (VIN-A to VIN-H) which may be configured as digital inputs (DIN), frequency inputs (FIN) or directional frequency inputs (DFIN). The XA2 module is also equipped with six double proportional ouputs (COUT-A to COUT-F) which may be configured as digital outputs (DOUT) and digital inputs (DIN). See wiring pin assignment diagram above for details. The function of these inputs determined by the machine program.

NOTE: Refer to the XS2-A0 CAB MODULE SCHEMATIC and ELECTRICAL SCHEMATIC in THIS SECTION for detailed pin and wiring assignment.

a. Error groups 1:n and 2:n are controlled by the master. b. FRAM memory error.

6.12

Tigercat AD610C Carrier

AD610C-04

Electrical and Computers

XA2-a0 FRONT CHASSIS MODULE SCHEMATIC 6.13

Tigercat AD610C Carrier

Electrical and Computers

id-tag Addressing Each module has a specific address, enabling the master module to communicate with it through the CAN-bus. Practically, the system distinguishes between different modules through firstly verifying the module type and then, secondly, through the modules having a unique addresses.

EXAMPLE If a system has an XS2 module with address 0, the system will denote this one as XS2-A0, The letter “A” refers to CAN-bus A.

42

29

28

15

14

1

ADDR-L, pos. 14

In order to assign any XS2 module a unique CANaddress, an Id-Tag will have to be connected to the positions ADDR-H and ADDR-L.

ADDR-H, pos. 1

Id-Tag

connecting id-tag (xS2 or xA2)

Terminating To eliminate interference in communication, through the CAN-bus, the CAN-bus must be terminated. Because the master module always is located at the beginning of the bus, the master is provided with an internal termination. If an IQANXA2 module is located at the end of the CAN-bus then use an Id-tag having a combined address and terminating function. This is denoted with a “T” for terminating, after the appropriate address such as; 0T, 1T, 2T...

Selecting appropriate Id-Tag •

Check the address number of the module.

•

If the module is located at the end of the CANbus then select the appropriate Id-Tag denoted with a “T”.

MODULE

ID-TAG

RESISTANCE

MD3

NO TAG

-

XS2 -A0

0

287 Ω

XA2 -A0

0T

432 Ω

assembling id-tag (xS2 or xA2) Assembling of the Id-Tag The Id-Tag is placed in the connector in order to address/ terminate the module. The Id-Tag is mounted under the connector casing. Bend the IdTag’s cables towards the opposite side, where the other cables enter the connector.

6.14

Tigercat AD610C Carrier

Electrical and Computers MD3 COMPUTER

COLOUR DISPLAY

635d-28A

MD3 COMPUTER, ELECTRONIC CONTROL AND DISPLAY

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY

MD3 COMPUTER USB PLUG

alarm MD3 COMPUTER LIGHT

master alarm

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

The front of the MD3 consists of a control panel with a display and nine buttons. The buttons are arranged on the bottom and right hand side of the display.

• F1 through F4 function buttons

,

, .

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

• Up and down arrow buttons

,

INSTRUMENT PANEL

,

.

• ’Esc’ or BACK button

.

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

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

• OK button .

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

• Menu button .

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

6.15

Tigercat AD610C Carrier 1

2

Electrical and Computers

3A 3B

4

5A

5B

6

15

14 13 7

8

9

10

11

12

main menu

AD610C-28

MD3 COMPUTER MAIN MENU 1. ** PARKING BRAKE - ENGAGED/DISENGAGED

10. ENGINE COOLANT TEMPERATURE GAUGE

2. * HAZARD LIGHTS ON/OFF

11. INFORMATION MENU - Press F3 to select

3A. ** REAR DIFFERENTIAL LOCK - ENGAGED/DISENGAGED

12. ALARM INDICATORS - Press F4 to select

3B. ** FRONT DIFFERENTIAL LOCK - ENGAGED/DISENGAGED

14. HYDRAULIC OIL TEMPERATURE GAUGE

4. *UNLOCK-ACTIVATE CRANE 5A. * WINCH ON/OFF (

13. HYDRAULIC OIL GRADE INDICATOR 15. FUEL LEVEL GAUGE * When the icon is illuminated, function is ON.

)

5B. * WINCH FREE SPOOL (

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

)

6. * COLD IDLE ON/OFF 7. ENGINE TACHOMETER GAUGE 8. ENGINE MENU - Press F1 to select 9. ADJUSTMENT MENU - Press F2 to select

6.16

Tigercat AD610C Carrier

Electrical and Computers Press the F2 button to toggle the cold idle function ON/OFF. Refer to COLD IDLE OPERATION and COLD IDLE SPEED ADJUSTMENT in SECTION 2 of the OPERATOR’S MANUAL.

ENGINE MENU

Press the F3 button to toggle between metric and imperial units of measure.

Press the back button again to return to the main menu.

From the main menu press the F1 button to select the engine display.

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

The fuel information on display is as follows: • • • •

Fuel Rate - US gph or L/h (instantaneous) Total Fuel Used - US gal or L Trip Average Fuel Rate - US gph or L/h Trip Fuel Used - US gal or L Press the F1 button to reset the trip average fuel rate and trip fuel used functions.

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

Press the back button to return the engine display.

Press the back button again to return to the main menu.

The engine functions on display are as follows: • • • • • • • •

Engine Speed - rpm Engine Torque - % Coolant Temperature - °F or °C Engine Oil Pressure - psi or bar Turbocharger Boost Pressure - psi or bar Charge Air Temperature - °F or °C Voltage - V Engine Hours - h Press the F1 button to select the fuel information display.

6.17

Tigercat AD610C Carrier

Electrical and Computers 1. Engine Speed (rpm) This display indicates engine speed in rpm.

Maintaining Correct Engine RPM It is important that the engine speeds be correct at all times: Cummins QSB Series Engine: Low Idle 950 RPM (No Load) High Idle 2230 RPM (No Load) NOTE: The above values are measured with the hydraulic and engine oil at normal operating temperatures and no functions activated.

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

ENGINE FUNCTIONS Press the F1 button to select the fuel information display.

Press the F2 button to toggle the cold idle function ON/OFF. Refer to COLD IDLE OPERATION and COLD IDLE SPEED ADJUSTMENT in SECTION 2 of the OPERATOR’S MANUAL. Press the F3 button to toggle between metric and imperial units of measure.

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

Press the back button to return to the main menu.

2. Eng % Torque (%) This display indicates the percentage of maximum engine torque being consumed at the current engine rpm level.

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

13-16%

Readings with the parking brake DISENGAGED should be a maximum of 4% higher than the reading with the parking brake ENGAGED. If the readings are outside this range investigate the cause.

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

6.18

Tigercat AD610C Carrier 3. Coolant Temperature - °F or °C

Electrical and Computers 5. Boost ( psi or bar)

This display indicates the current engine coolant temperature.

If temperature rises above 225°F (107°C), alarm will sound, check the following:

This display indicates air intake manifold boost pressure in psi.

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

• Plugged air intake access panel screens • Plugged radiator.

If temperature rises above 205°F (96°C), alarm will sound, check the following:

DO NOT continue to operate machine.

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

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR’S MANUAL.

DO NOT continue to operate machine.

NOTE: Coolant temperature can also be monitored using the engine coolant

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR’S MANUAL. Refer also to COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION for more information about the hydraulic oil temperature warning.

temperature gauge shown on the main menu.

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

Refer to the COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION for more information about the hydraulic oil temperature warning.

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

If engine voltage goes outside the normal range, an alarm will sound. Refer to COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION.

4. Oil Pressure (psi or bar) This display indicates engine oil pressure.

The oil pressure reading will either be 0 psi (0 bar) (engine stopped) or 70 psi (4.8 bar) (engine running).

A reading in excess of 30 volts indicates a possible faulty voltage regulator.

A reading less than 20 volts indicates a possible faulty battery or alternator.

If oil pressure falls too low, an alarm will sound. Refer to the COMPUTER ~ MESSAGES AND WARNINGS in THIS SECTION.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM 8. Engine Hours - h This display indicates the total number of hours the engine has run.

6.19

Tigercat AD610C Carrier

Electrical and Computers

FUEL INFORMATION Press the F1 button to reset the trip average fuel rate and trip fuel used functions.

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

Press the back button to return the engine display.

Press the back button again to return to the main menu.

1. Fuel Rate - US gph or L/h (instantaneous) This display indicates the current rate of fuel consumption in gallons per hour.

2. Total Fuel Used - US gal or L This display indicates the total fuel used during the life of the machine.

3. Trip Average Fuel Rate - US gph or L/h This display indicates the average fuel consumption rate for the machine since last reset.

4. Trip Fuel Used - US gal or L This display indicates the total fuel used since last reset.

FUEL GAUGE The fuel level gauge is shown on the main menu.

6.20

Tigercat AD610C Carrier

Electrical and Computers

ADJUSTMENT MENU

ENGINE SETTINGS From the main menu press F2 button to select the ADJUSTMENT MENU. When selected the adjustment menu icon is on display and all the adjustment selections will also be displayed.

Press the F1 button to select the Engine Settings Menu from the ADJUSTMENT MENU. The engine settings menu will appear.

Press F1 (Adjust) to adjust engine settings.

Press the back button to return the Engine Settings Menu display.

Press the back button again to return to the main menu.

The adjustable engine settings are: Engine High Idle Adjust Range 1800 to 2230* rpm Auto RPM On* or Off Cold Idle Speed Range 950 to 1500 rpm (1200* rpm) * NOTE: Reset default settings are marked.

The adjustment selections are as follows: •

Engine Settings - Shown first by default.

•

Fan Settings - Press F2 to select

•

Service Settings - Press F3 to select

Refer to COMPUTER ~ ADJUSTMENT MENU ~ EXAMPLE ~ ADJUSTMENT MENU NAVIGATION for an example of adjustment menu navigation.

Refer to COLD IDLE OPERATION and COLD IDLE SPEED ADJUSTMENT in SECTION 2 of the OPERATOR’S MANUAL.

Press the back button to return to the main menu.

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fan settings (IF EQUIPPED) Press F2 button to select Fan Settings Menu from the ADJUSTMENT MENU. Note that this menu is applicable only for machines equipped with the optional variable pitch fan.

The fan settings menu will appear.

Press F2 (Adjust) to adjust fan settings Press the back button to return the Fan Settings Menu display.

Press the back button again to return to the main menu.

The adjustable fan settings are: Fan Auto Clean On* or Off Clean Frequency Range 1 to 420 minutes (*30 minutes) Clean Duration Range 5 to 20 seconds (*15 seconds) * NOTE: Reset default settings are marked.

Refer to COMPUTER ~ ADJUSTMENT MENU ~ EXAMPLE ~ ADJUSTMENT MENU NAVIGATION for an example of adjustment menu navigation.

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Electrical and Computers Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HYDRAULIC OIL TEMPERATURE HIGH in THIS SECTION for more information about the hydraulic oil temperature warning.

Refer to COMPUTER ~ INFORMATION MODE MENU ~ HYDRAULIC OIL TEMPERATURE in THIS SECTION for hydraulic oil temperature information display.

Front Tire Size Not Configured 28L 24.5 30.5L 35.5L DH73

SERVICE SETTINGS Press F3 button to select the Service Settings Menu from the ADJUSTMENT MENU.

This information is used by the machine program to accurately calculate and display machine travel speed.

The service settings menu will appear.

Press F3 (Adjust) to adjust service settings

Program Mode Normal* Engine HP Test Mode Drive Motor Setup Mode Drive Pump POR Setup Mode Function Valve Setup Mode

Press the back button to return the Service Settings Menu display.

Press the back button again to return to the main menu.

The adjustable service settings are:

* NOTE: Reset default settings are marked.

Hydraulic Oil Grade

Refer to COMPUTER ~ ADJUSTMENT MENU ~ EXAMPLE ~ ADJUSTMENT MENU NAVIGATION for an example of adjustment menu navigation.

ISO 22* Petro CAN MV 22 ISO 32 Petro CAN MV 36 ISO 46 Petro CAN MV 60 ISO 68 This information is used by the machine program to adapt hydraulic oil temperature warning messages for the operating range of each Hydraulic Oil Grade.

IMPORTANT !

Machine must be in the Normal Program Mode to operate normally.

Other program modes are used for service/setup procedures only.

When setup program modes are chosen an information message is shown on the electronic display until the message is acknowledged.

In Engine HP Test Mode, Drive Motor Setup Mode and Drive Pump POR Setup Mode dozer, winch and attachment pressure are deactivated.

Attempting to use these controls will reactivate the information message.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge.

In Function Valve Setup Mode the drive pedals are deactivated. Attempting to use these controls will reactivate the information message.

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

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EXAMPLE ~ ADJUSTMENT MENU:

Press the arrow up or arrow down buttons to scroll to the setting to be adjusted.

From the main menu press F2 button to select the ADJUSTMENT MENU.

Press the F2 button to reset to default setting.

Press F2 (Yes) or F3 (No) to confirm.

The engine settings menu will appear by default.

Press F1 (Adjust) to adjust engine settings

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OR

OR

Press the OK button to go to the adjustment display.

To reset to default setting press the F2 button.

Press F2 (Yes) or F3 (No) to confirm.

Press the arrow up or arrow down buttons to make the adjustment.

Press the OK button to confirm the setting.

Press the back button to return to the adjustment menu.

Press the back main menu.

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button again to return to the

Tigercat AD610C Carrier

Electrical and Computers

INFORMATION MODE MENU

The information functions on display are as follows: Press the F3 button to access the information menu.

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

•

Hydraulic Oil Temp -°F or °C

•

Drive Pressure Forward - psi or bar

•

Drive Pressure Reverse - psi or bar

•

Drive Motor Speed - rpm

•

Hydrostatic Circuit Temperature -°F or °C

•

Machine Hours - h

•

Machine Voltage - V

•

Travel Speed - mph or km/h Press the F1 button to toggle between imperial and metric units of measure.

Press the back button to return to the main menu.

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Electrical and Computers Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge.

Operating outside the recommended operating range will shorten hydraulic component life.

Refer to COMPUTER ~ ADJUSTMENT MENU - SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in THIS SECTION for hydraulic oil grade selection settings information.

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HYDRAULIC OIL TEMPERATURE HIGH in THIS SECTION for more information about the hydraulic oil temperature warning.

INFORMATION FUNCTIONS 1. Hydraulic Oil Temperature (°F or °C) This display indicates the current hydraulic oil temperature registered in the main hydraulic tank.

If the temperature rises above the recommended operating range for the type of hydraulic oil in use, alarm will sound, check the following: • • • • • •

Plugged oil cooler Malfunction in a hydraulic system High loads on the hydraulic system Malfunction of the cooling fan Low hydraulic oil level Correct Hydraulic Oil Grade Selection

If hydraulic oil temperature rises above the recommended operating range DO NOT continue to operate the machine.

2. Drive Pressure Forward - psi or bar This display indicates forward drive pressure.

3. Drive Pressure Reverse - psi or bar This display indicates reverse drive pressure.

4. Drive Motor Speed - rpm This display indicates the drive motor speed in rpm.

5. Hydrostatic Circuit Temperature -°F or °C This display indicates the hydrostatic circuit temperature as read by the temperature sensor located on the drive pump.

6. Machine Hours - h This display indicates the total number of hours the machine has run.

NOTE ALSO: Hydraulic oil temperature can also be monitored using the hydraulic oil temperature gauge shown on the main menu.

The alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main menu of the computer display, together with the operating range chart in SECTION 3 to prevent damage to the hydraulic system.

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7. Machine Voltage - V This display indicates voltage levels in the electrical system.

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

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

A reading less than 20 volts indicates a possible faulty battery or alternator.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM 8. Travel Speed - mph or km/h This display indicates machine travel speed.

Note that front tire size information is used by the machine program to accurately calculate and display machine travel speed. Refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ FRONT TIRE SIZE to check or update front tire size settings.

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MAIN MENU PAGE From any menu page.

Press the menu button to go to the main menu page.

The main menu page displays the following selections: •

Adjust - Press F1 to select

•

Measure - Press F2 to select

•

Preferences - Press F3 to select

•

Info - Press F4 to select Press the back button to return to the page which was displayed when the main menu page was selected.

OR Press the menu button again to return to the page which was displayed when the main menu page was selected.

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ADJUST MENU

ENGINE ADJUST GROUP*

From the main menu page press the F1 button (Adjust) to access the adjust menu.

FAN ADJUST GROUP* (if equipped)

SERVICE ADJUST GROUP*

The following menu items can be selected: •

Engine Adjust Group*

•

Fan Adjust Group* (if equipped)

•

Service Adjust Group*

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection. *NOTE: Marked menu items can also be accessed from the main menu. Refer to COMPUTER ~ ADJUSTMENT MENU in THIS SECTION for more information.

NOTE ALSO: Service technicians have access to more options. Refer also to SERVICING THE MD3 WITH IQANrun 2 ~ ADJUST for more information about service related adjust options.

Press the back button (or F1) to return to the main menu page.

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MEASURE MENU

The following menu items can be selected.

• Voltage Inputs • Digital/Frequency Inputs • Digital Outputs • Current Outputs • J1939 Parameter Inputs CAC Temp PIN Engine % Torque PIN Engine Speed PIN Engine Temp PIN Engine Voltage PIN Engine Wait to Start PIN Fuel Rate PIN Total Fuel Used PIN Lamp Status PIN Low Coolant Level PIN Oil Pressure PIN Total Engine Hours PIN Water in Fuel Indicator PIN

From the main menu page press the F2 button (Measure) to access the measure menu.

•

Drive/HP Test

Used for drive test procedures refer to SECTION 8 in THIS MANUAL.

• Function Valve All control valve related inputs and outputs (winch, dozer, attachment pressure) • Variable Pitch Fan (if equipped) All variable pitch fan control related inputs and outputs.

• Differential Locks All differential lock related inputs and outputs.

•

Module Diagnostics

IQAN module diagnostic information.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

Press the back button (or F1) to return to the main menu page.

Refer to COMPUTER~MAIN MENU PAGE MEASURE MENU~EXAMPLE ~ MEASURE MENU for an example of measure menu navigation.

This menu is used by Tigercat Service technicians to view measured values on the MD3 display.

Refer also to SERVICING THE MD3 WITH IQANrun 2 ~ MEASURE/ GRAPH for more information about graphing and exporting measured values for service diagnostics.

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INPUT AND OUTPUT CHANNELS

Type Voltage in Voltage in Voltage in Voltage in Voltage in Voltage in Voltage in

Channel Name Drive Pedal Fwd Drive Pedal Rev Winch Lever Dozer Lever Joystick X Steer Travel Direction Select Travel Speed Control

Module Display (MD3) (VIN-A) Display (MD3) (VIN-B) Display (MD3) (VIN-C) Cab Module (XS2-A0) (VIN-C) Cab Module (XS2-A0) (VIN-E) Cab Module (XS2-A0) (VIN-F) Cab Module (XS2-A0) (VIN-G)

INPUTS Function Group Drive Logic Drive Logic Main Hydraulics Main Hydraulics Main Hydraulics Drive Logic Drive Logic

Activating Control/Sensor/Switch Front drive pedal potentiometer Rear drive pedal potentiometer Winch Select Switch/ Winch Lever Dozer lever Joystick movement left/right Direction selection switch Maximum speed control - Joystick Steer

Location Cab - Joystick Steering Cab - Joystick Steering Control panel RH Armrest LH Steer Joystick LH Steer Joystick LH Steer Joystick

Voltage in Voltage in Voltage in Voltage in Voltage in Voltage in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Digital in Frequency in

Drive Pressure Fwd Drive Pressure Rev Hystat Circuit Temp Hyd Oil Temp Brake Press. Low = 0V Fuel Level Winch Free Spool Fan Full On Fan Clean Engine Stop Lamp Charge Filter Bypass = 0V Front Diff Lock Crane Activate Crane Not Stowed Hazard Lights Hyd Oil Level Low = 5V Rear Diff Lock Constant Pressure AC Compressor Air Filter Restricted = 5V Seat Direction Park Brake Sensor Drive Motor Speed

Front Chassis Module (XA2-A0) (VIN-A) Front Chassis Module (XA2-A0) (VIN-B) Front Chassis Module (XA2-A0) (VIN-C) Front Chassis Module (XA2-A0) (VIN-D) Front Chassis Module (XA2-A0) (VIN-F) Front Chassis Module (XA2-A0) (VIN-G) Display (MD3) (DIN-D) Display (MD3) (DIN-E) Display (MD3) (DIN-F) Display (MD3) (DIN-G) Cab Module (XS2-A0) (DIN-J) Cab Module (XS2-A0) (DIN-K) Cab Module (XS2-A0) (DIN-M) Cab Module (XS2-A0) (DIN-O) Cab Module (XS2-A0) (DIN-Q) Cab Module (XS2-A0) (DIN-L) Cab Module (XS2-A0) (DIN-N) Cab Module (XS2-A0) (DIN-P) Cab Module (XS2-A0) (DIN-R) Cab Module (XS2-A0) (DIN-T) Cab Module (XS2-A0) (DIN-H) Front Chassis Module (XA2-A0) (DIN-H) Front Chassis Module (XA2-A0) (FIN-A)

Drive Logic Drive Logic Drive Logic Fan Control Logic Fault Management Fault Management Main Hydraulics Fan Control Logic Fan Control Logic Fault Management Fault Management Diff Lock Logic Main Hydraulics Main Hydraulics Drive Logic Fault Management Diff Lock Logic Main Hydraulics Fan Control Logic Fault Management Drive Logic Drive Logic Drive Logic

Drive pump forward pressure sensor Drive pump reverse pressure sensor Drive pump reverse pressure sensor Hydraulic oil temperature sensor Service brake pressure switch Fuel level sender Winch Select Switch Fan Control Switch Fan Control Switch Engine ECM Charge filter bypass switch Front Differential Lock Switch Unlock-Activate Crane/Park Brake Switch Crane Stowed Limit Switch Hazard Lights Switch Hydraulic oil level switch Rear Differential Lock Switch Constant Pressure (Grapple) button Air Conditioner Switch Air Filter Restrictor Sensor Seat direction switch Parking brake relay Drive motor speed sensor

Drive pump Drive pump Drive pump Hydraulic tank Main pump outlet manifold Rear chassis Control panel Control panel Control panel Engine Charge Pressure Filter head RH Armrest Control panel Rear Chassis Control panel Hydraulic tank RH Armrest RH Joystick button Control panel Front Chassis Rotating Seat Instrument Panel (Fuse and Relay) RH Drive motor

ad610c INPUTS OUTPUTS.xls 12/09

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Type Digital out Current out Current out Current out Current out Current out Digital out Digital out Digital out Digital out Digital out Digital out Digital out Digital out Digital out Digital out Digital out Digital out

Channel Name Alarm Drive Pump Fwd-/Rev+ Drive Motor Crane Activate Dozer Up-/Dn+ Steer Left-/Right+ Park Brake Off Winch In Winch (Aux) Out Back-Up Alarm Unloading Valve Off Front Diff Lock Rear Diff Lock Axle Oscillation Unlock Load Sense Override Axle Oscillation Make Up Fan Decrease/Block Fan Block/Increase

Module Display (MD3) (DOUT-A) Front Chassis Module (XA2-A0) (COUT-A) Front Chassis Module (XA2-A0) (COUT-B) Front Chassis Module (XA2-A0) (COUT-C) Front Chassis Module (XA2-A0) (COUT-E) Front Chassis Module (XA2-A0) (COUT-F) Cab Module (XS2-A0) (DOUT-D) Cab Module (XS2-A0) (DOUT-E) Cab Module (XS2-A0) (DOUT-F) Cab Module (XS2-A0) (DOUT-G) Cab Module (XS2-A0) (DOUT-H) Cab Module (XS2-A0) (DOUT-J) Cab Module (XS2-A0) (DOUT-K) Front Chassis Module (XA2-A0) (DOUT-J) Front Chassis Module (XA2-A0) (DOUT-A) Front Chassis Module (XA2-A0) (DOUT-B) Front Chassis Module (XA2-A0) (DOUT-E) Front Chassis Module (XA2-A0) (DOUT-F)

Electrical and Computers

OUTPUTS Function Group Fault Management Drive Logic Drive Logic Main Hydraulics Main Hydraulics Main Hydraulics Drive Logic Main Hydraulics Main Hydraulics Drive Logic Main Hydraulics Diff Lock Logic Diff Lock Logic Main Hydraulics Main Hydraulics Main Hydraulics Fan Control Logic Fan Control Logic

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Control Activated Alarm Light and Master Alarm Drive Pump Directional Solenoids Proportional solenoid control Control valve attachment pressure section Control valve Dozer section Joystick Steer Valve Park Brake Latch Relay Control valve winch section Control valve winch section Back-up alarm signal Main pump unloading valve Rear Differential Lock Solenoid Front Differential Lock Solenoid Axle Oscillation Unlock Solenoid Load Sense Override Solenoid Axle Oscillation Make Up Solenoid Fan Decrease/Block Solenoid Fan Block/Increase Solenoid

Location Intrument Panel Drive pump - front chassis Drive motor - front chassis Rear chassis Rear chassis Front chassis Cab fuse and relay panel Rear chassis Rear chassis Cab Main pump Multifunction Manifold Multifunction Manifold Pilot Manifold Pilot Manifold Pilot Manifold Pilot Manifold Pilot Manifold

Tigercat AD610C Carrier Channels The definition ‘channels’ is a collective name for the inputs and outputs found on the different IQAN modules. There are also channels internally in the system, to handle for example, MD3 messages and mathematical calculations. The channels are used to collect and/or send data. Input and output channels are described below.

Electrical and Computers TROUBLESHOOTING diagnostic breakout harnesses Diagnostic breakout harnesses are available for use to verify computer readings independently.

Refer to ELECTRICAL KIT - SERVICE AND DIAGNOSTICS in this section for more information about diagnostic breakout harnesses.

INPUTS Voltage in (vin) The input signal at these inputs comes primarily from analog sensors, levers, and switches. These devices use a power/signal/ground system to provide an input value (VIN) between the high (+5V) and low (-5V) signals generated in the modules.

Digital in (din) An input that is typically on or off, such as a switch. This input is often used to determine if an event has occurred, such as pushing a button or engaging a relay.

630c-211

Frequency in (fin) Typical functions are speed measure or revolution measure. This input can count the number of signals per second to determine the speed of a rotating or reciprocating body.

OUTPUTS PWM out (pwmout) PWM (Pulse Width Modulation) Out is a way of producing an analog signal level with a digital output that turns on and off many times a second.

By varying the ratio between on and off time (duty cycle) an output proportional to the system voltage can be obtained. PWMOUT maintains a constant output voltage, and the output current is governed by output voltage and the resistance in the circuit.

Current out (cout) In this application outputs labeled COUT are actually PWM signals programmed to operate in closed loop mode. The close loop mode features a PWM signal with current regulation. The programmed COUT channel maintains a constant output current to control proportional solenoids.

The voltage is regulated to maintain the constant current based on the programmed input command independant of the resistance of the circuit.

Digital out (dout) A PWMOUT with 100% duty cycle is a Digital Out (DOUT). The outputs have a value of low or high.

These are mostly used to activate lamps, on/off valves or to pull relays.

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diagnostic breakout harness

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EXAMPLE ~ MEASURE MENU:

measure group. Module and pin information for the highlighted channel is shown on screen.

The grey arrow(s) to the right at the top and/ or bottom of the screen indicate that more channels can be viewed above or below those currently on screen.

From the main menu page press the F2 button (Measure) to access the measure menu.

Press F2 to toggle between scaled value and raw value readings. Scaled values show the measured value in a scaled unit of measure (°C, %, psi etc). Raw value (where applicable) shows same readings as the raw value (mV, Hz etc) in which they are measured.

Note that for some channel types the raw value selection is not applicable and the reading will be displayed as “-” when viewing raw values.

Press F2 to return to the scaled values to view readings for these channels.

Press F1 (Main) to return to the main menu page.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

Press the back button return to the main menu.

OR Press the back button to return to the measure menu.

Press again to return to the main menu page.

Press again to return to the main menu.

Use the Arrow Up or Arrow Down move through the list of measured values in a 6.35

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PREFERENCES MENU

From the main menu page press the F3 button (Preferences) to access the preferences menu.

The following menu items can be selected for adjustment.

•

Display - Press F1 to select

•

Date/Time - Press F2 to select

•

Language - Press F3 to select Press the back button to return to the main menu page.

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DISPLAY ADJUSTMENT From the preferences menu press the F1 button to access display adjustment.

Screen Saver Adjustment Press F3 to access the screen saver adjustment.

•

Main Menu Page - Press F1 to select

Use the Arrow Up and Arrow Down buttons to scroll through the choices. Three choices are available:

•

Backlight - Press F2 to select Screen Saver - Press F3 to select

•

SCREEN SAVER OFF

•

•

DIMMED - Timeout - Dimmed light

•

BLACK - Timeout

The following menu items can be selected:

Press the back button to return to the preferences menu.

Backlight Adjustment Press F2 to access the backlight adjustment.

After making a selection press the OK button to confirm selection.

Use the Arrow Up or Arrow Down buttons to adjust the display backlight. The range is 10 to 100. The default setting is 100.

When the desired setting is selected press the OK button to confirm the setting. A good rule to follow is the lower the number the longer the life of the display unit.

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DATE/TIME ADJUSTMENT

Date Adjustment

From the preferences menu press the F2 button to access date/time adjustment.

Press F1 to access the date adjustment.

The following menu items can be selected:

Use the Arrow Up or Arrow Down to scroll through the YEAR list to select the year.

•

Date - Press F1 to select

Press the OK button to confirm year selected.

•

Time - Press F2 to select Press the back button to return to the preferences menu.

When the year has been confirmed the display will highlight the MONTH. Use the Arrow Up or Arrow Down to select the month.

Press the OK button to confirm month selected.

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Electrical and Computers Time Adjustment Press F1 to access the time adjustment.

When the month has been confirmed the display will highlight the DAY. Use the Arrow Up or Arrow Down to select the day.

Use the Arrow Up or Arrow Down to select the HOUR.

Press the OK button to confirm day selected.

Press the OK button to confirm selection.

The display will return to the Date/Time menu.

When the hour has been confirmed the display will show the MINUTES highlighted.

Press the back button to return to the preferences menu.

Use the Arrow Up or Arrow Down to select the minute.

Press OK button to confirm the selection.

The display will return to the DATE/TIME menu screen.

Press the back button to return to the preferences menu.

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LANGUAGE ADJUSTMENT

INFO MENU

From the preferences menu press the F2 button to access language adjustment screen.

From the main menu page press the F4 button

The languages available for selection will be shown.

Use the Arrow Up or Arrow Down to move to the preferred language.

Press OK to confirm the selection.

The display will return to the LANGUAGE menu screen.

Press the back button to return to the preferences menu.

(Info) and the access the info menu.

The machine ID information will be displayed on the screen.

The following menu items can be selected: •

Modules - Press F1 to select

•

Logs - Press F3 to select Press the back button to return to the main menu page.

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MODULES

LOGS

From the Info menu press F1 to select the modules menu.

Press F3 from the info menu page to select logs.

This menu provides information on the following machine modules: • • • •

Display (MD3 Computer Module) Cab Module (XS2 Module) Front Chassis Module (XA2 Module) Cummins Engine ECM

This menu lists the logs available in the machine program and the number of records within each log.

The records are a list of all the fault occurrences in each log. Records cannot be cleared by operators.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat Service technicians to view logs on the MD3 display. Refer also to IQANrun 2 ~ LOGS in THIS SECTION for more information regarding access and maintenance of logs using IQANrun 2.

Press the back button (or F1) to return to the main menu page.

Shown above the MD3 module has been selected.

Specific information for the MD3 is displayed on the screen.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

This menu is used by Tigercat service technicians.

Selected module diagnostics information is also accessible through the measure menu Press the back button (or F1) to return to the main menu page.

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MESSAGES AND WARNINGS alarm MD3 COMPUTER LIGHT

master alarm

INSTRUMENT PANEL The MD3 computer displays messages and warnings, activates the master alarm and alarm light whenever a system fault occurs. Note that the computer control system will automatically perform a bulb test at engine start up to ensure that master alarm and alarm light are functioning.

Refer to STARTING ENGINE in THIS SECTION. There are different types of Messages and Alarms, they appear on the screen as a block message.

The types of messages are: • • • •

CRITICAL MESSAGE - Colour RED ERROR MESSAGE - Colour RED ALERT MESSAGE - Colour YELLOW INFORMATION MESSAGE - Colour BLUE

Messages can be hidden or acknowledged by pressing the F2 button (Hide or OK).

All messages that have been hidden or acknowledged are stored in the computer.

In some instances it will be necessary to immediately stop the machine, shut the engine OFF and repair the problem causing the message.

Active fault messages that have been hidden can be reviewed by pressing the F4 button. Recalled messages and warnings will be displayed in order starting with the highest priority first.

NOTE: When contacting Tigercat Customer service about any message or warning it is very important to write down and communicate the whole message (all text shown on the screen).

This will greatly reduce troubleshooting time.

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CRITICAL MESSAGES and warnings (red) Critical messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Critical messages have the highest level of priority and are used to alert operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

When a critical message is displayed, the master alarm and alarm light will sound and flash continuously. The message remains on the screen until the operator hides it.

The message will give brief details of the fault and advise what action is necessary.

A list of CRITICAL MESSAGES is as follows: Hydraulic Oil Level Low. Drive Motor Overspeed Hydraulic Oil Temperature High

In some instances the machine requires immediate action to correct the problem which requires the operator to STOP machine operation, SHUT THE ENGINE OFF and service the machine to correct the problem.

Interlock System

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to move the machine to a safe location then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

Hardware Fault - XS2

Messages can be hidden by pressing the F2 button (Hide).

Engine Oil Pressure Low

Critical messages and warnings flash the critical

Engine Stop Hardware Fault - MD3 Hardware Fault - Engine Hardware Fault - XA2 Engine Coolant Temperature High Engine Coolant Level low Engine Intake Manifold Temperature High Engine Fault Code Messages - Critical

symbol above the F4 button when active messages are hidden. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Active messages that have been hidden can be reviewed by pressing the F4 button.

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CRITICAL messages and warnings

Hydraulic Oil Level Low.

Hydraulic Oil Level Low This warning will be displayed, alarm warning light will flash and alarm will sound when the main hydraulic tank oil level is low.

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

When this alarm is activated stop the engine and look for signs of broken hoses or other leaks.

Repair leaks and refill the main hydraulic tank to FULL mark on the sight gauge. Restart engine and inspect for leaks.

Drive Motor Overspeed. Reduce travel speed.

Drive Motor Overspeed This warning will be displayed, alarm warning light will flash and alarm will sound when the drive motor is overspeeding.

Reduce speed immediately when this alarm is activated to prevent damage to the machine.

Operating drive motors at high speeds will damage the drive motors.

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Hydraulic Oil Temperature High.

Hydraulic Oil Temperature High This warning will be displayed, alarm warning light will flash and alarm will sound when the oil temperature exceeds the recommended operating range for the type of hydraulic oil in use.

If the temperature rises above the recommended operating range for the type of hydraulic oil in use check the following: • • • • • •

Plugged oil cooler Malfunction in a hydraulic system High loads on the hydraulic system Malfunction of the cooling fan Low hydraulic oil level Correct Hydraulic Oil Grade Selection

If hydraulic oil temperature rises above the recommended operating range DO NOT continue to operate the machine.

This alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main menu, together with the operating range chart in SECTION 3 to prevent damage to the hydraulic system.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge.

Operating outside the recommended operating range will shorten hydraulic component life.

Refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in THIS SECTION for hydraulic oil grade selection settings information.

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

Refer to COMPUTER ~ INFORMATION MODE MENU ~ HYDRAULIC OIL TEMPERATURE in THIS SECTION for hydraulic oil temperature information display.

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Electrical and Computers

Interlock System Door open or park brake on! Machine drive disabled.

Interlock System This warning will be displayed, alarm warning light will flash and alarm will sound to a alert the operator that the interlock system has disabled the machine drive.

The interlock system prevents the machine from being driven and function controls from being operated while the parking brake is ENGAGED. The parking brake is operated using the parking brake switch. In addtion this machine automatically engages the parking brake whenever a cab door is open.

This message indicates that the parking brake was engaged, by the parking brake switch or opening a cab door, while the machine was in motion.

Engine Stop Critical engine fault active - contact dealer.

Engine stop This warning will be displayed, alarm warning light will flash and alarm will sound when the engine stops while the ignition switch is in the RUN position and/or when critical engine alarms are triggered.

Refer to engine manufacturer's manual for specific information regarding the engine.

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Hardware Fault - MD3 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - MD3 This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the MD3 Display module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF error is an example of the type of hardware fault which will be the original active fault which triggers this message.

Hardware Fault - Engine Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - Engine This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the Engine has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

No contact error is an example of the type of hardware fault which may be the original active fault which triggers this message.

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Hardware Fault - XS2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XS2 This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the XS2 Cab module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which triggers this message.

Hardware Fault - XA2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XA2 This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the XA2 Front Chassis module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF and no contact errors are examples of the type of hardware fault which may be the original active fault which triggers this message.

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Electrical and Computers

Engine Coolant Temperature High

Engine Coolant Temperature High This warning will be displayed, alarm warning light will flash and alarm will sound when engine temperature exceeds 225°F (107°C).

When this alarm is activated check for:

• •

Plugged air intake access panel screens Plugged radiator.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR’S MANUAL.

SPN: 111 FMI: 1 1 of 1 Engine coolant level low Below normal, severe.

SPN: 111 FMI: 1 1 of 1 Engine coolant level low Below normal, severe.

Engine Coolant Level low This warning will be displayed, alarm warning light will flash and alarm will sound when the coolant level drops below a safe operating level. The sensor is located in the surge tank.

WARNING

If this light comes on when the engine is running, stop the engine immediately and correct the fault.

With engine running, top up radiator using correct solution of coolant antifreeze.

Refer to SERVICE AND LUBRICATION POINTS CHART in SECTION 3 of THIS MANUAL.

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

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

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

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SPN: 105 FMI: 0 1 of 1 Intake manifold temperature high Above normal, most severe SPN: 105 FMI: 0 1 of 1 Intake manifold temperature high Above normal, most severe

Intake manifold Temperature High This warning will be displayed, alarm warning light will flash and alarm will sound when engine charge air cooler temperature exceeds 205°F (96°C).

When this alarm is activated check for: •

Plugged air intake access panel screens

•

Plugged charge air cooler.

DO NOT continue to operate machine.

Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR’S MANUAL.

SPN: 100 FMI: 1 1 of 1 Engine Oil Pressure Low Below normal, most severe SPN: 100 FMI: 1 1 of 1 Engine Oil Pressure Low Below normal, most severe

Engine Oil Pressure Low This warning will be displayed, alarm warning light will flash and alarm will sound when engine oil pressure falls below 10psi (0.7Bar).

Stop the engine when this alarm is activated.

Check engine oil levels.

Refer to STARTING ENGINE in SECTION 2 of the OPERATOR’S MANUAL for more information.

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Electrical and Computers

SPN: 612 FMI: 2 1 of 1 Crankshaft speed/position signal lost Erratic or intermittent SPN: 612 FMI: 2 1 of 1 Crankshaft speed/position signal lost Erratic or intermittent

ENGINE FAULT CODE MESSAGES - CRITICAL Critical engine fault message(s) will be displayed, alarm warning light will flash and alarm will sound when a critical engine fault message is received from the engine electronic control module.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Critical engine fault codes are higher priority messages than alert level engine fault code messages. Critical messages can be hidden but immediate action must be taken, STOP machine operation and service engine immediately to resolve the cause of the fault.

An example of a critical engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

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ERROR MESSAGES (red) Error messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Error messages are computer system generated and are generally triggered by computer system error and fault related conditions.

Error messages have the second highest level of priority and are used to alert operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

A list of some types of ERROR MESSAGES is as follows:

Error messages are activated whenever a fault such as an electrical connection is broken/ disconnected. Most error messages are due to computer system hardware or connection faults.

Module No Contact Error Module VREF Error Voltage Input Error (VIN)

When an error message is displayed, the master alarm and alarm light will sound and flash continuously. The message remains on the screen until the operator hides it.

Digital Input Error (DIN) Digital Output Error (DOUT) Current Output Error (COUT)

The message will give brief details of the fault and advise what action is necessary.

* Note that not all error messages are shown.

In some instances the machine requires immediate action to correct the problem which requires the operator to STOP machine operation, SHUT THE ENGINE OFF and service the machine to correct the problem.

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to move the machine to a safe location then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

Messages are acknowledged by pressing the F2 button (OK). To recall active messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

Error messages flash the critical symbol

or the

above the F4 button when active messages are hidden depending on the type of error message. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Active messages that have been hidden can be reviewed by pressing the F4 button.

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ERROR messages MD3

Display VREF error

XS2-A0

Cab Module VREF error

XA2-A0

Front Chassis Module VREF error

MODULE VREF ERROR The module VREF message will be displayed to indicate a problem related to the 5 V reference signal coming from the module.

The module is identified on the display screen.

This message indicates a problem with a sensor, connecting wires or the 5V reference signal itself.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HARDWARE FAULT in THIS SECTION.

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Electrical and Computers Cab Module Pin C1:25

Travel Direction Select VIN High error

VOLTAGE INPUT ERROR (VIN) Voltage input error messages will be displayed to indicate a problem with a voltage input signal to a computer system module.

The module and pin number are identified on the display screen.

CURRENT OUTPUT ERROR (COUT)

The heading identifies the signal source and the text indicates the type of error.

Current output error messages will be displayed to indicate a problem with a current output signal from a computer system module.

An example of a voltage input error message is shown above.

The module and pin number are identified on the display screen.

DIGITAL INPUT ERROR (DIN)

The heading identifies the signal destination and the text indicates the type of error.

Digital input error messages will be displayed to indicate a problem with a digital input signal to a computer system module.

The display is similar to the voltage input error message shown above.

The module and pin number are identified on the display screen.

Once acknowledged these message will be replaced with a hardware failure message for the corresponding module when active faults recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAILURE in THIS SECTION.

The heading identifies the signal source and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

DIGITAL OUTPUT ERROR (DOUT) Digital output error messages will be displayed to indicate a problem with a digital output signal from a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal destination and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

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Electrical and Computers XS2-A0

Cab Module No contact

XA2-A0

Front Chassis Module No contact

J1939-B0

Cummins QSB 6.7L No contact

MODULE NO CONTACT ERROR The module no contact error message will be displayed to indicate a loss of communication with or power to a module. The module is identified on the display screen.

When a module goes loses contact all machine functions controlled by that module cease and all messages and warnings associated with that module are triggered. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

Note that if the MD3 display module has a loss of power or other malfunction the screen may go blank and all machine functions controlled by the computer system will be affected..

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HARDWARE FAULT in THIS SECTION. Continued on page 6.56

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MD3 MODULE BLANK SCREEN The MD3 module is the central unit in the IQAN control system, which works as both a master and a display unit. Faults or failure in this unit will affect all other IQAN components.

Likely causes are: • Power - Fuse (MD3 module) • Ground • LCD display settings too light to read • Faulty MD3 module

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Electrical and Computers B A

XS2 MODULE LED INDICATORS 2. Check module status indicators The XS2 module also indicates error status through the yellow/red blinking LED.This gives an immediate diagnosis as to the nature of the error that has occurred.

XS2-A0 MODULE no contact ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(A) Supply Voltage LED (green).

1. Check for other error/alarm messages on screen

LED OFF indicates supply voltage is OFF.

LED with green light ON indicates supply voltage is ON.

Press OK to acknowledge each error message. Note that module no contact errors will be followed by other alarm messages associated with the module(s) which is(are) out of contact.

(B) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

If XS2-A0 MODULE NO CONTACT is the only module is NO CONTACT error message the likely causes are:

•

One red primary flash and one secondary yellow flash indicates an error controlled by the master (MD3).

• Power - Fuse (XS2 MODULE)

•

Two red primary flashes in a row and one yellow secondary flash indicates an error controlled by the master (MD3).

•

Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN-bus.

•

Three red primary flashes in a row and two yellow secondary flashes in a row indicates that the fault is related to the address.

•

Four red primary flashes in a row and one yellow secondary flash indicates a memory error.

•

Continuous red primary flashing indicates a fatal error.

• Ground • Address (ID-Tag) If the XS2-A0 MODULE NO CONTACT is followed by an XA2-A0 NO CONTACT error the likely cause is: • CAN wire connection LED indicator showing different XS2 and XA2 modes Status

Flash

Normal operation (yel.)

Error code

Error

1:n

See note a

2:n

See note a

3:1

CAN error

3:2

Address error

4:1

Memory errorb

FE

Fatal error

Primary Flash (red) Error category

Secondary Flash (yellow) Error description

Internal diagnostics in the master (MD3) can be used to get more information about the XS2 module. The following values are supervised: • • • •

a. Error groups 1:n and 2:n are controlled by the master. b. FRAM memory error.

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Internal temperature (°C) Power supply (V) Reference voltage (V) CAN address voltage (V)

Tigercat AD610C Carrier

Electrical and Computers B A

XA2 MODULE LED INDICATORS 2. Check module status indicators The XA2 module also indicates error status through the yellow/red blinking LED.This gives an immediate diagnosis as to the nature of the error that has occurred.

Xa2-A0 MODULE no contact ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(A) Supply Voltage LED (green).

LED with green light ON indicates supply voltage is ON.

1. Check for other error/alarm messages on screen

LED OFF indicates supply voltage is OFF.

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) out of contact.

Note also that the XA2-A0 module is the terminal module in the series connection.

Therefore failure of this module alone will not affect any other modules in the series.

(B) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: • •

If XA2-A0 MODULE NO CONTACT is the only module is NO CONTACT error message the likely causes are: • Power - Fuse (XA2 MODULE)

•

Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN-bus.

•

Three red primary flashes in a row and two yellow secondary flashes in a row indicates that the fault is related to the address.

• Ground • Address (ID-Tag) • CAN wire connection If the XA2-A0 MODULE IS OFFLINE error is not the only module is offline error message check other affected modules in order from the MD3 connection (XS2-A0).

One red primary flash and one secondary yellow flash indicates an error controlled by the master (MD3).

Two red primary flashes in a row and one yellow secondary flash indicates an error controlled by the master (MD3).

LED indicator showing different XS2 and XA2 modes Status

Flash

Normal operation (yel.)

Refer to MODULE NO CONTACT ERROR for each module for more detailed information.

Error code

Error

1:n

See note a

2:n

See note a

3:1

CAN error

3:2

Address error

4:1

Memory errorb

FE

Fatal error

Primary Flash (red) Error category

Secondary Flash (yellow) Error description

a. Error groups 1:n and 2:n are controlled by the master. b. FRAM memory error.

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Electrical and Computers

Four red primary flashes in a row and one yellow secondary flash indicates a memory error.

•

Continuous red primary flashing indicates a fatal error.

Internal diagnostics in the master (MD3) can be used to get more information about the XS2 module. The following values are supervised: • • • •

Internal temperature (°C) Power supply (V) Reference voltage (V) CAN address voltage (V)

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ALERT MESSAGES (YELLOW) Alert messages advise the operator that machine operation will be compromised.

Alert messages have the third level of priority and are used to indicate to the operator that action is required to prevent future damage to the machine.

All alert message will give brief details of the fault and advise what action is necessary.

Action should be taken to service the machine to correct the problem at the earliest opportunity to prevent future damage to the machine.

There are two types of alert messages: Alert programmed messages generally triggered by machine function related conditions.

Alert messages flash the alert symbol above the F4 button when active messages are hidden.

When an alert message is displayed, the external alarm and light will sound and flash three times to alert the operator of the message. The message remains on the screen until the operator hides it.

Messages can be hidden by pressing the F2 button (Hide).

Alert computer system generated messages are generally triggered by computer system error and fault related conditions.

Active messages that have been hidden can be reviewed by pressing the F4 button. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

When a system generated alert message is displayed he external alarm and light will sound and flash three times to alert the operator of the message.

Note that if both a critical level fault and an alert level fault are present the critical symbol will take priority until the critical fault becomes inactive.

The message remains on the screen until the operator hides it.

Note that active hardware fault alert messages are acknowledged by pressing the F2 button (OK). To recall these messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

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A list of ALERT MESSAGES is as follows: Fuel Level low.

Engine Air Intake Filter Restricted Drive Charge Filter Bypassed Machine Voltage Low. Machine Voltage High Drive Motor Speed Sensor No motor speed Service Brake Pressure Low Drive Charge System Pressure Low. Fuel Water In Fuel Hardware Fault - MD3 Hardware Fault - XS2 Hardware Fault - XA2 Hardware Failure - VIN Hardware Failure - DIN Hardware Failure -DOUT Hardware Failure -COUT Engine Voltage Low Engine Voltage High Engine Fault Code Messages - Alert Some types of computer system generated alert messages are listed below: Module High Temperature - Alert Module High Supply Voltage - Alert Module Low Supply Voltage - Alert * Note that not all system generated alert messages are shown.

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ALERT MESSAGES

Fuel Level low.

Fuel Level low This warning will be displayed when the fuel level falls below 5% of full.

Refer to FUEL TANK in SECTION 2 of the OPERATOR’S MANUAL for tank capacities.

Engine Air Intake Filter Restricted. Service Machine to correct.

Engine Air Intake Filter Restricted This warning will be displayed when a signal is received from the restriction indicator switch on the engine air cleaner.

When this happens the engine air cleaner requires immediate service.

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

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Drive Charge Filter Bypassed. Service machine to correct.

Drive Charge Filter Bypassed This warning will be displayed when an oil flow restriction in excess of 50 psi (3.5 Bar) is encountered at the hydrostatic oil charge filter.

This pressure build up also opens the filter bypass valve in the filter head allowing oil to bypass the filter element.

When this happens the filter requires immediate service.

If alarm sounds during cold start-ups, the engine speed should be reduced and the warm-up procedure continued. Note that the bypass warning will only be displayed when hydraulic oil temperature is above 85°F (29°C) and the filter is in bypass mode.

Machine Voltage Low. Service machine to correct.

Machine Voltage Low This warning will be displayed when machine voltage readings of less than 20 volts are detected.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

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Machine Voltage High. Service machine to correct.

Machine Voltage High This warning will be displayed when machine voltage readings of greater than 30 volts are detected.

Machine voltage readings indicate voltage levels in the electrical system.

When this alarm is activated investigate the cause immediately.

Drive Motor Speed Sensor No motor speed. Drive overload or speed sensor malfunction.

Drive Motor Speed Sensor No motor speed This warning will be displayed when a drive motor speed sensor malfunction is detected.

If the message is displayed when the machine is not travelling it indicates a drive overload. Check drive pump POR. If this message is displayed when the machine is travelling it indicates a sensor malfunction.

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Service Brake Pressure Low. Service machine to correct.

Service Brake Pressure Low This warning will be displayed when service brake pressure falls below 800 psi (55 Bar).

When this warning is activated check first for leaks in the brake circuit. If no leaks are found check for proper operation of the brake pressure section of the control valve and check the brake pressure sensor for proper operation.

For more information about the service brake circuit refer to SECTION 9 of THE SERVICE MANUAL.

Drive Charge System Pressure Low. Service machine to correct.

Drive Charge System Pressure Low This warning will be displayed when drive charge pressure falls below 250 psi (17 Bar). The charge pressure is monitored at the forward and reverse pressure sensors on the drive pump.

When this warning is activated check the charge filter for proper operation then, if necessary, check the charge pressure using a gauge.

Refer to DRIVE PUMP PRESSURE CHECKS in SECTION 8 of THE SERVICE MANUAL. Refer also to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ DRIVE CHARGE FILTER BYPASSED in THIS SECTION.

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SPN: 97 FMI: 15 1 of 1 Water in Fuel Above normal.

SPN: 97 FMI: 15 1 of 1 Water in Fuel Above normal.

Fuel - Water In Fuel This warning will be displayed when water is detected in the fuel by the engine computer system.

Refer to engine manufacturer's manual for specific information regarding the engine.

Hardware Fault - MD3 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - MD3 This warning will be displayed when an alert level active hardware fault related to the MD3 Display module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

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Hardware Fault - XS2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XS2 This warning will be displayed when an alert level active hardware fault related to the XS2 Cab module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

Hardware Fault - XA2 Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XA2 This warning will be displayed when an alert level active hardware fault related to the XA2 Front Chassis module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

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Hardware Failure - VIN Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

hardware failure - vin This warning will be displayed when a voltage input error message has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

Hardware Failure - DIN Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

hardware failure - din This warning will be displayed when a digital input error message has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

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Hardware Failure - DOUT Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

hardware failure - dout This warning will be displayed when a digital output error message has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

Hardware Failure - COUT Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

hardware failure - cout This warning will be displayed when a current output error message has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

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SPN: 168 FMI: 18 1 of 1 Engine voltage low Below normal, severe SPN: 168 FMI: 18 1 of 1 Engine voltage low Below normal, severe

Engine Voltage Low This warning will be displayed when engine voltage readings of less than 20 volts are detected.

When this alarm is activated investigate the cause immediately.

SPN: 168 FMI: 16 1 of 1 Engine voltage high Above normal, severe SPN: 168 FMI: 16 1 of 1 Engine voltage high Above normal, severe

Engine Voltage High This warning will be displayed when engine voltage readings of greater than 30 volts are detected.

When this alarm is activated investigate the cause immediately.

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SPN: 110 FMI: 16 1 of 1 Engine coolant temperature high Above normal, severe SPN: 110 FMI: 16 1 of 1 Engine coolant temperature high Above normal, severe

ENGINE FAULT CODE MESSAGES - alert Alert engine fault message(s) will be displayed, alarm warning light will flash and alarm will sound when an alert engine fault message is received from the engine electronic control module.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Alert engine fault codes are lower priority messages than critical level engine fault code messages. Alert messages can be hidden but action (service engine) is required to resolve the cause of the fault.

An example of an alert engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

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Electrical and Computers MD3

Display High temperature

Value: 75 °C

XS2-A0

Cab Module High temperature

Value: 81 °C

XA2-A0

Front Chassis Module High temperature

Value: 84 °C MODULE HIGH TEMPERATURE - ALERT Module high temperature alert message will be displayed to indicate that the computer control system has detected high temperature readings in a system module.

The module is identified on the display screen.

The temperature reading value is also displayed.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAULT in THIS SECTION.

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Display High supply voltage

Value: 34 V

XS2-A0

Cab Module High supply voltage

Value: 37 V

XA2-A0

Front Chassis Module High supply voltage

Value: 34 V MODULE HIGH SUPPLY VOLTAGE - ALERT Module high supply voltage alert message will be displayed to indicate that the computer control system has detected high supply voltage readings in a system module.

The module is identified on the display screen.

The voltage reading value is also displayed.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAULT in THIS SECTION.

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MODULE LOW SUPPLY VOLTAGE - ALERT MD3

Display Low supply voltage

XS2-A0

Cab Module Low supply voltage

XA2-A0

Front Chassis Module Low supply voltage

Module low supply voltage alert message will be displayed to indicate that the computer control system has detected low supply voltage readings in a system module.

The module is identified on the display screen.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAULT in THIS SECTION.

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INFORMATION MESSAGES (BLUE) Information messages give the operator information regarding an event or problem condition while the event or problem exists.

Information messages have lowest priority and are used to give the operator information that is useful to the operator, but requires no action to prevent immediate or future damage to the machine When an information message is displayed on the screen the message will either automatically disappear when the condition no longer exists or stay on the screen until the operator acknowledges the message.

A list of the INFORMATION MESSAGES is as follows:

Information messages can be acknowledged by pressing the F2 button (OK). Acknowledged information messages are removed from the screen.

Setup Mode - Function Valve Setup

Setup Mode - Drive Motor Setup Mode - Drive Pump POR Setup Mode - Engine HP Test Mode Interlock System - Crane Not Stowed. Machine drive disabled.

Interlock System - Crane Not Stowed. Machine hydraulics disabled.

Information messages do not have an indicator after they have been acknowledged.

Most information messages that have been acknowledged cannot be reviewed.

Recurrence of an event or problem condition related to an information message may cause the message to be shown again.

Restarting the machine may also cause the message to be shown again.

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INFORMATION MESSAGES

IMPORTANT !

Machine must be in the Normal Program Mode to operate normally.

setup mode One of these warnings will be displayed until the message is acknowledged when the machine is placed in a service program mode: •

Engine HP Test Mode

•

Drive Motor Setup Mode

•

Drive Pump POR Setup Mode

•

Function Valve Setup Mode

Other program modes are used for service/setup procedures only.

When setup program modes are chosen an information message is shown on the electronic display until the message is acknowledged.

In Engine HP Test Mode, Drive Motor Setup Mode and Drive Pump POR Setup Mode dozer, winch and attachment pressure are deactivated.

Attempting to use these controls will reactivate the information message.

Setup Program Modes are intended for setup and testing and should only be used by qualified Tigercat service technicians or on specific instructions from a service technician.

In Function Valve Setup Mode the drive pedals are deactivated. Attempting to use these controls will reactivate the information message.

NOTE ALSO: •

In Engine HP Test Mode, Drive Motor Setup Mode and Drive Pump POR Setup Mode dozer, winch and attachment pressure are deactivated. Attempting to use these controls will reactivate the information message.

•

In Function Valve Setup Mode the drive pedals are deactivated. Attempting to use these controls will reactivate the information message.

For more information on the setup mode settings refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ PROGRAM MODE in THIS SECTION.

Setup Mode Engine HP Test Mode for service use only.

Return to Normal Mode to operate machine.

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Electrical and Computers

Setup Mode Drive Motor Setup Mode for service use only.

Return to Normal Mode to operate machine.

Setup Mode Drive Pump POR Setup Mode for service use only. Return to Normal Mode to operate machine.

Setup Mode Function Valve Setup Mode for service use only.

Return to Normal Mode to operate machine.

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Interlock System Crane Not Stowed. Machine drive disabled.

Interlock System crane not stowed. machine drive disabled This message will be will be displayed when attempted is made drive the machine while the crane is not stowed.

Check that the crane is properly stowed and locked and the sensor is functioning correctly.

The interlock system prevents accidental activation of the drive controls while the crane is not stowed.

Interlock System Crane Not Stowed. Machine hydraulics disabled.

Interlock System crane not stowed - machine hydraulics disabled This message will be displayed when an attempt is made to operate a machine hydraulic function while the crane is not stowed.

Check that the crane is properly stowed and locked and the sensor is functioning correctly.

The interlock system prevents accidental operation of machine hydraulic functions not related to the operation of the crane from being operated while the crane is not stowed.

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Electrical and Computers

Interlock System Park brake on. Cycle switch to disengage.

Interlock SPN: 168 System FMI: 16 1 of 1

Park brake on. high Cycle Engine voltage - switch to disengage.

Above normal, severe

interlock system park brake on. CYCLE SWITCH TO DISENGAGE This message will be will be displayed when the engine is started with the parking brake/unlockactivate crane switch is not in the parking brake ON position.

Place the parking brake/unlock-activate crane switch in the parking brake ON position and then choose either the parking brake OFF (drive) position or the activate-unlock crane position to proceed.

This interlock prevents accidental machine movement when starting the machine.

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Electrical and Computers

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Electrical and Computers

TEMPORARY FIX for ENGINE RPM CONTROL PROBLEMS CAUSED BY J1939 CONNECTION ERRORS In the event of a J1939 connection error normal engine RPM control may be disabled.

It is possible to temporarily default engine RPM to high idle in order to move the machine to a better location for further trouble shooting and repair.

To temporarily default engine RPM control to high idle place any fuse in the position shown.

place any fuse to default engine rpm to high idle 625C-95

electrical box (left side front chassis)

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Tigercat AD610C Carrier

Electrical and Computers

ELECTRICAL KIT - SERVICE AND DIAGNOSTICS This kit includes a variety of electrical connectors, tools, cable, IQAN components, diagnostic breakout harnesses and service harnesses (Tigercat part number 20045B).

Selected Items 1. DIAGNOSTIC BREAKOUT HARNESS DEUTSCH connector - CURRENT (20036B) This harness is used to check current (amps) flow to a component with a Deutsch connector and verify outputs.

630c-211

2. DIAGNOSTIC BREAKOUT HARNESS DEUTSCH connector - voltage (20037b)

7. ID-TAG ‘0’ (an068) This is a replacement address tag. Refer to ID-TAG in THIS SECTION for more detailed information.

This harness is used to check voltage (volts) to a component with a Deutsch connector and verify inputs.

8. ID-TAG ‘0T’ (an071) This is a replacement address/terminating tag.

Refer to ID-TAG in THIS SECTION for more detailed information.

3. DIAGNOSTIC BREAKOUT HARNESS amp connector - CURRENT (20038b) This harness is used to check current (amps) flow to a component with a Amp connector and verify outputs.

9. DEUTSCH 2 POLE SERVICE HARNESS (24860b) This harness is used to bypass a wiring harness while troubleshooting electrical problems. This will identify or eliminate the wiring harness as a cause.

4. DIAGNOSTIC BREAKOUT HARNESS amp connector - voltage (20039b) This harness is used to check voltage (volts) to a component with an Amp connector and verify inputs.

10. AMP 2 POLE SERVICE HARNESS (24859b)

5. USB CABLE (TYPE A-B) (AN155) This cable is used to connect the IQAN MD3 (via the machine USB port) to an isolated USB hub plugged into a PC/Laptop.

IMPORTANT !

Connecting the USB cable directly to the USB port on a PC/Laptop is NOT recommended.

Using an isolated USB hub will protect your PC/Laptop USB port and the MD3 module from ground loops which can cause communication signal problems or damage to the PC/Laptop and MD3 module.

6. USB HUB (4 PORT, TYPE A, isolated (AN154)

diagnostic breakout harness

)

This isolated USB hub is used to protect your PC/Laptop and the MD3 module from ground loops. can cause communication signal problems or damage to the PC/Laptop or module.

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This harness is used to bypass a wiring harness while troubleshooting electrical problems. This will identify or eliminate the wiring harness as a cause.

Tigercat AD610C Carrier

Electrical and Computers

1

2

9

3

4

10

5

TWISTED PAIR WIRE REPAIR HARNESS

6

7

855c-002

8

ELECTRICAL KIT - SERVICE AND DIAGNOSTICS - SELECTED ITEMS 6.83

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Electrical and Computers

iqan software IQAN Active Studio software can be downloaded from the Tigercat Dealer Website.

All software required for PC/Laptop use is included in this download. A user’s manual in PDF format is also included. Some of the software requires a software key (available from Tigercat).

Contact Tigercat Customer Service for more information about specific hardware requirements for PC/Laptop.

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application PROGRAM UPDATES for product service bulletins Machine program updates are also available on the Tigercat dealer website. These program updates are generally associated with specific Product Service Bulletins. Updating of programs should only be undertaken as part of a PSB or under instruction from Tigercat Customer Service.

The latest version of the application can be run on any machine provided that all applicable Product Service Bulletin updates have been completed.

DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE NOTE: The following downloading instructions apply to the Tigercat dealer website format at the time of printing. If you experience difficulty due to changes on the website contact Tigercat Customer Service for assistance.

3. Select the folder you wish to save the program in.

4. Click on Save.

5. The IQAN program file has now been downloaded.

1. Click on the IDA to the right of the file you wish to download.

2. Click on Save.

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Tigercat AD610C Carrier SERVICING THE MD3 WITH IQANrun 2

IQANrun 2 QUICK SUMMARY

REQUIRED EQUIPMENT & INFORMATION

CONNECT TO THE MD3 WITH IQANrun2

1. PC/Laptop

Servicing the computer system requires a PC/ Laptop, the use of IQANrun2 software, a USB hub and a USB cable. Refer to CONNECT TO THE MD3 WITH IQANrun 2 in THIS SECTION for details.

2. IQAN MD3 SERVICE KIT (40705B) a. IQAN Active Studio software,Tigercat part number DG047. Refer to IQAN SOFTWARE in THIS SECTION for dealer website download information. b. USB hub (4 port, Type A, isolated Tigercat part number AN155

),

c. USB cable (Type A-B), Tigercat part number AN154 3. Service Password. Contact Tigercat Service department to obtain passwords and additional information.

Electrical and Computers

LOGIN Some service operations require username and password access. Refer to LOGIN in THIS SECTION for details.

UPDATE Most commonly used operation. Use to update the MD3 to a newer program or program revision.

Does not overwrite settings. Refer to UPDATE APPLICATION in THIS SECTION for details.

GET SETTINGS Gets and saves the existing settings from the MD3. Recommended as a backup prior to tuning or updating the applicaton. Refer to IQANRUN 2 ~ UPDATE APPLICATION ~ GET SETTINGS in THIS SECTION for details.

SEND SETTINGS Sends a previously saved settings file to the MD3.

Overwrites factory default, adjustable and stored values. Only to be used under the direction of Tigercat Customer Service or Engineering. Refer also to important notes on the use of settings files at the end of IQANRUN 2 ~ UPDATE APPLICATION ~ GET SETTINGS in THIS SECTION. GET CLONE Gets and saves the existing application, settings and machine ID from the MD3. Recommended as a backup prior to tuning or updating the application.

Refer to IQANRUN 2 ~ UPDATE APPLICATION ~ GET CLONE in THIS SECTION for details.

SEND CLONE Sends a previously saved clone file to the MD3.

Overwites the application, factory defaults, adjustable values, stored values and machine ID. Only to be used under the direction of Tigercat Customer Service or Engineering. Refer also to important notes on the use of settings files at the end of IQAN RUN 2 ~UPDATE APPLICATION ~ GET CLONE in THIS SECTION.

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ADJUST Allows access to adjustment groups. In addition to adjust groups normally accessible on screen additional adjust groups that require sufficient rights restricted by username and password login. Refer to IQANRUN 2 ~ ADJUST in THIS SECTION for details.

MEASURE (GRAPH) Allows the user record, graph and measure group channel readings during machine operation, testing or setup procedures. These recordings can be saved or printed. Refer to IQANRUN 2 ~ MEASURE (GRAPH) in THIS SECTION for details.

LOGS Allows the user to access to logs for service troublshooting, maintenance documentation or clearing. Some log operations require sufficient rights to perform. Refer to IQANRUN 2 ~ LOGS in THIS SECTION for details.

SYSTEM Allows the user to access system information including machine serial number information.

Refer to IQANRUN 2 ~ SYSTEM in THIS SECTION for details.

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CONNECT TO THE MD3 WITH IQANrun 2

grey indicates, not connected to md3

PC/Laptop USB port and the MD3 module from ground loops which can cause communication signal problems or damage to the PC/Laptop and MD3 module.

4. Connect the other end of the USB A/B Cable to the MD3 USB connector. Exact location of the connector will vary between machine models.

1. Turn on PC/Laptop and launch IQANrun by double clicking the shortcut on your desktop.

IQANrun is part of the IQAN Active Studio.

2. Turn the machine key switch to the ‘ON’ position, so the MD3 has power. Do not start machine.

green indicates, connected to md3

5. IQANrun will now indicate that it is online.

Proceed with service operations and login if required. Refer to LOGIN in THIS SECTION. NOTE: If the MD3 does not contain an application (replacement module), the application will have to be Updated, before a user can login. Refer to UPDATE APPLICATION and LOGIN in THIS SECTION.

3. Connect the USB Hub into the PC/Laptop USB jack. Then connect the USB cable into the hub.

IMPORTANT !

Connecting the USB cable directly to the USB port on a PC/Laptop is NOT recommended.

Using an isolated USB hub will protect your 6.88

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Electrical and Computers

LOGIN 1. Press the Login button on the left.

login

LOGGED IN username

NOT LOGGED IN

4. The Login status at the bottom of the screen now indicates the login username.

1. A dialog box will appear, asking for a Username and Password. Contact the Tigercat Service Department for the Username and Password.

5. Note that each username and password combination comes with access rights appropriate for that user’s function.

If a user has insufficient rights to perform an operation (or is not logged in when login is required) a dialog box will pop up to inform the user that this operation is not possible without the correct login and password.

2. A dialog box will appear to confirm a successful login. Click OK to continue.

NOTE - SERVICE PASSWORDS: Contact Tigercat Service department to obtain passwords and additional information.

Note: After a successfully login, Windows provides the option to save the password. If Yes is selected, only the Username will be required at the next login.

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Tigercat AD610C Carrier UPDATE APPLICATION

Electrical and Computers A. GET CLONE FILE

Updating of machine programs should only be undertaken as part of a PSB or under instruction from Tigercat Customer Service.

Before updating an application, it is recommended that a Clone file and Settings file are taken from the MD3 and saved.

A. Get Clone file and save (*.irc).

A Clone file contains the application, machine ID, the settings and logs from the MD3. It is a good record of exactly what was in the machine before the update.

get clone

B. Get Settings file and save (*.isa).

A Settings file contains only the settings (factory defaults and adjustable values) from the MD3.

C. Update application.

1. Click on the Get Clone button on the left.

A dialog box will appear prompting the user to select whether or not to get the logs with the clone.

Application programs (*.ida) are available on the Tigercat dealer website. Refer to DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE in THIS SECTION.

Click on Yes to continue.

2. IQANrun will now get a clone. This might take several minutes.

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Tigercat AD610C Carrier

Electrical and Computers b. GET settings FILE

get settings

3. A dialog box will appear prompting selection of a suitable folder and file name to save the Clone file (.irc).

The file name by default is the machine ID (serial number). It is recommended to use the serial number followed by the date for the file name.

4. Click on the Get Settings button on the left.

5. A dialog box will appear prompting selection of a suitable folder and file name to save the Settings file (.irs).

The file name by default is the machine ID. It is recommended to use the serial number followed by the date for the file name.

Press Save to continue.

IMPORTANT !

A Clone file should rarely be used. It should only be used if updating the application and/ or settings file is not successful in returning a machine’s performance to a previously acceptable state. A Clone file may be date sensitive and should only be used on the day that they were taken.

Press Save to continue.

IMPORTANT !

A Settings file should rarely be used. It should only be used if manually adjusting machine settings is not successful in returning a machine’s performance to a previously acceptable state. Settings files may be date sensitive and should only be used on the day that they were taken.

A Clone should NOT be used on a machine different than that which it was taken from, as machine specific configurations may differ and cause the machine to function improperly.

If a Settings file is used on a machine different than that which it was taken from, all adjustments must be reviewed in IQANrun to ensure machine specific parameters (such as options, pump/motor currents, hour counters) are correct. If this is not done the machine may function improperly.

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c. update APPLICATION TO MD3 Ensure that a Clone file and Settings file are saved as a backup prior to Update. Refer to GET CLONE FILE and GET SETTINGS FILE in THIS SECTION.

update

10. IQANrun 2 will provide warning to ensure the machine is not moving and that the engine is shut down (keyswitch in the run position to power the MD3, engine not running).

Press OK to continue, if the machine is inactive.

6. Click on the Update button on the left.

7. A dialog box will appear, prompting the selection of an MD3 application file (.ida).

Select the appropriate application file for the machine.

8. Click on Open to continue.

11. IQANrun will now send the application to the MD3.

9. IQANrun 2 will request confirmation that the application being loaded is correct.

Click on Yes to continue, if the application is correct.

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12. Once the application is loaded successfully, the dialog box will indicate the application was successfully sent.

The MD3 will restart and show the main screen of the application.

The Update is now complete.

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ADJUST 1. Click on the Adjust button on the left.

ADJUST

LOCK SYMBOL INDICATES PIN REQUIRED

EXAMPLE ADJUST SCREEN WITHOUT LOGIN ACCESS

2. The adjust groups available will be shown on the right.

3. Double click an adjust group to adjust channels in that group.

Note that a lock symbol to the left of an adjust group indicates that a PIN/password is required to access that group. Contact Tigercat Service department to obtain password information.

Note also that some adjust groups are accessible through the MD3 menus unrestricted during normal operation.

Other service related or owner/supervisor use related adjust groups are restricted by passwords on screen or available only through IQANrun 2 with username and password restrictions.

Some adjust groups are only visible on screen for users with the appropriate username and password login rights.

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EXAMPLE ADJUST SCREEN WITHOUT LOGIN ACCESS

Tigercat AD610C Carrier

Electrical and Computers

MEASURE/ GRAPH 1. Click on the Measure button on the left.

STOP

start

MEASURE

pause

STOP

EXPAND MEASURE GROUP

USER DEFINED MEASURE GROUPS comment comment

+add

-delete

comment

9. User defined measure groups can be customized with the available channels in the existing groups.

2. All of the predefined measure groups available will be shown on the right.

It is not possible to add and delete measure groups or items while you are measuring.

Click on the red square to stop measuring and enable the +Add and -Delete buttons.

Each group can be expanded to view the channels in the groups.

3. To graph the channels in a measure group, double click the measure group and the graph will appear. (A single channel can also be chosen for graphing by double clicking on that channel.)

Click the +Add button on screen to add a New measure group. Click on the New measure group, then right click to rename the new measure group appropriately.

Available channels can then be dragged and dropped into the New measure group.

4. Click on the red square to stop measuring.

Click on the green arrow to start measuring.

Click on pause to pause the graph illustration while continuing to measure.

5. Click on Comment to add comments to the measure file at any time. The measure file data must be saved (*.irm) retain comments for later viewing.

6. Click on the red square to stop measuring and access the zoom function. Select an area of the graph to zoom in an view in more detail.

Click on Zoom Out to return to the full graph view.

7. Click on the red square to stop measuring and access save function. Click on Save to save the measure data as a *.irm file.

8. Click on the red square to stop measuring and access print function. Click on print to print the graph and data recorded.

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To delete User defined measure groups or items in a group click on the group or item you wish to remove then click the -Delete button.

Note that User defined measure groups are automatically saved on your PC. These groups are application program specific and will be available the next time the same application is in use on any machine using the same application program.

Tigercat AD610C Carrier

Electrical and Computers

LOGS 1. Click on the Logs button on the left.

logs

2. Logs available to view and/or clear will be shown on the right.

NOTE: User name and password access level rights determine whether the logs can be viewed and/or cleared. Some log items are restricted to higher level users only.

3. Double click on the log you wish to view or click on a log and click on Select to view the records in the log. Click on Done to return to the logs screen.

3. Click on Add Record to add a comment to the system log. For example to record a filter change or other service event in the log.

Entries are restricted to 250 characters.

4. Click on Clear log to clear log entries for the selected log. Note that this function is rights restricted.

5. Click on Get Log to get the log information and save as a *.irf file.

6. Click on Print to print the log being viewed.

7. Click on Save to save the log file as *.irl file.

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Electrical and Computers

SYSTEM 1. Click on the System button on the left.

SYSTEM

2. System info is on the right including the application program name and the Machine ID (Serial Number).

3. The Machine ID (Serial Number) is factory set. However, in the event that the MD3 is replaced, this information would need to be configured for the new module.

Updating Machine ID information requires a Login with sufficient rights.

Click on the Machine Id button. Enter the correct Serial Number. Click Set. If the update is successful a dialog box will pop up. Click OK to acknowlege the update.

A restart of the module will be requested.

Follow the on screen instructions to restart the module before continuing. If further service work is being performed you will need to login to IQANrun2 again.

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Tigercat AD610C Carrier CAB FUSE AND RELAY PANEL

Electrical and Computers

The fuse panel is located in the left rear of the cab behind the seat. The fuses and relays are protected beneath a panel which can be opened by removing two screws.

IMPORTANT 24 VOLT ELECTRICAL SYSTEM

E625C-120

fuse AND RELAY panel

CAB FUSE AND RELAY PANEL

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FUSES AND RELAYS (ELECTRICAL BOX) IMPORTANT 24 VOLT ELECTRICAL SYSTEM

625C-95

electrical box (left side front chassis)

electrical box fuses and relays

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Tigercat AD610C Carrier GAUGES AND ALARMS

Electrical and Computers

This machine is monitored for proper operation by sensors located in the hydraulic system and on the engine. These sensors are connected to the IQAN control system, which displays this information on the MD3 display in the cab and sounds all alarms.

For operation of the switches and sensors shown in the following diagram, 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 based on the position of the operator’s seat.

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Tigercat AD610C Carrier

Electrical and Computers front

ground strap

a/c compressor

alternator engine coolant level sensor

BATTERY DISCONNECT SWITCH

iqan xa2 front chassis module LOCATION (EARLIER DESIGN)

air intake sensor

electrical box

hydraulic oil level switch (main hydraulic tank)

ground strap starter

parking brake pressure sensor

charge filter bypass sender

manifold pressure sensorS DRIVE FORWARD (BOTTOM) REVERSE (TOP)

hydraulic oil temperature sensor

C A C

A/C BINARY SWITCH

iqan xa2 front chassis module LOCATION (LATER DESIGN)

A

speed sensor

B

batteries

cab ground strap

CAB ~ BOTTOM VIEW (FROM RIGHT SIDE OF THE MACHINE)

CRANE STOWED LIMIT SWITCH EMERGENCY PUMP SWITCH fuel shut off solenoid fuel level sender

635D-015 ad610c-005

switch and sensor locations 6.101

transmission

Tigercat AD610C Carrier

Electrical and Computers

ELECTRICAL SYSTEM SCHEMATIC DIAGRAMS NOTE: There are some exceptions to this wire numbering system. Where a wire branches off or a wire from a special prewired component connects to a machine harness, two numbers may be used on the same circuit wire.

The following pages of electrical schematic diagrams represent the complete electrical system for this machine. Use sheet 1 (shown below and also enlarged on later pages) as a guide or flow chart to help trace circuits and troubleshoot the electrical system. Circuit wires are numbered, and each wire from the source component to its connecting component should retain the same number. See note for wire number exceptions.

A A

B

B

C

D

E

F

G

C

1

1

2

2

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3

I

1

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Tigercat Industries Inc.

A

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D

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Tigercat Industries Inc.

1

4 Tigercat Industries Inc.

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Tigercat Industries Inc.

3

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Tigercat Industries Inc.

9 Tigercat Industries Inc.

A

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Tigercat Industries Inc.

A

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Tigercat Industries Inc.

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14 Tigercat Industries Inc.

Q

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5 20

Tigercat Industries Inc.

A

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19 Tigercat Industries Inc.

I

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20

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ELECTRICAL SCHEMATIC FLOW CHART

Tigercat wire colour code chart applicable to all products manufactured by Tigercat Industries Inc. COLOUR FUNCTION EXAMPLE Red Power..........................................(fused and unfused) Black Ground White Engine control.............................(fuel shut-off, start aid) Blue Propulsion Control......................(transmission/reverse solenoids) Purple Monitor, electrical and

mechanical systems....................(air cleaner, alternator, wheel speed, engine speed) Tan Electrical and

electromechanical control...........(park brake, alternator excitation)

(power door motor, backup alarm) Yellow Monitors......................................(flow, pressure, temperature, level) Grey Standard monitor system............(logic module to monitor) Brown Lights Green Electro-hydraulic control.............(pilot solenoids) Orange Accessories.................................(horn, A/C, heater) 6.102

Tigercat AD610C Carrier SECTION 7 - ENGINE START AND STOP

DECEMBER 2009

CONTENTS - SECTION 7 MAIN PUMP UNLOADING VALVE................................................................................. 7.3 START CIRCUIT DESCRIPTION................................................................................... 7.2 START CIRCUIT DIAGRAM........................................................................... 7.4, 7.5, 7.6 START MOTOR AND SOLENOID.................................................................................. 7.2

Tigercat AD610C Carrier engine Start circuit parking brake switch (driveline parking brake)

Engine start and stop CIRCUIT DESCRIPTION With the battery disconnect switch ON, current is supplied to the start solenoid contact, the start relay contact, the positive connection on the alternator and the BATTERY (BAT) contact of the key switch (ignition switch). Current is also supplied to the accessory fuses, the constant power fuses and the engine ECM power supply.

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.

When the battery disconnect switch is ON, the parking brake is ON and the key switch is turned to the RUN position, current is supplied to the accessory power relay contact (wire 58).

The accessory power relay closes and current is supplied to the parking brake off relay contact (wire P159A) and the engine ECM (wire 53).

When the parking brake is ON current is supplied to the park brake on relay (wire 159A). The parking brake on relay closes. When the parking brake on relay is closed and the parking brake off relay is open current is supplied to the start relay contact (wire P147) and to the main pump unloading valve (wire 135) via the open unloading valve off relay. The main pump unloading valve energizes to unload the main pump (margin pressure only will be available while the parking brake is ON).

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

The engine starting circuit is controlled by the parking brake switch on the instrument panel which prevents the engine from being started when the parking brake is OFF. The engine is started by turning ignition switch to the RUN position and observe computer display.

Wait for WAIT TO START warning on computer display to turn off. Always wait until the WAIT TO START warning to turn off before proceeding.

Turn ignition switch to the START position to crank engine. When engine starts, release ignition key to RUN position.

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.

When the battery disconnect switch is ON, the parking brake is ON and the key switch is turned to the START position, current is supplied to the parking brake off relay contact (wire P159A) and the start relay (wire 189). When the parking brake ON current is supplied to the park brake on relay (wire 159A). The parking brake on relay closes. When the parking brake on relay is closed and the parking brake off relay is open current is supplied to the start relay contact (wire P147) and to the main pump unloading valve (wire 135) via the open unloading valve off relay. The main pump unloading valve energizes to unload the main pump (margin pressure only will be available while the parking brake is ON).

Refer to simplified START CIRCUIT DIAGRAMS in THIS SECTION. Refer also to machine ELECTRICAL SCHEMATICS in SECTION 6.

off

run start

The start relay closes and supplies current to

INSTRUMENT PANEL PARKING BRAKE SWITCH

start motor

solenoid

CONTROL PANEL

604-53

7.2

start motor and solenoid

Tigercat AD610C Carrier

Engine start and stop

the start solenoid. The start solenoid closes and supplies current to the starter to turn the engine.

Fuel supply is controlled by the engine ECM.

has interlocks in place to prevent the machine from being driven with the crane unlocked, doors open or the parking brake ON.

When the battery disconnect switch is ON, the parking brake is OFF (DRIVE), cab doors are closed and the key switch is turned to the RUN position, current is supplied to the accessory power relay contact (wire 58). The accessory power relay closes and current is supplied to the parking brake off relay contact (wire P159A) and the engine ECM (wire 53). When the parking brake switch is placed in the OFF (DRIVE) position a signal is sent to the computer control system (DIN PARK BRAKE SWITCH DRIVE). A signal from the computer control system (DOUT PARKING BRAKE OFF) is sent to the parking brake latch relay (wire 159G). When the parking brake latch relay closes current is sent to the parking brake off relay contact (wire 343) current passes through the closed door switches to latch the parking brake off relay closed (wire 159B) and engergizes the parking brake valve (wire 159C) releasing the parking brake. When the parking brake off relay closes current to the main pump unloading valve is blocked. The main pump unloading valve de-energizes to load the main pump (full pump pressure will be available while the parking brake is OFF). Note that the computer control system has interlocks in place to prevent the machine from being driven with the crane unlocked, doors open or the parking brake ON.

POR ADJUSTMENT

MARGIN PRESSURE

610C-19

solenoid, integrated main pump unloading valve

main pump unloading valve

MAIN PUMP UNLOADING VALVE To relieve the load on the engine during start-up, the main pump is destroked to standby pressure by the main pump unloading valve. It is energized through wire 135B when the parking brake is placed in the ON position. The main pump unloading valve improves cold weather starting ability. The parking brake must be ON to activate the main pump unloading valve. The main pump unloading valve is part of the main pump.

When the parking brake is ON and the main pump unloading valve is energized the margin pressure can be read using the MAIN test port.

When the battery disconnect switch is ON, the parking brake is CRANE UNLOCK-ACTIVATE (CRANE - PARK BRAKE ON), and the key switch is turned to the RUN position, current is supplied to the accessory power relay contact (wire 58). The accessory power relay closes and current is supplied to the parking brake off relay contact (wire P159A) and the engine ECM (wire 53). When the parking brake switch is placed in the CRANE UNLOCK-ACTIVATE position current is supplied to the park brake on relay (wire 159A) and a signal is sent to the computer control system (DIN PARK BRAKE SWITCH CRANE).

The parking brake on relay closes. A signal from the computer control system (DOUT UNLOADING VALVE OFF) is sent to the unloading valve off relay (wire 135). The unloading valve off relay closes blocking current to the main pump unloading valve. The main pump unloading valve de-energizes to load the main pump (full pump pressure will be available while the parking brake switch is in the CRANE UNLOCK-ACTIVATE position). Note that the computer control system

When the parking brake is OFF, the main pump unloading valve is de-energized and the main pump is fully loaded the main pump POR pressure can be read using the MAIN test port.

7.3

Tigercat AD610C Carrier

Engine start and stop start circuit -at rest

AD610C-01

7.4

Tigercat AD610C Carrier

Engine start and stop start circuit battery disconnect on parking brake on ignition key - run position

AD610C-01A

start circuit

battery disconnect on parking brake on ignition key-start position

AD610C-01B

7.5

Tigercat AD610C Carrier

Engine start and stop start circuit battery disconnect on parking brake off (DRIVE) ignition key -run position CAB DOORS - CLOSED

AD610C-01C

start circuit battery disconnect on park brake on (crane unlock-activate) ignition key -run position

AD610C-01D

7.6

Tigercat AD610C Carrier SECTION 8 - DRIVE DECEMBER 2009

CONTENTS - SECTION 8 AXLES............................................................................................................................ 8.14 BRAKE BLEEDING.................................................................................................... 8.16 BRAKE LINING INSPECTION.................................................................................... 8.16 DIFFERENTIAL AND DIFFERENTIAL LOCKS.......................................................... 8.14 LUBRICATION............................................................................................................ 8.14 OSCILLATION SHIM CHECK AND ADJUSTMENT (FRONT AXLE).......................... 8.23 PLANETARY WHEEL END DISASSEMBLY AND REASSEMBLY............................. 8.25 SERVICING BRAKES................................................................................................. 8.15 CIRCUIT DESCRIPTION................................................................................................. 8.2 CIRCUIT DIAGRAM....................................................................................................... 8.12 CIRCUIT HYDRAULIC SCHEMATIC............................................................................. 8.13 DIRECTION SELECTION SWITCH................................................................................. 8.9 DRIVE MOTOR................................................................................................................ 8.6 drive motor pressure checks and adjustments...................................... 8.20 DRIVE MOTOR SPEED VERIFICATION....................................................................... 8.19 DRIVE PUMP................................................................................................................... 8.3 DRIVE PUMP PRESSURE CHECKS............................................................................ 8.18 HYDRAULIC OIL HEATING PROCEDURE................................................................... 8.22 maximum speed control...................................................................................... 8.10 SPECIAL TOOLS FOR WHEEL END ASSEMBLY......................................................... 8.40 STARTUP PROCEDURE AFTER MAJOR MAINTENANCE......................See SECTION 3 TRANSMISSION............................................................................................................ 8.11 TRAVEL/ENGINE SPEED PEDALS................................................................................. 8.8 WHEEL INSTALLATION................................................................................................. 8.41

Tigercat AD610C Carrier

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 hydrostatic drive system are a hydraulic pump and two hydraulic motors connected together by four 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 two connecting hoses. The motors then reconvert 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 two connecting hoses 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

swashplate, axial piston pump

FROM DIESEL ENGINE

bent axis piston motor

to vehicle drive

630C-12

continuous closed loop hydraulic circuit

8.2

Tigercat AD610C Carrier

Drive the charge pump oil is used as make up oil to the low pressure side of the closed loop to replenish losses due to internal leakage in the hydrostatic pump and motor. This same flow acts as a cooling fluid for the piston pump and motors to ensure peak hydrostatic drive performance and long service life.

DRIVE PUMP The hydrostatic drive pump is mounted to the engine flywheel via a torsional drive shaft coupling and has a through shaft to the main pump and multisection gear pumps.

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

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

The primary pump is a variable displacement, swashplate, axial piston type. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume and direction of oil flow from the piston pump is determined by the angle of this swashplate.

When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow in one direction in the closed loop.

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

The drive pump is equipped with an electrical control with proportional solenoid valves (A and B).

When no current is flowing to either of the proportional solenoid valves the pump will remain in the neutral position with the swashplate at an angle of zero and no flow.

The secondary pump is a fixed displacement, internal gear type which provides charge oil via the charge filter for the drive pump controls.

Charge oil continuously introduces oil from the hydraulic tank back into the hydrostatic drive system. The charge relief valve (in the drive pump) maintains a constant charge pressure for use by the swashplate control system. In addition,

When a travel foot pedal is operated a signal (VOLTAGE IN - Drive Pedal Fwd or Drive Pedal Rev) is sent to the computer control system.

The computer control system generates a corresponding signal (CURRENT OUT - Pump Drive) and sends it to one of the drive pump proportional solenoid valves (forward or reverse).

CHARGE PUMP

TO front chassis drain manifold

TO MOTORS (B)

TO MOTORS (A)

CHARGE FILTER

pressure override charge relief

HIGH PRESSURE RELIEF VALVE 'B'

HIGH PRESSURE RELIEF VALVE 'a'

proportional solenoid control spool

stroking piston

TO SUCTION STRAINER proportional solenoid

625c-96

HYDROSTATIC PUMP

drive pump schematic 8.3

Tigercat AD610C Carrier

Drive

DRIVE PUMP ELECTRICAL SCHEMATIC 604C-08

140CC Drive Pump Characteristics • • • • • •

Start of Control: 0 cc / 200 mA (Non-Adjustable) End of Control : 140 cc/ 600 mA (Non-Adjustable) High Pressure Relief: 6250 psi (430 Bar ) differential (Adjustable) Pressure Override: 5800-6000 psi (400-415 Bar) (Adjustable) Charge Pressure Relief: 350-360 psi (24-25 Bar) (Adjustable) Coil Resistance : 22.7 ohms

Drive Pump Characteristics 160 140

Displacement cc

120 100 80 60 40 20 0 0

100

200

300

400

500

600

700

Control Current ma

8.4

Tigercat AD610C Carrier

Drive

A magnetic force is generated at the solenoid coil, in the proportional valve a pressure corresponding to the solenoid signal acts on the control spool. The control spool then directs control oil in and out of the stroking piston to stroke the pump as required. A feedback lever, connected to the stroking piston, maintains the pump flow for any given current within the control range. If the signal at the solenoid is lessened, the proportional valve reduces pressure to the actuation piston and the swash plate angle becomes smaller.

In addition forward and reverse pressure sensors connected to the drive pump provide feedback signals (VOLTAGE IN - Drive PSI REV and VOLTAGE IN - Drive PSI FWD) to the computer control system for use in overall control of the drive circuit and protection of the system from pressure spikes during operation.

The drive footpedal control functions only when the parking brake switch is in the OFF position.

Drive prevent logic in the computer control system uses the parking brake signal (DIGITAL IN - Park Brake Sensor) to prevent driving the machine when the parking brake is ON. The hydrostatic piston pump is equipped with a pressure override (POR) valve to protect the closed loop hydrostatic drive components from excessive pressure. When the tractive effort requirements of the vehicle are demanding then pressure on the high side of the closed loop can reach maximum. At this pressure the POR valve signals the swashplate control valve to destroke the swashplate, reducing piston pump flow and maintaining system pressure at the POR setting.

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

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

8.5

Tigercat AD610C Carrier

Drive

DRIVE MOTOR

FLUSHING VALVE

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

CONTROL CYLINDER

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

TEST PORT

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.

BEGIN OF DISPLACEMENT

TO SUCTION STRAINER

POR

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.

FROM DRIVE PUMP PORT P

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 (POR) and a displacement control spool.

630C-14

For this application the POR valve is set at a high pressure so that it does not interfere with the operation of the computer control system. The motor POR must be correctly set for the system to function properly. Refer to DRIVE MOTOR PRESSURE SETTINGS for in THIS SECTION .

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

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

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

DRIVE MOTOR CHARACTERISTICS Start of Control : 160 cc / 400 mA

•

End of Control : 30cc / 1050 mA

•

Motor POR : Turn Fully In

•

Coil Resistance: 5.5 ohms

A speed ring on the motor's drive shaft generates a signal picked up by the speed sensor in the T port of the right hand motor. The speed sensor signal (FREQUENCY IN - Drive Motor rpm) is sent to the computer control system for use in controlling the drive system.

Drive Motor Characteristics 160 Displacement cc

140 120

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. Flushing occurs only when there is a pressure differential between

100 80 60 40 20 0 0

200

400

600

800

DRIVE motor SCHEMATIC

neutral position, shutting off the pressure to the displacement control cylinder thus increasing displacement to maximum.

The displacement control spool is operated by an electrical control with proportional solenoid. The control is proportional to the applied electrical signal (CURRENT OUT - Motor Drive) from the computer control system. When sufficient pressure from the proportional electrical control is directed to the spool, it shifts against a spring and directs oil past the POR valve to the displacement control cylinder thus decreasing the displacement of the motor. Removal of the pressure signal from proportional electrical control will cause the displacement control spool to return to the

•

FROM DRIVE PUMP PORT S

1000

1200

Control Current mA

8.6

Tigercat AD610C Carrier

Drive

DRIVE MOTOR ELECTRICAL SCHEMATIC

630C-16

the high pressure and low pressure sides of the loop. This valve is factory set (2.6 US gpm [9.8 L/ min]) and requires no adjusting.

proportional solenoid MINIMUM DISPLACEMENT ADJUSTING SCREW speed ring DRIVE SHAFT

PORT PORT 'B' 'A'

'A'

ROTATING GROUP

aq083

'e'

•

FLUSHING VALVE

aq083-1

'e'

VIEW 'A' NOTE: ORIFICE MUST BE REMOVED BEFORE INSTALLATION OF REPLACEMENT MOTORS (3 PARTS - ONE THROTTLE PIN AND TWO THROTTLE SCREWS)

section 'e-e' drive motor ~ (160 cc size) 8.7

aq083-3X

Tigercat AD610C Carrier

Drive

TRAVEL/ENGINE SPEED PEDALS

travel/engine speed pedal

Press the foot pedal to drive in the direction selected on the direction selection switch on the left hand joystick.

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

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

Refer also to DIRECTION SELECTION SWITCH in THIS SECTION.

E625C-23

Two travel/engine speed pedals are located on the floor of the operator's cab ( one forward facing and one rear facing).

FORWARD FACING FOOT PEDALS (SEAT FACING front of machine)

travel/engine speed pedal

Each foot pedal is used to move the machine in the direction selected on the direction selection switch on the left hand joystick.

A backup alarm will sound when travelling in reverse based on the position of the operator’s seat. A drive interlock circuit built into the computer control system prevents the machine from being driven when the parking brake is ENGAGED. Refer also to PARKING BRAKE in SECTION 9 of THIS MANUAL. FORWARD FACING PEDALS AND REAR FACING PEDALS The rotating seat cab is equipped with two sets of pedals one set forward facing and the other set rear facing.

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

For safe operation of all controls the operator’s seat must be locked in either the forward facing or rear facing position.

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

8.8

E625C-22

REAR FACING FOOT PEDALs (SEAT FACING REAR OF MACHINE)

Tigercat AD610C Carrier

Drive

foot pedal characteristics DIRECTION SELECTION SWITCH

• Electric Potentiometer • Start of Control:0% / 0 Deg / 750 (±250) mV

MAXIMUM SPEED CONTROL

• End of Control:100%/ 17 Deg/ 3875 (±375) mV Foot Pedal Characteristics 4800

Milli-Volts

4000 3200 2400 1600 800 0 0

20

40

60

80

100

Pedal Position %

Pedal motion is transmitted to the potentiometer through a mechanical linkage. A spring return automatically returns the pedal to the neutral position when not in use.

The pedal moves through 17° of motion. The potentiometer signal ranges from 750 mV (at 0°) to 3875 mV (at 17°) (VOLTAGE IN - Drive Pedal Fwd or Drive Pedal Rev). These signals are sent to the IQAN XS module of the computer control system to control the travel/engine speed and direction of travel of the machine. Through internal logic the computer control system uses the signal from the pedal to control engine speed, drive pump stroke and drive motor stroke.

A three pin connector is used to connect each pedal to the machine electrical system: Pin A: ground (white) Pin B: signal Pin C: supply (red) The position of the foot pedal is directly proportional to the travel/engine speed of the machine. Travel speed may also be limited by the position of the maximum speed control. Refer MAXIMUM TRAVEL SPEED CONTROL in THIS SECTION for more information.

E625C-11

LEFT HAND JOYSTICK

DIRECTION SELECTION SWITCH The direction selection switch is located on the left hand joystick. This switch selects the direction of travel for the travel/engine speed pedal in use (either forward facing or rear facing).

This is a three position switch.

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

Place switch in the center position for neutral.

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

This control is a three position switch with a proportional output. The signal generated by the switch position (VOLTAGE IN - Travel Direction Selection) is sent to the IQAN XS2 module of the computer control system to control travel direction FORWARD*, NEUTRAL or REVERSE* based on the position of the switch. *NOTE: Control of machine travel is automatically transferred by the computer control system from the forward facing travel/engine speed pedal to the rear facing travel/engine speed pedal based on the position of the operator’s seat. Therefore FORWARD and REVERSE as described above are considered to be forward and reverse as viewed by the operator either from the forward facing seat position or the rear facing seat position.

Refer also to TRAVEL/ENGINE SPEED PEDAL and MAXIMUM SPEED CONTROL in THIS SECTION.

8.9

Tigercat AD610C Carrier

Drive

maximum speed control The maximum speed control is located on the left hand joystick. This control allows the operator to set the maximum travel speed of the machine to maintain a given travel speed without having to feather the drive pedals.

DIRECTION SELECTION SWITCH

MAXIMUM SPEED CONTROL

Push control forward to increase the maximum travel speed.

Pull control back to decrease the maximum travel speed of the machine.

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

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

This control is a friction maintained proportional slider. The signal generated by the slider control position (VOLTAGE IN - Travel Speed ) is sent to the IQAN XS2 module of the computer control system to limit the travel speed of the machine based on the position of the slider.

E625C-11

Refer also to TRAVEL/ENGINE SPEED PEDAL and DIRECTION SELECTION SWITCH in THIS SECTION.

8.10

LEFT HAND JOYSTICK

Tigercat AD610C Carrier

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.

below right hand cab door

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.

transmission oil fill location

630D-15

The transmission disconnect lever is used to shift the transmission between the DRIVE and neutral positions, e.g. NEUTRAL for towing the machine.

transmission dipstick

transmission dipstick and fill location

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.

IMPORTANT !

When the transmission is in neutral, never tow the machine at over 2 mph (3.2 km/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.

342-1

TRANSMISSION DISCONNECT LEVER shown in neutral

8.11

Tigercat AD610C Carrier

Drive

DRIVE CIRCUIT HYDRAULIC SCHEMATIC AD610C-S8

8.12

Tigercat AD610C Carrier

604-31

Drive

DRIVE CIRCUIT HYDRAULIC SCHEMATIC 8.13

Tigercat AD610C Carrier

Drive

AXLES Power from the two drive motors is transmitted to the front and rear axles via a transmission and the front and rear drive shafts.

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

Apart from the mounting, both front and rear axle assemblies are configured in a similar way except that the rear axle has internal brakes and the front has none.

Each axle assembly consists of: (1) Differential gear set (2) Hydraulic differential lock (3) Outboard wet disk brakes, (1-each side in rear axle only) (4) Outboard planetary final drive wheelends, (1-each side) (5) Axle housings and shafts The final drive (4) is an outboard mounted planetary gear wheelend, which further reduces speed and increases torque to the axles.

The input side receives drive power from the differential via a sun gear splined to an axle shaft.

The output side wheel hub is splined onto the axle and rotates on the bearings.

DIFFERENTIAL AND DIFFERENTIAL LOCKS The differentials (1) distribute the power to each side of the axle while allowing the wheels to turn at different speeds. The differential locks (4), in the front and rear axle assemblies, are hydraulically controlled and can be independently turned ON or OFF by switches in the cab.

Using the front and rear differential lock switches the operator chooses to activate the front differential lock and/or rear differential lock which energizes the differential lock control valve solenoid(s) (located on the multifunction manifold) and directs pilot oil to the corresponding differential clutch pack assembly pistons to lock the differential(s).

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

IMPORTANT !

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

Axle Lubrication Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in SECTION 3 for more information.

The lubricant in both axle assemblies is axle gear oil. The axle assemblies are a closed circuit with one breather per axle. There are lines plumbed to each axle to activate the differential locks and/ or brakes, which use the same hydraulic oil as the machine.

4

3 604C-10

5

2

1

4

3

AXLE ASSEMBLY (REAR AXLE SHOWN) 8.14

Tigercat AD610C Carrier

Drive Service brakes (rear axle only)

SERVICE BRAKE

The “wet” disk type service brakes (3) consist of a piston, a stationary brake disk, a friction brake disk with brake facing material, and a brake backing plate. One brake assembly is located outboard on each side of the differential case and before the final drive wheelend.

rear DIFFERENTIAL LOCK

The piston, stationary brake disk and the backing plate are attached to the case; and the friction brake disk is splined onto the sun gear of the planetary final drive.

rear AXLE

front differential lock

BREATHER

When the brake foot control is depressed, brake pressure oil moves the piston and stationary brake disk up against the friction brake disk , trapping it against the backing plate. Maximum operating pressure is 1000 psi. For information on the brake hydraulic circuit refer to SECTION 9 of THIS MANUAL.

front AXLE 604-41

hydraulic connections

e620c-03

8.15

service brake

Tigercat AD610C Carrier

Drive

BRAKE LINING INSPECTION

BRAKE BLEEDING

Inspection ports are provided in the differential case of the rear axle. They are located outboard, at the connection between the case and the final drive wheelend.

The rear 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.

Note that on some earlier machines may not have an inspection port. The drain plug located at the bottom of the final drive wheelend can be used as an alternative inspection location.

•

Remove the brake inspection port plugs.

•

Inspect the brake lining on both sides of the brake friction disk.

•

If brake lining material is worn down to the bottom of the oil grooves, the brake friction disk and piston pressure plate assemblies must be replaced.

procedure 1. Park machine on level ground, dozer and set parking brake ON. Install articulation lock pin and stop engine.

drive pump

610C-17

connectors

disconnect two connectors on drive pump prior to bleeding brakes

2. Prior to bleeding brakes disconnect the two connectors on the drive pump. This is a safety precaution to prevent the machine from travelling while brake bleeding is being performed.

3. Place a clear plastic tube over bleed screw with other end in a container.

4. Start engine and run at IDLE

8.16

Tigercat AD610C Carrier

Drive

BLEED SCREW SERVICE BRAKE INSPECTION PORT

E620C-39

rear AXLE SERVICE BRAKE

5. Loosen bleed screw 6. 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).

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

8. Release brake foot pedal.

9. Repeat above procedure for each bleed screw.

10. Reconnect the two connectors on the drive pump.

8.17

Tigercat AD610C Carrier drive pump pressure checks

Drive por adjustment

check charge pressure 1. Park machine on level ground, lower dozer and set parking brake ON. Install articulation lock pin and stop engine.

'charge' test port

2. Connect a 0-1000 psi (0 -70 Bar) gauge to the 'CHARGE' test port.

charge pressure adjustment

3. Start engine and allow to idle.

4. Ensure that hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in THIS SECTION.

DRIVE PUMP figure 2-620c

5. Check charge pressure.

Reading should be 350-360 psi (24-25 Bar) at an engine speed of 950 rpm.

6. Turn the engine off.

7. If charge pressure readings are not correct check the charge filter for proper operation before taking further corrective action.

ADJUST CHARGE PRESSURE 8. If necessary, adjust the charge pressure adjustment screw on the drive pump.

Turning the screw IN will increase the pressure.

Turning the screw OUT will decrease the pressure.

9. Repeat steps 3 to 7 and verify correct pressure reading.

8.18

Tigercat AD610C Carrier DRIVE MOTOR SPEED VERIFICATION Drive motor speed should be checked prior to making any drive motor pressure checks or adjustments.

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 ft (45 m).

Dozer blade UP. CHECK FOR FULL DRIVE PUMP FLOW 1. Start the engine.

2. Set the maximum speed control dial to its lowest setting ).

3. Use the IQAN MDM to view motor speed information from the cab. Use the MEASURE MENU and select INPUTS ~ DIGITAL/ FREQUENCY INPUTS ~ DRIVE MOTOR SPEED to view drive motor rpm readings.

Refer to MEASURE MENU OPERATION in SECTION 6 of THIS MANUAL for more information.

Drive CHECK FOR CORRECT MOTOR MINIMUM DISPLACEMENT 1. Start the engine.

2. Set the maxiimum speed control dial to its highest setting ).

3. Use the IQAN MDM to view motor speed information from the cab. Use the MEASURE MENU and select INPUTS ~ DIGITAL/ FREQUENCY INPUTS ~ DRIVE MOTOR SPEED to view drive motor rpm readings.

Refer to MEASURE MENU OPERATION in SECTION 6 of THIS MANUAL for more information.

4. Drive the machine forward with the drive pedal fully depressed. The drive motor rpm display should read 3800-4000 rpm.

6. A correct reading indicates the motor minimum displacement is set correctly.

An incorrect reading indicates the motor minimum displacement requires adjustment or drive motor max current settings may be out of calibration.

4. Drive the machine forward with the drive pedal fully depressed. The drive motor rpm display should read 925-975 rpm.

Refer to HYDROSTATIC SETUP PROCEDURE in THIS SECTION.

5. A correct reading indicates the there is full flow in the drive pump.

An incorrect reading indicates a problem with flow from the drive pump or drive pump max current settings may be out of calibration.

Refer to HYDROSTATIC SETUP PROCEDURE in THIS SECTION.

8.19

Tigercat AD610C Carrier

Drive

drive motor pressure checks and adjustments

PROPORTIONAL SOLENOID

begin of displacement ADJUSTING SCREW

Do not adjust drive motor pressure settings without first confirming the need to do so.

Drive motor pressure settings are checked as part of the test drive procedure. Refer to TEST DRIVE - REXROTH PUMP AND REXROTH MOTORS in THIS SECTION. To set the hydrostatic drive motor pressures and speeds, the following procedure must be performed in the order shown.

MINIMUM DISPLACEMENT ADJUSTING SCREW (SOME HOSES REMOVED FOR CLARITY)

A. Set the motor minimum displacement.

B. Set the motor begin of displacement control pressure.

630C-173

MOTOR PRESSURE OVERRIDE ADJUSTING SCREW (POR)

DRIVE MOTOR (LH SHOWN)

A. Motor Minimum displacement Adjustment

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.

NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE 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

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.

• Also note that an orifice must be removed on all replacement motors for proper operation.

Failure to remove this orifice will cause the motor to function erratically with the electronic controller. Refer to DRIVE MOTOR in THIS SECTION for illustration showing location of parts to be removed.

2. Remove the minimum displacement adjusting screw (largest screw) from the top of motor housing and measure its length.

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 17mm. (For different length screws, measure the length and subtract 73mm from this total length. This is the amount of screw that should be exposed above the locknut.) (For example: 100mm screw, minus 73mm will leave 27mm above locknut).

NOTE: Repeat for the other motor. b. Motor Begin of displacement control Pressure check This procedure is done through the IQAN computer control system.

Contact Tigercat service department for more information.

WARNING To prevent injury caused by accidental steering of the machine when setting pressures, make sure the articulation lock pin is held securely in place by the lynch pins provided.

8.20

Tigercat AD610C Carrier

Drive

c. Motor pressure override adjustment (POR) NOTE: Ensure hydraulic oil is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in this section of the manual.

Perform this procedure on BOTH MOTORS. 1. Park machine on level ground, lower grapple and dozer and set parking brake ON. Install articulation lock pin and stop engine.

2. Turn drive motor POR adjusting screw all the way IN until lightly seated, then back out 1/8 turn.

NOTE: Repeat for the other motor.

8.21

Tigercat AD610C Carrier HYDRAULIC OIL HEATING PROCEDURE There is a specific procedure to heat up the hydraulic oil in the machine in preparation for performing pressure measurements and setups.

1. Park machine on level ground, lower dozer and set parking brake ON. Install articulation lock pin and stop engine.

drive pump

Drive 5. Make sure that the area is clear operate the dozer down in function and HOLD in the operating position, while monitoring the ENGINE coolant temperature and the HYDRAULIC oil temperature. Temperatures can be monitored on the computer control system (MAIN MENU ~ INFORMATION (F3) ~HYDRAULIC OIL TEMPERATURE). This should be done at full throttle and will take 10 to 45 minutes.

IMPORTANT !

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

connectors

6. Ensure that the hydraulic oil temperature is between 120 and 130°F (49 and 54°C).

610C-17

disconnect two connectors on drive pump prior to PERFORMING PROCEDURE

7. Once the hydraulic oil is up to temperature, proceed to required hydraulic set-up procedure.

IMPORTANT !

Remove the cardboard blocking the oil cooler if necessary to maintain the proper temperature.

2. Prior to performing this procedure disconnect the two connectors on the drive pump. This is a safety precaution to prevent the machine from travelling during the procedure.

3. Place a sheet of cardboard in front of oil cooler section of the heat exchanger. The radiator and charge air cooler must remain uncovered to prevent engine overheating.

4. Start the engine (full throttle).

8.22

Tigercat AD610C Carrier

Drive 3.

FRONT AXLE OSCILLATION SHIM CHECK AND ADJUSTMENT

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.

E620C-34

REMOVE GREASE HOSE

E620C-36

E620C-33

Use long pry bar

REMOVE GREASE HOSE

E620C-35

8.23

BETWEEN CHASSIS AND AXLE HOUSING

Tigercat AD610C Carrier

E620C-32

Drive

TIP AXLE SIDE TO SIDE

e620c-04

front axle

10. Remove the outer cover plate. Carefully remove the center pivot cover plate from the axle (9 bolts). Care must be taken to ensure that the thrust washer and shims do not fall.

11. If the measurement was below .004” (0.1 mm) ADD shims to get the required range.

A 0.010” (0.25 mm) shim will change the reading by 0.010” (0.25 mm). Stock shims are 0.010” and 0.040” (0.25 and 1.0 mm) thick.

E620C-28

12. If the measurement was above .014” (0.4 mm) REMOVE SHIMS to correct the reading.

A 0.010” (0.25 mm) shim will change the reading by 0.010” (0.25 mm). Stock shims are 0.010” and 0.040” (0.25 and 1.0 mm) thick.

TIP AXLE SIDE TO SIDE

5. Zero the dial indicator.

13. Replace the thrust washer.

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.

14. Replace the center pivot cover plate. Make sure that the thrust washer and shims do not slide out of place and become damaged.

Torque cover bolts (9) to 100 lbf-ft (135 Nm).

15. Repeat steps 4 to 7 to check the adjustment again. This reading should be checked twice.

7. Read the dial indicator. Axle movement should be 0.004” to 0.014” (0.1 to 0.4 mm).

Check the reading twice by repeating steps 4 through 7.

16. Reinstall grease hoses in the axle pivot and add grease until back pressure is felt.

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.

8.24

Tigercat AD610C Carrier

Drive

PLANETARY WHEEL END DISASSEMBLY AND REASSEMBLY PROCEDURES A. Planetary Wheel End Removal B. Planetary Wheel End Disassembly C. Disassembly of the Planetary Spider Assembly D. Spindle and Planetary Ring Gear SubAssembly E. Wheel Hub, Inner Bearing Spacer, Wheel Bearings, Seal, and Spindle Sub-Assembly F.

Metal Face Seal into Hub and into Spindle

G. Check for Correct Installation of the Metal Face Seal H. Wheel Hub to Spindle Assembly I.

Planetary Spider Sub-Assembly

J.

Planetary Spider Assembly, Spindle & Planetary Ring Gear Assembly, and Wheel Hub Assembly

K. Install the Planetary Wheel End Assembly On the Axle Housing

8.25

Tigercat AD610C Carrier

Drive

A. Planetary wheel end removal

3. Loosen without removing the M18 lock nuts and washers at the studs at the spindle to axle housing joint.

NOTE: There may be some small quantity of oil remaining within the planetary wheel end reduction when the planetary assembly is opened.

Care should be taken to capture this small amount of oil and dispose of it properly.

CAUTION Do Not remove the studs as they support the planetary ring gear and spindle assembly on the axle housing. Use care to keep planetary ring gear from falling off spindle flange.

E620C-05

1. Remove the M18 capscrews and washers from the spindle to axle housing joint.

NOTE: These capscrews had blue loctite added at original axle assembly.

E620C-07

4. Use a brass or leather mallet to hit spindle flange and loosen wheel end assembly from the axle housing.

5. Remove O-Ring from inner side of ring gear.

For safety, remove M18 lock nuts while wheel end is still supported by studs, assemble (2) M18 capscrews with washers through spindle flange and planetary ring gear mounting holes and assemble (2) nuts with washers onto capscrew threads so the ring gear cannot fall off the spindle flange.

E620C-06

6. Remove the wheel end assembly from the axle housing assembly and place safely on a work bench, where further wheel end disassembly can be completed as needed.

2. Support the wheel end to be serviced with a lifting device.

WARNING Take care when using lifting devices. When you use a lifting strap, inspect the strap for damage before you use it. Do not use a lifting strap to shock load or drop load a component. Serious personal injury can result.

8.26

Tigercat AD610C Carrier

Drive

b. PLANETARY WHEEL END DISASSEMBLY NOTE: If further disassembly is required to service all the internal wheel end components, the following procedure is recommended:

e620c-10

3. Remove the cover and O-ring from the driver. e620c-08

1. Set with planetary pin facing downward with planet pins on a 50mm thick spacer whose O.D. is smaller than ring gear’s I.D.

4. Remove the snap ring from the planetary spider. The snap ring removal will now permit the wheel end spindle and hub assembly to be carefully removed as a sub assembly from the planetary spider assembly.

e620c-11

e620c-09

2. Remove the socket head M8 capscrews from the cover on the planetary wheel end.

NOTE: These capscrews had a blue loctite applied at original production assembly.

5. Remove the (3) M8 socket head capscrews that retain the driver to wheel hub.

NOTE: These capscrews had blue loctite applied at original assembly.

6. Remove the driver and larger O-ring from the wheel hub.

8.27

Tigercat AD610C Carrier

Drive 10. If required, use a suitable bearing cup puller to remove both the cups from the planetary hub assembly. Wrap both the bearing cups to prevent contamination. If bearing cups are not to be removed, please proceed to the next step.

WARNING Observe all warnings and cautions provided by the press manufacturer to avoid serious personal injury.

11. Remove the inner bearing spacer from the spindle only if required. This spacer has had Loctite 680 or equivalent applied at original production assembly and should not be removed unless damaged.

e620c-12

7. Remove the (3) M8 socket head capscrews from the lockplate that retains the wheel bearing adjusting nut.

NOTE: These capscrews had blue loctite applied at original assembly.

NOTE: Should the planetary spider and gearsets need to be disassembled, please go to the specific section for disassembly required.

8. Remove the wheel bearing adjusting nut.

Early design nut was hexagonal. Later design is round nut shown. A special tool (Tigercat Part # 204691) is available that fits both nuts.

Refer to SPECIAL TOOLS FOR WHEEL END ASSEMBLY in THIS SECTION. NOTE: The bearing cups stay with the wheel hub and the outer bearing cone will be loose while being disassembled from spindle. The inner bearing cone will be removed with the wheel hub assembly and will not stay on the spindle during hub assembly removal. Half of the metal face seal will be removed as part of the planetary hub assembly when removed.

9. Remove both the inner and outer bearing cones, planetary hub assembly, and metal face seal half from the spindle. Wrap the inner and outer bearing cones and the (2) halves of the metal face seal to prevent contamination and set aside for later cleaning, inspection and re-assembly.

e620c-13

12. Separate the planetary ring gear and O-ring from the spindle flange, if required. Set aside these components for later inspection and reassembly.

8.28

Tigercat AD610C Carrier c. DISASSEMBLY OF THE PLANETARY SPIDER ASSEMBLY

Drive 6. Using the grease pencil, label the outer washer with the same number as marked for the planetary gear/needle roller assembly.

7. Repeat steps 1 to 6 for each planetary gear to be removed.

NOTE: Removal and reassembly of the pinion shafts can change the precision pinion shaft locations relative to each other.

IMPORTANT !

DO NOT remove the planetary pinion shafts from the planet spider.

e620c-14

1. Place the planetary spider assembly safely in a vertical position with the planetary gears facing upwards.

The planetary pinion shafts are not serviceable items and must not be pressed out of the planetary spider shaft.

Be careful not to bump or damage the pinion shafts.

NOTE: Using a grease pencil, mark each planet pinion shaft/planetary pinion gear with same number to identify which pinion shaft and gear were originally pre-assembled together for later re-assembly.

2. Mark each planet pinion shaft and its planetary pinion gear with matching numbers.

3. Remove the snap ring from the groove near end of each planetary pinion shaft.

4. Remove the inner washer from each planetary pinion shaft. During removal, mark the washer with the pinion shaft number to retain with same original planetary shaft/gear assembly or place in numbered plastic bags.

NOTE: The (33) needle rollers/planetary gear assembly should also be placed in separate bags as removed from each planetary pinion / shaft assembly and marked to keep the rollers with the same planet gear/shaft for later inspection and re-assembly.

5. Carefully lift the planet pinion gear, full complement of needle rollers, and outer thrust washer as an assembly. It may be easier to slide a thin shim stock under the thrust washer or planetary pinion gear as it is lifted to capture all the loose needle rollers. The needle rollers should be retained or replaced, if required, as a set for each planetary pinion and pinion shaft.

8.29

Tigercat AD610C Carrier

Drive Method 2:

d. SPINDLE AND PLANETARY RING GEAR SUB-ASSEMBLY

An optional assembly method is as follows if a press is not used: 1. Apply a light coat of grease to the O-Ring.

2. Install the O-Ring into the groove of the planetary ring gear face. Care should be taken not to twist or damage the O-Ring during assembly.

3. Apply a light coat of oil to the outer diameter edge of the planetary ring gear that will be pressed into the spindle flange bore.

4. Set the spindle over the planetary ring gear and O-Ring already assembled and align the holes in the spindle flange with the planetary ring gear spacing by using 1 or 2 temporary guide pins that fit the M18 holes.

e620c-15

The planetary ring gear is installed between the spindle and axle housing. The ring gear can first be reassembled onto the axle housing or onto the spindle. In either case, the final assembly requires O-rings installed in the grooves on both sides of the ring gear.

5. Using a rubber or rawhide mallet (NOT a steel hammer) tap the spindle over the planetary ring gear by hitting around the spindle flange several times until ring gear is seated.

6. Remove the temporary guide pins.

If the planetary ring gear was disassembled from the spindle earlier, one of the following two assembly procedures are recommended to reassemble the ring gear and spindle.

7. A piece of thin shim stock ~0.0254mm (0.001in) is to be inserted in several places around the diameter to check the ring gear is properly seated.

IMPORTANT !

Care should be taken not to press directly on the spindle threads as damage to these threads may occur. Use of 3 steel bars assembled to allow the press to push on the spindle flange directly and not on the spindle threads is recommended.

Method 1: 1.

Apply light coat of grease to the O-Ring.

2. Install the O-Ring into the groove on the planetary ring gear face. Care should be taken not to twist or damage the O-Ring during assembly.

3.

Align the capscrew holes in the ring gear when you are pressing the ring gear into the spindle. The hole alignment must be done prior actually pressing ring gear into spindle.

4. A piece of thin shim stock ~0.0254mm (0.001") is to be inserted in several places around the diameter to check the ring gear is properly seated.

5. Install (2) bolts, nuts and washers, for safety.

8.30

Tigercat AD610C Carrier e. WHEEL HUB, INNER BEARING SPACER, WHEEL BEARINGS, SEAL, AND SPINDLE SUB-ASSEMBLY

Drive 4. Remove the wheel hub from the press and place on suitable workbench for further safe assembly.

NOTE: The inner bearing cone must be installed in the wheel hub and not on the spindle bearing diameter because the Metal Face Seal, once installed in the wheel hub assembly will not fit over the bearing cone assembly.

5. Apply a light coat of oil to the inner bearing cone rollers and install in the wheel hub assembly.

e620c-16

If the wheel hub,spindle, and bearings were disassembled during disassembly, the following procedure is recommended.

WARNING Observe all warnings and cautions provided by the press manufacturer to avoid serious personal injury.

e620c-18

6. If the wheel bearing spacer was previously removed, apply Adhesive #Q58-Grade -226 or #Q44 to the spindle face of the bearing spacer.

7. Slide the spacer over the spindle and against the spindle shoulder tapping with a brass rod to properly seat the wheel bearing spacer.

Alternatively, a large, thin-wall tube (TOOL 1), for installing the inner bearing onto the spindle during hub assembly, could be used to push the bearing spacer onto the spindle.

Refer to SPECIAL TOOLS FOR WHEEL END ASSEMBLY in THIS SECTION.

e620c-17

1. Place the wheel hub upright in a press to install the bearing cups.

2. Press each bearing cup into the wheel hub against the shoulder in the wheel hub by using the appropriate bearing cup drivers, TOOL 2 and TOOL 3 . Refer to SPECIAL TOOLS FOR WHEEL END ASSEMBLY in THIS SECTION. 3. A piece of thin shim stock ~0.0254mm (0.001") is to be inserted in several places around the diameter to check the bearing cups are properly seated.

8.31

Tigercat AD610C Carrier f.

Drive

METAL FACE SEAL INTO HUB AND INTO SPINDLE

IMPORTANT !

Install face seal halves in the same positions where they were located prior to disassembly.

Mixing up face seal halves can cause component damage.

The Metal Face Seal halves must be installed in the spindle and in the hub before the hub can be assembled to the spindle. Install the Metal Face Seal halves in the spindle and in the hub as follows:

e620c-19

1. Make sure the formed seal ring, Toric Ring (O-ring) and wheel hub are clean and free of any oil or other contaminants. If required, use a solvent like isopropyl alcohol, that evaporates quickly, leaves no residue, and is compatible with the Toric Ring.

IMPORTANT !

Install the Toric Ring into the seal ring and make sure it is flat. Do not twist the Toric Ring when installing onto the seal ring. A twisted Toric Ring will not seal correctly, allowing leakage of lubricant and pumping of debris past the ring. Damage to components can result.

IMPORTANT !

Check for solvent residue on all seating surfaces.

Solvents that leave a residue on the Toric Ring, metal face seal or on housing seal seating surface can cause the Toric Ring to roll into the seal, rather than slide. Damage to the seal can result.

2. Install the Toric Ring onto the formed seal ring so that it rests in the radius of the tail of the seal ring and is not twisted. Install the Toric Ring onto the seal ring as follows:

WARNING Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleumbase cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer’s instructions and these procedures: • • • • •

A. Wet the Toric Ring with isopropyl alcohol and install it onto the formed seal ring so that it is seated at the bottom of the seal ring ramp and against the retaining lip.

IMPORTANT !

Do not use Stanosol® or any other liquid that leaves an oily film and does not evaporate quickly, since this may result in incorrect seating of the Toric Ring in the housing, resulting in seal leakage.

Wear safe eye protection.

Wear clothing that protects your skin.

Work in a well-ventilated area.

Do not use gasoline, or solvents that contain gasoline. Gasoline can explode.

You must use hot solution tanks or alkaline solutions correctly. Carefully follow the manufacturer’s instructions.

B. Make sure the Toric Ring is not twisted by rapidly pulling it away from the seal ring and letting it snap back. Do this in a number of places until the seal is correctly seated. Be careful not to nick or cut the Toric Ring seal, as this will cause leaks.

8.32

Tigercat AD610C Carrier

Drive installation tool (207897)

e620c-22

e620c-20

6. Shake excess lubricant from the assembly.

Immediately install (“pop”) the seal into the wheel hub with a firm push of the installation tool.

7. Remove the installation tool. installation tool (207897)

e620c-21

make sure toric ring is not twisted

3. Coat the Toric Ring with isopropyl alcohol so that it slides easily past the retainer lip in the wheelhub and installs correctly on the spindle ramp.

4. Place installation tool (Tigercat Part #207897) around the metal seal ring and Toric Ring.

Refer to SPECIAL TOOLS FOR WHEEL END ASSEMBLY in THIS SECTION. 5.

e620c-23

8. Follow the same procedure to install the other half of the face seal assembly onto the wheel spindle.

Wipe the Toric Ring with a lint-free towel or clean foam brush saturated with isopropyl alcohol.

8.33

Tigercat AD610C Carrier g. Check for Correct Installation of the Metal Face Seal Check the spindle and wheel hub for correct installation of the Metal Face Seal before the hub can be installed onto the spindle.

Drive 3. Apply isopropyl alcohol as a lubricant to the Toric Ring and place in the seating area. If installation does not appear smooth, flat and correct, remove the seal from the spindle and repeat the process.

IMPORTANT !

Apply isopropyl alcohol to the Toric Ring. Check the retaining lip of the seal seating area for burrs or fins, which can cause a seal to leak. Damage to components can result.

IMPORTANT !

To prevent slippage of the Toric Ring, allow sufficient evaporation time for the assembly lubricant before proceeding with further assembly.

Damage to components can result.

check assembled height variation

a

e620c-24

1. Check assembled height variation (A) in at least four places, 90 degrees apart, using a caliper, toolmaker’s rule, or other accurately calibrated measuring device. The difference in height around the ring must not be more than 0.5 mm (0.02 in).

4. Seat Toric Ring correctly. Once correctly in place, the Toric Ring must roll on ramp only. See below for examples of incorrect installation.

2. If required, adjust the seal standout height by using the following methods.

•

If the standout height cannot be brought into specification: Remove the seal and repeat the installation procedure.

IMPORTANT !

Push or pull the Toric Ring and face seal only. Do not push or pull directly on the seal ring. This can cause component damage.

e620c-25

A. Use the installation tool to push down on the Toric Ring and face seal.

B. With your fingers, pull up uniformly on the Toric Ring and face seal.

8.34

examples of incorrect installation

Tigercat AD610C Carrier

Drive

h. Wheel Hub to Spindle Assembly NOTE: Complete the assembly of the wheel hub to the spindle. Before installing the wheel hub onto the spindle, however, keep the following points in mind to ensure correct sealing between the faces of the Metal Face Seal: 1. Check both sealing faces carefully to make sure they are clean and free of any dirt, debris, lint, and even human hair.

IMPORTANT !

Bring the housings together slowly. High impact can result in component damage. Remove protective pad from the spindle’s seal journal.

e620c-27

2. Remove the protective pad from the spindle’s seal journal.

•

Shown above, the Toric Rings have slipped, instead of rolling on the left-hand side of the seal. Note how the top Toric Ring is to the right and the bottom Toric Ring is to the left. The same seals are also shown after the bottom half is rotated 90 degrees.

•

If the Toric Ring slips at any location, it will twist, causing the formed seal rings to seat incorrectly.

IMPORTANT !

Do not apply lubricant to the Toric Ring. The Toric Ring can leak. Damage to components can result.

4. Install the hub. Use a large thin-wall tube (tool number 1, see Special Tool Section), to push the inner bearing onto spindle while installing hub onto spindle.

e620c-26

•

When installing the hub onto the spindle, both seal housings must be aligned correctly.

•

Slowly bring the hub and spindle assembly together as the spindle bearing adjustment nut is tightened.

3. Apply a light coating of Dow Corning GN molybdenum assembly paste lubricant to the two mating surfaces of the face seal’s steel rings only. Do not allow this lubricant to contact the Toric Ring. The Toric Ring can leak.

•

If the seals are not aligned correctly: The seals will move. Any wobbling motion of the seals is an indication of incorrectly positioned (cocked) seals. Dirt can enter past the Toric Ring.

e620c-28

5. Apply a light coat of oil to the bearing cone rollers and install the outer bearing cone onto the spindle.

NOTE: The (3) M8 threaded holes in the wheel bearing adjusting nut should be facing outward as the nut is assembled against the 8.35

Tigercat AD610C Carrier

Drive i.

wheel bearing cone. Rotate the wheel hub by hand while tightening adjusting nut in order to seat the wheel bearings and seal assembly.

Planetary Spider Sub-Assembly

The planetary pinion shafts are not serviceable items and should not have been disassembled from the planetary spider.

6. Install the wheel bearing adjusting nut using the wheel bearing adjusting nut tool (Tigercat Part # 204691). Tighten the nut to 500 lbf-ft (678 N-m). Refer to SPECIAL TOOLS FOR WHEEL END ASSEMBLY in THIS SECTION.

Further sub-assembly of the planetary pinion gears, needle rollers, and thrust washers is as follows if the planetary spider gears had been removed.

7. Rotate the hub three to five revolutions in both directions.

Re-Use Components If the re-assembly of the planetary spider will re-use the components that were previously disassembled and inspected:

8. Tighten the nut to 500 lbf-ft (678 N-m) again.

9. Rotate the hub three to five revolutions in each direction again.

1. Open each bag containing the previously removed planet gear, snap ring, thrust washers, and needle bearing components that were marked and match to the planetary pinion shaft from which they were removed.

Keep these parts matched to their planetary pinion shaft during assembly.

10. Repeat above steps until nut torque level stabilizes.

11. Install the wheel bearing lock plate over the wheel bearing adjusting nut and align the tabs on lock plate with slots in the spindle.

12. Review the alignment of the holes in the lock plate and holes in the spindle nut. Review amount the spindle bearing nut must be loosened to make the holes align with lock plate.

New Components If new components are to be assembled on the planetary pinion shafts, please follow the identical recommended procedure:

13. Repeat steps 11 & 12 with lock plate indexed 180 degrees and review the hole alignment in the lock plate and wheel bearing adjusting nut.

Repeat the following steps for each planetary pinion shaft /gear assembly.

1. Place the planetary spider with the (4) planetary pinion shafts pointing upward in a safe workbench orientation so the planetary spider assembly will not roll or fall off the work bench and cause personal injury or component damage.

14. Choose between the (2) lock plate positions that requires the “least loosening” of the wheel nut. The maximum recommendation is no more than 5.5 degrees “loosening” of the adjusting nut.

2. Apply a light coating of oil or grease to the base of planetary spider where the outer thrust washer will be placed and the planetary pinion shaft,outer thrust washer faces and slide the outer washer over the pinion shaft and against the spider.

NOTE: Do not further tighten the wheel nut to align the capscrew holes.

15. Add a few drops of BLUE Loctite to each capscrew threads to install the (3) lock plate M8 capscrews and tighten to 28.2 lbf-ft (38.3 N-m). Safely set the planetary wheel hub, planetary ring gear, and spindle assembly on a workbench.

IMPORTANT !

Never mix new and old needle rollers, nor needle rollers from different manufacturers, on the same planetary pinion shaft and gear assembly.

Component damage can occur.

Two optional methods of assembling the planetary gears with needle rollers to each planetary pinion shaft are recommended:

8.36

Tigercat AD610C Carrier

Drive 5. Add light coat of oil or grease to the faces of the inner thrust washer and slide over the planetary pinion shaft and insert the locking tab into the planetary pinion shaft to eliminate the thrust washer rotation.

NOTE: The snap ring should rotate freely in the groove on the planetary pinion shaft when properly seated.

6. Install the snap ring into the planetary pinion shaft groove to retain the planetary gear assembly on the planetary spider assembly.

NOTE: If the gear does not rotate smoothly or if excessive axial end play is noted, the outer thrust washer may have been omitted and this gear assembly should be removed and checked that all components were assembled.

e620c-29

Method 1: 3. Apply a light coat of grease to the planetary pinion gear bore and assemble the (33) needle rollers into the planet gear bore until there is no further space to add additional needle rollers. If new needle rollers are being used in the planetary gear assembly, they must be from the same vendor, and belong to the same tolerance group (0.002mm).

4. Carefully, lift the planet gear with needle rollers assembled and place on the planetary pinion shaft. It is recommended to use a pointed tool to stick between the needle rollers to help align the needle rollers and verify there is no gap large enough to insert an extra roller. Proceed to step 5.

7. After each planetary pinion gear,needle rollers, thrust washers and snap ring are assembled on each pinion shaft, a check should be done to assure the planetary gear rotates smoothly and has little axial endplay ( ~ < 0.07mm or 0.003") .

8. Safely set the assembled planetary spider shaft on a work bench for later assembly into the planetary wheel end.

Method 2: 3. Apply a light coat of grease to the planetary gear bore and install the gear over the planetary pinion shaft.

NOTE: Oscillating the planetary pinion gear will help in seating the needle rollers during assembly. Use of a pointed tool to stick between the needle rollers may be required until all rollers are aligned and installed with no gap large enough for an additional roller.

4. Individually add each needle roller to the gear assembly until all (33) rollers are installed.

Proceed to step 5.

8.37

Tigercat AD610C Carrier

Drive

j. Planetary Spider Assembly, Spindle & Planetary Ring Gear Assembly, and Wheel Hub Assembly To assemble the planetary wheel end using the above sub-assemblies, the following procedure is recommended:

WARNING Take care when using lifting devices. When you use a lifting strap, inspect the strap for damage before you use it. Do not use a lifting strap to shock load or drop load a component. Serious personal injury can result.

e620c-31

3. Apply a light coat of grease to the O-ring that will be fitted onto the driver pilot diameter and install O-ring onto the driver against the flange. Care should be taken to not twist or damage the O-ring during this assembly.

4. Slide the driver and O-ring assembly onto the planetary spider shaft splines. Fit the driver pilot diameter in the wheel hub pilot bore, aligning the (3) M8 capscrew mounting holes.

5.

Add BLUE Loctite to the (3) M8 Allen head capscrew threads and tighten the capscrews to 28.2 lbf-ft (38.3 N-m).

NOTE: The snap ring should rotate freely in the snap ring groove, if properly seated.

e620c-30

6. Install the snap ring into the groove of the planetary spider shaft, locking it against the driver.

1. Using a lifting strap to secure the planetary spider assembly, place the assembly with the planet pins setting on a 50 mm thick spacer whose O.D. is smaller than ring gear’s I.D.

7. Apply a light coat of grease to the O-ring and add Oring to the cover groove. Care should be taken not to twist or damage the O-ring during assembly on the cover groove.

2. Using a lifting strap to secure the spindle, wheel hub and planetary ring gear assembly, safely lower this assembly onto the the planetary spider allowing the planetary spider shaft to pass through the spindle bore and then mesh the planetary gears into the planetary ring gear teeth as the subassembly is slowly and safely lowered together.

8. Place the cover against the wheel driver and the end of the planetary spider.

9.

NOTE: Use care not to damage or twist the O-ring during assembly.

8.38

Add BLUE Loctite to each of the (8) holes in the wheel driver and install the (8) M8 Allen head capscrews and tighten to 28.2 lbf-ft (38.3 N-m).

Tigercat AD610C Carrier

Drive

k. Install the Planetary Wheel End assembly On the Axle Housing

WARNING Take care when using lifting devices. When you use a lifting strap, inspect the strap for damage before you use it. Do not use a lifting strap to shock load or drop load a component. Serious personal injury can result.

To continue with this axle assembly, the axle housing should have carrier input horizontal. All instructions provided are per axle housing end and must be repeated on the opposite housing end for a complete axle assembly.

e620c-33

3. Carefully install the (0.8 mm thick) shim with the adhesive side against the axle housing flange face while guided on the wheel end studs. Apply pressure around the shim surface to make sure the shim will be bonded to the entire axle flange diameter surface.

4. Apply a thin coat of grease to the O-ring that will be assembled to the planetary ring gear face.

5. Install the O-ring into the groove on the face of the planetary ring gear with care not to twist or damage the O-ring during installation.

e620c-32

1. If (2) studs are not already installed in the axle housing flanges, then add a few drops of BLUE Loctite into (2) threaded holes at 10:00 and 2:00 positions in the axle housing flange and add (2) M18 studs. Tighten to engage all threads.

NOTE: The following 2 steps apply only to axles equipped with Outboard Wet Disk Brakes. If the axle being assembled does not have the outboard wet disk brake option, proceed to step 4.

WARNING Take care when you use adhesives, thread locking compounds, silicone gasket materials or any sealants to avoid serious personal injury. Follow the manufacturer’s instructions to prevent irritations to the eyes and skin.

6. Using the lifting strap, carefully lift the preassembled planetary wheel end assembly and slide the assembly along the (2) wheel end studs that were installed in the axle housing flange. Remove the (2) M18 safety bolts, nuts and washers, if installed, through the spindle flange and ring gear.

7. Align the sun gear and planet teeth .

8. Verify that O-rings have not fallen out of grooves on both sides of ring gear.

9. Fully insert the ring gear into the pilot on the axle housing.

10. Add BLUE Loctite to the (18) M18 axle housing flange threads. Install the (18) M18 capscrew and washers to the axle housing flange/wheel end assembly. Torque to 375.4 lbf-ft (509 N-m).

11. Install the (2) nuts and washers on the (2) studs.

NOTE: Thread locker is NOT required as these nuts are lock nuts. Torque to 303.9 lbf-ft (412 N-m).

2. If the axle uses outboard wet disk brakes and if a shim is not installed against axle housing flange face, then apply a thin uniform coat of adhesive #Q58-grade-226 on one side of the ring gear shim.

8.39

Tigercat AD610C Carrier

Drive

SPECIAL TOOLS FOR WHEEL END ASSEMBLY

e620c-35 e620c-34

tigercat part # 207897 tigercat part # 204691 e620c-37

e620c-36

8.40

Tigercat AD610C Carrier

Drive

WHEEL INSTALLATION NOTE: All wheel installation joints and surfaces should be clean, flat surfaces (free of paint, grease and oil etc.) using grade 8 bolts, hardened washers and standard torque practices.

•

Use tapered assembly studs to help with wheel installation. Two or three studs can be used on each side.

2.17" MIN. FULL THREAD

.79" .406" DRILL

.06" x 45° 7/8" - 14 UNF THREAD

20°

2.64" 3.41"

TAPERED ASSEMBLY STUD FOR 7/8" BOLTS

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.

When cleaning in flange, double check and be sure to use the proper size tap , 7/8" - 14 UNF thread.

•

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: 7/8"-14 UNF torque to 500-550 lbf/ft. lubricated.

IMPORTANT !

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.

8.41

Tigercat AD610C Carrier

Drive

8.42

Tigercat AD610C Carrier SECTION 9 - BRAKES AND DIFFERENTIAL LOCKS

DECEMBER 2009

CONTENTS-SECTION 9 ACCUMULATOR ACCUMULATOR.......................................................................................................... 9.5 CHARGING AND TESTING DEVICE........................................................................... 9.5 CHARGING THE ACCUMULATOR.............................................................................. 9.5 CHECKING GAS PRESSURE..................................................................................... 9.5 BRAKES BRAKE PEDAL VALVE................................................................................................. 9.4 REAR AXLE BRAKE...............................................................................See SECTION 8 CHARGING VALVE, ACCUMULATOR............................................................................. 9.5 CIRCUIT DESCRIPTION................................................................................................. 9.8 CIRCUIT DIAGRAM....................................................................................................... 9.10 CIRCUIT HYDRAULIC SCHEMATIC............................................................................. 9.11 MAIN PUMP..................................................................................................................... 9.3 MAIN PUMP UNLOADING VALVE......................................................................... 9.3, 9.17 MULTIFUNCTION MANIFOLD......................................................................................... 9.6 PARKING BRAKE - HYDRAULIC SPRING APPLIED HYDRAULIC RELEASE..................................................... 9.12, 9.13 PILOT MANIFOLD............................................................................................................ 9.7 PRESSURE SETTINGS, MAIN PUMP.......................................................................... 9.17 PRIORITY VALVE.................................................................................... See SECTION 11 SERVICE BRAKE, REAR AXLE.................................................................See SECTION 8

Tigercat AD610C Carrier

Brakes and Differential Locks

9.2

Tigercat AD610C Carrier

Brakes and Differential Locks

MAIN PUMP

TO PILOT MANIFOLD LS

POR ADJUSTMENT

MAIN PUMP POR VALVE

solenoid, integrated main pump unloading valve

MARGIN PRESSURE

610C-19

margin VALVE

TO ACCUMULATOR, BRAKE AND PRIORITY VALVE

main pump

The main pump is driven off the power take off of the drive pump.

The main pump provides hydraulic oil to the pilot manifold(fan speed, axle oscillation unlock, axle oscillation make up, parking brake), multifunction manifold (differential locks, winch freespool), brake circuit and priority valve, which in turn provides hydraulic oil to the steer circuit, brake circuit and control valve (winch, dozer, attachment pressure) circuits.

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 destroked the flow smoothly decreases until there is no flow at an angle of zero (0°).

INTEGRATED UNLOADING VALVE

AD610C-06

TO FROM HYDRAULIC SUCTION TANK SUCTION STRAINER LINE

MAIN PUMP HYDRAULIC SCHEMATIC

The pressure compensator provides maximum pump flow until the main pump reaches the preset main pump POR setting. The pressure compensator then regulates output flow to match machine requirements for the steering, brake, winch, dozer and attachment pressure functions.

When the parking brake is ON and the integrated main pump unloading valve is energized the margin pressure can be read using the MAIN test port. When the parking brake is OFF, the main pump unloading valve is de-energized and the main pump is fully loaded the main pump POR pressure can be read using the MAIN test port.

Refer to MAIN PUMP UNLOADING VALVE in SECTION 7 of THIS MANUAL.

The pressure compensator is mounted directly onto the pump and has a MARGIN pressure adjustment and a POR (pressure override) adjustment. An integrated unloading valve is sandwiched between the POR valve and the main pump to effectively de-stroke the swashplate when an electric signal is provided.

The MARGIN PRESSURE adjusting screw is factory set at 300 psi (20 bar) @ 950 rpm.

The POR is adjusted to operate at 3400-3500 psi (234-241 bar) @ 2200 rpm.

9.3

Tigercat AD610C Carrier

Brakes and Differential Locks

BRAKE PEDAL VALVE The brake pedal valve is a manually operated directional valve and operates on the same principal as a pressure reducing valve.

As the pedal is depressed, pressure is provided to the brakes in the rear 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.

A positive stop in the brake valve limits the brake pressure to a preset value.

This preset value is determined by the requirements of the brakes in the rear axle, which in this case is 1000 psi (69 Bar). The brake pedal therefore regulates the pressure in the brake lines to 1000 psi (69 Bar).

When the pedal is released, the spool returns to its neutral position and allows the brake cylinders to drain to tank.

A

P

T

T A P MO-02

MO-01

CROSS SECTION OF VALVE BODY

BRAKE VALVE

9.4

Tigercat AD610C Carrier

Brakes and Differential Locks CHARGING THE ACCUMULATOR

ACCUMULATOR The accumulator is bladder type and is installed with a nitrogen pre-charge pressure of approximately 750 psi (52 Bar).

WARNING USE ONLY NITROGEN for charging accumulators, NEVER USE OXYGEN OR AIR, due to the risk of explosion.

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

NOTE: A detailed instruction sheet is provided with the charging and testing device. The following is only a suggested guide.

NITROGEN BOTTLE

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.

ADAPTER*

ADAPTER*

ASSEMBLY PART NO. 90254 INCLUDES PARTS SHOWN *

VALVE CAP

ACCU-2

GAS VALVE

BLADDER

POPPET (Seats against oil port after oil evacuation)

ACCUMULATOR (BLADDER TYPE)

CHECKING THE GAS PRE-CHARGE PRESSURE Bleed off the system pressure as stated earlier.

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.

BODY

ACCU-1

PRESSURE GAUGE*

ACCUMULATOR

VALVE GUARD

HYDRAULIC CONNECTION

HOSE*

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

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

If the gas pre-charge is low, investigate cause and correct. Possible causes of lost pre-charge pressure include leaking or damaged gas valve, or damaged bladder.

WARNING The accumulator must not be altered. DO NOT weld or machine the pressure vessel.

9.5

•

Disconnect hose from nitrogen bottle.

•

Remove charging and testing device from accumulator and install valve cap and guard, torque to 175-350 lbf-in (20-40 N-m).

•

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.

Tigercat AD610C Carrier MULTIFUNCTION MANIFOLD

610c-21

Brakes and Differential Locks

MULTIFUNCTION manifold

AD610C-07

MULTIFUNCTION MANIFOLD ELECTRICAL SCHEMATIC

The multifunction manifold controls the front differential lock, rear differential lock and winch freespool functions.

This manifold contains a non-adjustable pressure relief valve and five solenoid operated pilot valves.

The pressure relief valve is used to provide pilot oil for use by the solenoid operated pilot valves in the manifold when a function is activated.

This manifold has two tank ports T and T1.

Coil resistance for all five solenoids is 33.8 ohms.

604-17

For information about the winch functions functions refer to SECTION 13 of THIS MANUAL.

9.6

MULTIFUNCTION MANIFOLD HYDRAULIC SCHEMATIC

Tigercat AD610C Carrier PILOT MANIFOLD

Brakes and Differential Locks

The pilot manifold controls the oscillation lockout, osciloation makeup, parking brake and variable pitch fan functions.

Secondary pressure reducing valve ‘PRA’

pressure relief vavle ‘rv1’

pressure reducing valve ‘pr1’

This manifold contains a non-adjustable pressure reducing valve and pressure relief valve to provide pilot oil for use by the solenoid operated pilot valves in the manifold when a function is activated.

There are five sections labelled A, B, C, D and E. The valves in each section are different and specific to the function for which they are used.

Section A is controlled by a soilenoid operated pilot valve and contains a secondary pressure reducing valve which further reduces the pressure of the pilot oil supplied. Not used at this time.

E620C-20

MULTIFUNCTION manifold

Sections B, C and D are controlled by solenoid operated pilot valves and provide pilot oil to the oscillation lockout, oscillation makeup and parking brake release functions respectively when a function is activated.

Section E is controlled by two solenoid operated pilot valves operating together to provide pilot oil to the variable pitch fan functions (FULL ON, AUTO, CLEAN) when a function is operated.

This manifold has two tank ports T and T1.

Coil resistance for all solenoids is 33.8 ohms.

For information about the oscillation lockout function refer to SECTION 8 of THIS MANUAL.

AD610C-09

MULTIFUNCTION MANIFOLD ELECTRICAL SCHEMATIC

For information about the variable pitch fan function refer to SECTION 10 in THIS MANUAL.

AD610C-08

PILOT MANIFOLD HYDRAULIC SCHEMATIC 9.7

Tigercat AD610C Carrier CIRCUIT DESCRIPTION BRAKE Oil is supplied by a variable displacement piston pump (main pump). Oil is directed through a check valve to the brake accumulator. The oil from the brake accumulator side of the check valve is sent to the brake foot control valve to operate the rear brakes. The main pump also supplies oil to the priority valve for steering and control valve functions.

The brake accumulator ensures that the brake remains responsive at all times by maintaining an optimum pressure to the brake foot control valve.

The brake accumulator holds sufficient pressure for up to 5 brake applications after the engine stalls or is shut down. Beyond this the pressure drops substantially.

As the brake pedal is depressed, pressure from the accumulator is provided to the brakes in the rear axle. 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.

A positive stop in the brake valve limits the brake pressure to a preset value.

This preset value is determined by the requirements of the brakes in the rear axle, which in this case is 1000 psi (69 Bar). The brake pedal therefore regulates the pressure in the brake lines to 1000 psi (69 Bar).

When the pedal is released, the spool returns to its neutral position and allows the brake cylinders to drain to tank.

Note that this machine equipped with a brake pressure switch which sends a signal to the IQAN computer system (VOLTAGE IN - Brake Pressure Low) when service brake pressure falls below 800 psi (55 Bar). This signal triggers a Brake Pressure Low warning message in the event of a loss of brake pressure.

Brakes and Differential Locks DIFFERENTIAL LOCKS Pilot oil is supplied to the multifunction manifold from the main pump via the pilot manifold. The pressure relief valve in the manifold provides pilot oil at reduced pressure for use by the solenoid operated pilot valves in the manifold when a function is activated. Refer to MAIN PUMP in THIS SECTION for main pump information.

When the operator presses the front differential lock switch a signal (DIGITAL IN - FRONT DIFF LOCK ) is sent to the computer control system. The computer control system sends a signal (DIGITAL OUT- FRONT DIFF LOCK ) to activate the front differential lock solenoid on the multifunction manifold and provide pilot oil to the front differential lock. The front differential lock icon on the main menu of the computer display will be illuminated when front differential lock is engaged.

When the operator presses the rear differential lock switch a signal (DIGITAL IN - REAR DIFF LOCK ) is sent to the computer control system.

The computer control system sends a signal (DIGITAL OUT- REAR DIFF LOCK) to activate the rear differential lock solenoid on the multifunction manifold and provide pilot oil to the rear differential lock. The rear differential lock icon on the main menu of the computer display will be illuminated when rear differential lock is engaged.

Refer also to SECTION 6 of THIS MANUAL for complete electrical schematics and more detailed information about the computer control system.

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

For more information about the rear axle service brakes refer to SECTION 8 in THIS MANUAL.

9.8

Tigercat AD610C Carrier

Brakes and Differential Locks

DRIVELINE PARKING BRAKE Pilot oil is supplied to the pilot manifold from the main pump.

The driveline parking brake is spring applied and hydraulically released.

When the parking brake switch is in the ON position the parking brake is spring applied. A signal is sent to the park brake on relay which in turn sends an electrical signal to the main pump unloading valve to unload the main pump.

The parking brake icon on the main menu of the computer display will be illuminated when the parking brake is engaged. Note that only margin pressure is available from the main pump when the parking brake switch is in this position.

When the parking brake switch is in the OFF (DRIVE) position a signal is sent to the computer control system (DIN PARK BRAKE SWITCH DRIVE). A signal from the computer control system (DOUT PARKING BRAKE OFF) is sent to the parking brake latch relay. When the parking brake latch relay closes current is sent to the parking brake off relay contact current passes through the closed door switches to latch the parking brake off relay closed and engergizes the parking brake valve releasing the parking brake.

When the parking brake off relay closes current to the main pump unloading valve is blocked.

The main pump unloading valve de-energizes to load the main pump (full pump pressure will be available while the parking brake is OFF).

When the parking brake switch is in the UNLOCKACTIVATE CRANE position current is supplied to the park brake on relay and a signal is sent to the computer control system (DIN PARK BRAKE SWITCH CRANE). The parking brake on relay closes. A signal from the computer control system (DOUT UNLOADING VALVE OFF) is sent to the unloading valve off relay (wire 135). The unloading valve off relay closes blocking current to the main pump unloading valve. The main pump unloading valve de-energizes to load the main pump (full pump pressure will be available while the parking brake switch is in the CRANE UNLOCK-ACTIVATE position). The unlock-activate crane icon on the main menu of the computer display will be illuminated.

Note that the computer control system has interlocks in place to prevent the machine from being driven with the crane unlocked, doors open or the parking brake ON. Refer also to START CIRCUIT DIAGRAMS in SECTION 7 or ELECTRICAL SCHEMATICS in SECTION 6 of THIS MANUAL for more detailed information.

9.9

Tigercat AD610C Carrier

Brakes and Differential Locks

ILLUSTRATION NOT AVAILABLE AT TIME OF PRINTING

BRAKE and differential lock CIRCUIT 9.10

Tigercat AD610C Carrier

Brakes and Differential Locks

BRAKE AND DIFFERENTIAL LOCK CIRCUIT HYDRAULIC SCHEMATIC AD610C-HS9

9.11

Tigercat AD610C Carrier

Brakes and Differential Locks

PARKING BRAKE PARKING BRAKE ASSEMBLY

604-63

604-62

SPRINGS

STATIONARY DISKS

DRIVE SHAFT

ROTATING DISKS

724E-007

PARKING BRAKE The parking brake assembly is installed in the drive line between the transmission and the rear axle. Five rotating discs are splined to the brake shaft and 6 stationary discs are held in place in the brake housing. The brake is spring applied and hydraulically released.

PARKING BRAKE SWITCH

AD610C-02

parking brake on

A parking brake switch on the instrument panel activates and deactivates the brake, also the brake will be activated when the key switch is ‘OFF’.

9.12

Tigercat AD610C Carrier

Brakes and Differential Locks

PARKING BRAKE

PARKING BRAKE ASSEMBLY

The spring applied and hydraulically released parking brake assembly installed in the drive line between the transmission and the rear axle does not require any adjustment.

Service of the brake assembly is limited to oil change or removal, disassembly and replacement of worn or damaged parts and reinstallation of the brake assembly.

604-63

BRAKE ASSEMBLY REMOVAL 1. Park machine on level ground, lower dozer blade to the ground, install articulation lock bar, shut engine off.

604-62

AD610c-02

SPRINGS

STATIONARY DISKS

DRIVE SHAFT

ROTATING DISKS

BLOCK WHEELS

2. Install wheel blocks in front of and in rear of all four wheels 3. Remove the cover plate under the rear chassis to access the brake assembly.

4. Disconnect the hydraulic hose and breather hose at the brake assembly. Plug the hose ends and ports on the brake housing.

724E-007

PARKING BRAKE

5. Disconnect and remove the drive shafts at the brake assembly.

724E-035

6. Remove the four hex head bolts nuts and washers. Slide the assembly over and support the brake assembly using a floor jack.

BL024

7. Lower the brake assembly out of the rear chassis.

9.13

Tigercat AD610C Carrier

Brakes and Differential Locks - ASSEMBLY

1

23

6

7

•

16 19 27 25 26

724E-008

•

•

• 22

•

•

•

•

•

18

•

12 21

•

19 15

•

•

13

•

• •

•

•

•

20 24 13

•

•

•

•

13

•

15

17

9

•

23

•

20

21

•

•

28

•

•

•

•

11

10

4

•

•

•

6

2

•

• •

•

•

•

14

•

BL024

9.14

5

8

3

24

Tigercat AD610C Carrier PARTS DESCRIPTION

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Qty.

1 1 1 7 as req.

2 1 1 18 18 1 1 5 2

Brakes and Differential Locks Item

Description

15 16 17 18 19 20 21 22 23 24 25 26 27 28

ASSEMBLY . Disc, primary . Cap, end . Bolt, hex. . Shim . Bearing, tapered roller . Shaft, splined . O-ring . Spring, outer . Spring, inner . Retainer, spring . Housing . Disc, rotating . Plug

Qty. 5 1 1 6 2 2 2 1 2 2 1 1 1 1

Description

. . . . . . . . . . . . . .

Disc, stationary Gasket Plate, power Bolt Pin, torque Ring, retaining Spacer Plug, protective Seal, oil Seal, oil O-ring Piston O-ring Valve, pressure relief

BRAKE DISASSEMBLY

ASSEMBLY

1. Remove the yokes from the input shaft.

1. Reverse disassembly procedure for assembly with the following notes and additions.

2. Position the brake with the power plate (12) up, the side with the mounting lugs.

3. Remove spacers (21) from each end.

4. Remove the bolts (18) alternately and slowly, keeping power plate parallel to the housing to prevent damage to the bearings. Use extreme caution springs (9 and 10) can cause power plate to pop off housing.

5. After the bolts (18) have been removed, remove the power plate assembly from brake.

2. Pre-lube O-rings, piston and cylinder of the power plate with hydraulic oil.

Piston Assembly 3. Assemble piston into power plate using a shop press. Take care not to damage O-ring or teflon back-up rings.

4. Vissually align the centre of the cutouts in the piston with the torque pin holes in the power plate.

CAUTION: The depth the piston is installed into the power plate is critical. The surface of the piston at the cutouts must be flush to 3.05 mm (0.120”) below the surface of the power plate or the piston will cock resulting in complete loss of braking.

6. Remove shaft and disc stack from the brake.

If the disc stack is to be serviced use a shop press to remove the bearing cones from the shaft.

7. Remove primary plate (2), springs and spring retainer from housing spring pocket.

8. Remove piston (26) from power plate by using Low Pressure air 1 Bar (15 psi) through hydraulic inlet. Make sure the piston is directed away from the operator.

9. Remove O-rings from the OD and ID of the groove of the piston.

NOTE: If the bearings or seals are removed both must be replaced. Seal can be removed by prying it out with an appropriate tool taking care not to damage the bore.

Bearing Assembly 5. Using a shop press install one cone on the shaft, bearing must be seated tight against the stop. Press only on the inner race of the bearing cone, not on the rollers.

6. Install the disc in the order shown in the parts illustration. Install the other bearing cone on the shaft observing the preceding cautions.

10. Thoroughly clean all the parts.

11. Inspect and replace any worn, damaged or defective parts.

9.15

Tigercat AD610C Carrier

Brakes and Differential Locks

Brake Assembly

INSTALLATION

7. Install parts in reverse order of disassembly leaving the shaft seals to last. Release the brake using 20.7 Bar (300 psi) and measure the torque to rotate the shaft. The free rolling torque of the brake shaft is an indication of bearin seating and fit. The rolling torque should be 2.26 Nm (20 inch lbs) maximum. If it does not meet this specification, check that the bearings are well seated.

724E-035

1. Install the brake assembly in reverse order as removed. Torque the mounting bolts to 216237 Nm (159-175 lbf/ft ).

2. Remove the plug installed for the hydraulic hose fitting and pre fill the brake assembly with system hydraulic oil (refer to service and lubrcation chart for oil specification).

3. Reinstall the breather hose and hydraulic hose.

4. Install the drive shafts. Torque the yoke (universal joint) retainer bolts to 50 Nm (37 lbf/ft ).

724E-007

5. Install the cover plate on the bottom of the rear chassis.

Lip Seal Assembly 8. After the brake is assembled, install the shaft seals with caution not to cut the seal lips on the shaft splines. The inner seals are installed with spring facing inwards. The outer seals are installed with spring facing outward.

10. Install the spacers and yokes on the brake assembly. Torque the yoke retainer bolts to 244 Nm (180 lbf/ft).

9.16

Tigercat AD610C Carrier

Brakes and Differential Locks

PRESSURE SETTINGS MAIN PUMP POR AND MARGIN PRESSURES

POR ADJUSTMENT

1. Park the machine on level ground, lower dozer blade to the ground, engage the parking brake, and shut off the engine. Install articulation lock.

2. Connect a 0-345 Bar (0-5000 psi) gauge to the ‘MAIN’ test port. All pressure readings for this procedure will be read from the ‘MAIN’ test port.

MARGIN PRESSURE

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

drive pump

connectors

610C-17

disconnect two connectors on drive pump prior to procedure

solenoid, integrated main pump unloading valve

‘main’ test port

610C-19

main pump

9. Engage the parking brake to activate the main pump unloading valve. The main pump must be unloaded to correctly set the main pump margin pressure.

10. Set the margin pressure to 300 (20 bar) psi @ 950 rpm.

11. Turn off the engine, reconnect two connectors on drive pump, remove gauge, reinstall plugs on test ports, and replace the covers. Remove articulation lock.

4. Prior to performing this procedure disconnect the two connectors on the drive pump. This is a safety precaution to prevent the machine from travelling.

5. Start the engine. Set engine speed to 2200 rpm.

6. Disengage the parking brake. This deactivates the main pump unloading valve. The main pump must be fully loaded to correctly set the main pump POR. 7. Set the main pump POR to 3500-3600 psi (240-248 Bar) @ 2200 rpm.

8. Set engine speed to 950 rpm.

9.17

Tigercat AD610C Carrier

Brakes and Differential Locks

9.18

Tigercat AD610C Carrier SECTION 10-OIL COOLER AND FAN DECEMBER 2009

CONTENTS - SECTION 10 CIRCUIT DESCRIPTION OIL COOLER.............................................................................................................. 10.6 CIRCUIT DIAGRAM..................................................................................................... 10.11 OIL COOLER CIRCUIT............................................................................................... 10.7 CIRCUIT HYDRAULIC SCHEMATIC............................................................................. 10.9 COOLING PUMP........................................................................................................... 10.3 FILTER, HYDRAULIC DOUBLE ELEMENT................................................................... 10.4 FLEXXAIRE® FAN (OPTIONAL)................................................................................. 10.10 CIRCUIT DIAGRAM.................................................................................................. 10.11 CIRCUIT HYDRAULIC SCHEMATIC........................................................................ 10.11 HYDRAULIC OIL TANK, MAIN....................................................................................... 10.4 OIL COOLER/ RADIATOR/ cHARGE AIR COOLER..................................................... 10.2 SUCTION STRAINER.................................................................................................... 10.5

Tigercat AD610C Carrier

Oil Cooler and Fan

OIL COOLER/ RADIATOR/ CHARGE AIR COOLER/a-c condenser The side by side A/C condenser, radiator, charge air cooler (CAC) and hydraulic oil cooler is mounted at the front of the machine. The engine fan draws air from the engine compartment, through the A/C condenser and cooling assembly and blows it out through the front door screen.

The screened access panels on each side of the engine compartment act as debris screens to prevent debris from being drawn into the engine compartment.

A/C CONDENSER

CHARGE AIR COOLER (CAC)

RADIATOR

The complete oil cooler/radiator/CAC/A-C condenser 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 AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR’S MANUAL.

610-03

604-60

10.2

COOLING ASSEMBLY

engine fan

HYDRAULIC OIL COOLER

Tigercat AD610C Carrier

Oil Cooler and Fan

cooling PUMP The cooling pump is a fixed displacement gear pump driven off the power take off of the main pump.

cooling pump

The oil cooler bypass manifold is mounted on the outlet side of the cooling pump. The oil cooler bypass manifold ensures that the differential pressure between the oil cooler inlet and outlet does not exceed 100 psi (6.7 Bar).

OUTLET DRIVEN (IDLER) GEAR

DRIVE GEAR 610C-22

INLET GEAR1

TYPICAL gear pump

The operation of a typical external gear pump (so called because the gear teeth are on the external surface of the hub) is shown in Figure gear1.

A gear pump carries oil from the inlet to the outlet in the spaces between gear teeth. The pumping chamber is formed by the gears, the pump housing, and thrust plates. One of the two gears, called the drive gear, will be connected to the drive shaft. The other idler gear is driven by the drive gear.

10.3

COOLING PUMP

Tigercat AD610C Carrier

Oil Cooler and Fan

MAIN HYDRAULIC OIL TANK

DOUBLE ELEMENT FILTER

Located at the rear of the engine compartment, the hydraulic tank has a capacity of 23.5 US gal (89 L).

The hydraulic cooling circuit contains a two element, full flow, 7 micron filter with a built in 25 psi (1.7 Bar) bypass valve. It is recommended that all machines use two different filter elements:

A sight gauge, accessible through the right front quick access lift out panel, indicates the HIGH and LOW level of the main hydraulic oil tank.

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

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

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

For additional information on these filters refer to FILTERS and SERVICE AND LUBRICATION POINTS in SECTION 3.

A hydraulic oil level switch is connected to the IQAN computer control system. This switch triggers the hydraulic oil level low warning. Refer also to INFORMATION CENTER ~ SYSTEM WARNING MESSAGES in SECTION 2 of THE OPERATOR'S MANUAL. hydraulic tank

double element filter

breather

BLUE ELEMENT sight gauge

CHARGE PRESSURE FILTER

610C-11

hydraulic tank, filters and sight gauge

10.4

Tigercat AD610C Carrier

Oil Cooler and Fan

SUCTION STRAINER

strainer head

o-ring

suction strainer

ay061

suction strainer

The suction strainer collects hydraulic oil from case drains (drive pump, main pump, and drive motor), brake valve drain line, priority valve and rear chassis (winch and grapple) drain line. This oil passes through the suction strainer element before entering the cooling circuit.

The suction strainer element requires no regular maintenance over the life of the machine. This element requires maintenance only in the case of damage or contamination due to a hydraulic pump or motor failure.

IMPORTANT !

The suction strainer element is NOT a filter element. Always use the correct replacement element. Use of an incorrect (filter type) element will result in pump damage.

10.5

Tigercat AD610C Carrier

Oil Cooler and Fan

CIRCUIT DESCRIPTION The suction strainer collects hydraulic oil from case drains (drive pump, main pump, and drive motor), brake valve drain line, priority valve and rear chassis (winch and grapple) drain line.

This oil and passes through the suction strainer element before entering the cooling circuit.

The cooling pump draws oil from the suction strainer and 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 (6.7 Bar). Pressure increases within the oil cooler can occur in cold weather when oil temperatures at start-up are very low.

Cooling of the oil occurs as air is drawn over the oil cooler cooling fins. Cooled oil then passes through the front chassis return manifold, the double element filter and back to the hydraulic tank.

Oil is added to the hydraulic reservoir using the hydraulic hand fill pump located on the front of the hydraulic tank (right side access). Oil is pumped through the double filter element directly into the reservoir.

Oil entering the hydraulic reservoir passes through a diffuser situated inside the reservoir below the oil surface.

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

10.6

Tigercat AD610C Carrier

610C-04

Oil Cooler and Fan

OIL COOLER CIRCUIT 10.7

Tigercat AD610C Carrier

Oil Cooler and Fan

10.8

Tigercat AD610C Carrier

610C-07

Oil Cooler and Fan

COOLING CIRCUIT HYDRAULIC SCHEMATIC 10.9

Tigercat AD610C Carrier

Oil Cooler and Fan

FLEXXAIRE® FAN (OPTIONAL) Information to follow.

Information was not available at the time of publication.

Refer also to manufacturer's manual.

10.10

Tigercat AD610C Carrier

Oil Cooler and Fan

illustration not available at time of printing

FAN CIRCUIT HYDRAULIC SCHEMATIC

ad610c s10f

FAN CIRCUIT DIAGRAM 10.11

Tigercat AD610C Carrier

Oil Cooler and Fan

10.12

Tigercat AD610C Carrier SECTION 11 - STEERING AND CENTER JOINT

DECEMBER 2009

CONTENTS - SECTION 11 CENTER JOINT CHECKING CENTER JOINT VISUALLY FOR LOOSENESS.................................... 11.7 CHECKING THE CENTER JOINT PRELOAD CENTER JOINT PRELOAD ADJUSTMENT........................................................... 11.8 DIAGRAM................................................................................................................... 11.8 GREASE SEALS - ORIENTATION............................................................................. 11.9 LUBRICATION............................................................................................................ 11.7 MAINTENANCE.......................................................................................................... 11.7 CONTROL VALVE.......................................................................................................... 11.3 PRIORITY VALVE.......................................................................................................... 11.4 STEERING CIRCUIT DIAGRAM.................................................................................................... 11.6 CIRCUIT HYDRAULIC SCHEMATIC.......................................................................... 11.5

Tigercat AD610C Carrier

Steering and Center Joint

left hand steering joystick The left hand steering joystick is mounted on the operator's seat armrest. The joystick consists of a single axis analog joystick base, a direction selection switch and a maximum speed control.

DIRECTION SELECTION SWITCH

MAXIMUM SPEED CONTROL

Movement of the joystick controls the steering function: Move the joystick to the RIGHT* to articulate the machine to the RIGHT* .

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

E625C-11

This machine is equipped with variable ratio load sensing steering. The speed that the vehicle responds to the steering control input will vary, depending on the speed at which the steering control is moved.

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

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

For safe operation of all controls the operator’s seat must be locked in either the forward facing or rear facing position. Refer also to ROTATING SEAT KICK LEVER in THIS SECTION. Refer to SECTION 8 for informtion about the direction selection switch and the maximum speed control.

One button is used to turn the differential lock function on and off. Refer to SECTION 9 for more differential lock function information.

The trigger switch is used to increase engine speed when performing machine functions which do not require machine travel.

Refer also to CONTROL LEVER in SECTION 2 of the OPERATOR'S MANUAL for more detailed function information.

11.2

LEFT HAND JOYSTICK

Tigercat AD610C Carrier

Steering and Center Joint

STEERING CONTROL VALVE The steering control valve is located in the left hand step compartment below the left cab door.

This control valve consists of an inlet section; one spool section; and an end section with integrated pilot supply.

The inlet section receives oil from the pump and supplies the control valve section through the pressure gallery. For this application the inlet section is also used to direct oil back to tank via the T2 port. The end section internal and external ports have been plugged so that oil is internally redirected back to the T2 port of the inlet section.

The inlet section also includes a plug which separates the pressure gallery and the free flow gallery for closed center operation of the valve.

The inlet section is equipped with relief valve which acts as a main relief control valve.

STEERING CONTROL VALVE OPERATING DESCRIPTION AD610C-207

Oil is supplied by a variable displacement piston pump (main pump) via the priority valve. The priority valve directs oil to the steering control valve .

Oil enters the inlet section and is allowed to pass through the closed center spool sections to the end section and is prevented from returning to tank by a plugs in the T1, T3 and TP ports.

Internal pilot pressure supply is generated by a pressure reducing valve in the end section for use in operating the spool sections. If none of the functions of the control valve are in use there will be no oil flow through the valve, therefore oil flow to the control valve will be regulated to zero as the piston pump de-strokes to a zero angle.

The end section contains the internal pilot pressure supply used to operate the spools.

The internal pilot pressure supply is a valve function which acts as both a reducing valve and a pressure relief valve. A separate safety valve prevents maximum reduced pressure from being exceeded. Pilot pressure of 35 bar (508 psi) is generated by the pressure reducing valve and is available in the pilot gallery for operation of spool sections. A pilot pressure connection at port PS provides pilot pressure for external use (if required by machine options). Tank ports T1, T3 and TP are plugged to redirect tank oil back to the inlet section port T2.

Each electro-hydraulically controlled spool section has a closed centered 3-position spool with spring centering. When a function is brought into use the electrical current from the computer control system creates a magnetic force proportional to the current supplied within the solenoid. The solenoid shifts the actuator and allows the spool to be shifted by internal pilot pressure applied to the end of the spool. Shifting the spool directs oil from the pressure gallery to operate the function required. Return oil from the function in use is directed through the control valve to the inlet section T2 port where it returns to tank. When more than one function is operating at the same time there will be reduced flow to each.

Spool sections are equipped with double acting three position spools blocked in the neutral position. Spool sections are operated by electrohydraulic proportional spool actuators with spring centering. Each solenoid valve is equipped with manual override and air bleeding functions. Each spool section's pressure gallery is fitted with a load-hold check valve to prevent load sinking of a heavy load while a light load is operated.

Pressure relief ports in each spool are equipped differently according to the machine function controlled. The steering section is with pressure relief cartridges on both the A and B sides. All relief valves are cartridge style, factory set for each function and nonadjustable.

To prevent over pressurizing of the operating circuits, some of the work ports in the spool sections have a port relief valve cartridge. All relief valves are cartridge style, factory set for each function and nonadjustable. All relief valves are anti-cavitation relief valves.

Spool limiting set screws are factory set for all spool sections. (Factory settings are: dozer section 6mm from the end of the screw to the tightened jam nut, all other sections 10 mm)

Refer to SECTION 12 of THIS MANUAL for additional illustrations and information about this type of valve.

11.3

Tigercat AD610C Carrier

Steering and Center Joint

PRIORITY VALVE

P

The priority valve receives hydraulic oil from the main hydraulic pump.

T

The oil then passes through the priority valve, where it is divided up to go to either the steer valve and on to the steer cylinders, or the grapple, dozer or winch functions.

LS

The priority valve is a feature that allows the steer circuit to have first call on oil before the grapple, dozer or winch circuits.

This control is accomplished by a load-sensing feedback circuit from the steer valve to the priority valve.

EF

The priority valve contains a built-in relief valve which is factory set to 2750 psi* (190 Bar). When this relief setting is exceeded, most of the flow will be directed to the auxiliary circuit (EF). *Note: On later machines this relief valve is not adjustable, factory set at 3000 psi (205 Bar).

When full oil flow is not required for steering the excess supply of oil is directed to the other circuits.

OIL 'IN' FROM main pump

RELIEF VALVE CARTRIDGE (earlier adjustable cartridge shown)

T

CF

Back flow into the steering system is prevented by a check valve in the steer control 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.

RETURN OIL TO TANK

PRIORITY VALVE

AT028-2

P

•

LS

• AT028-1

LOAD SENSE CONNECTION TO STEER VALVE

CF

EF HIGH PRESSURE CARRYOVER TO GRAPPLE, WINCH AND DOZER VALVES

PRIORITY VALVE AT028

11.4

TO STEER VALVE

Tigercat AD610C Carrier

Steering and Center Joint

STEER CIRCUIT HYDRAULIC SCHEMATIC 11.5

Tigercat AD610C Carrier

Steering and Center Joint

ILLUSTRATION NOT AVAILABLE AT THE TIME OF PRINTING

STEER CIRCUIT 11.6

Tigercat AD610C Carrier

Steering and Center Joint

center joint

checking the center joint preload 1. Park the machine on level ground. Engage parking brake, grapple and dozer blade UP and shut off engine.

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.

2. Torque the top and bottom retainer bolts (items 1 and 2) to 282-310 lbf-ft (393-420 Nm).

Pin retainers use 4 bolts each. dial indicator plunger

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.

front chassis

b

dial indicator

rear chassis

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

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.

DIG-06

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

dig-003

check preload

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.

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.

rear chassis

check for movement in this joint area

A

5. Fully loosen only the bottom pin retainer bolts (item 2) that were torqued in step 2. DO NOT REMOVE BOLTS.

front chassis

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.

center joint preload check

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 (AA164)

11.7

PRELOAD RANGE LOWER

UPPER

0.018 in 0.457 mm

0.020 in 0.508 mm

Tigercat AD610C Carrier

Steering and Center Joint

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

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.

With dial indicator still in place;

This is the proper bearing preload setting.

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).

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.

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 (393-420 Nm).

1

1

torque to 282-310 lbf-ft (393-420 Nm) NO LOCTITE REQUIRED (note: earlier style not shown used 6 bolts)

3 4 bolt tightening sequence

4

2

FRONT CHASSIS

11

SEAL ORIENTATION

REAR CHASSIS

9 10 3 2

6

torque to 282-310 lbf-ft (393-420 Nm) NO LOCTITE REQUIRED (earlier style not shown used 6 bolts)

4 5 8 11

625C-95

7

torque to 80-88 lbf-ft (109-119 Nm) USE 243 LOCTITE (REMOVABLE)

center joint 11.8

Tigercat AD610C Carrier

Steering and Center Joint

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 * (109-119 Nm).

11.9

Tigercat AD610C Carrier

Steering and Center Joint

11.10

Tigercat AD610C Carrier SECTION 12 - CRANE (ATTACHMENT PRESSURE) december 2009

CONTENTS - SECTION 12 CIRCUIT DESCRIPTION............................................................................................... 12.8 CIRCUIT diagram....................................................................................................... 12.9 CIRCUIT SCHEMATIC................................................................................................... 12.7 CONTROL VALVE.......................................................................................................... 12.2 CONTROL VALVE ELECTRICAL SCHEMATIC............................................................. 12.4 HYDRAULIC SCHEMATIC, CIRCUIT............................................................................ 12.7 IQAN MODULES........................................................................................See SECTION 6 MAIN PUMP...............................................................................................See SECTION 9 PARKING BRAKE / UNLOCK-ACTIVATE CRANE SWITCH......................................... 12.6 PRESSURE checks and adjustments.............................................................. 12.10 PRIORITY VALVE.................................................................................... See SECTION 11

Tigercat AD610C Carrier

Crane (Attachment Pressure)

CONTROL VALVE oil OUT

PRESSURE REDUCING VALVE CARTRIDGE (INTERNAL PILOT SUPPLY)

oil IN

front

PILOT PRESSURE CONNECTION FOR EXTERNAL USE

inlet section

A

A

a

DOZER

b

a

WINCH

b

a

ATTACHMENT PRESSURE

CROSS SECTION VIEW TOWARD INLET SECTION

INTERNAL PILOT PRESSURE SUPPLY

b

END section SECTION A-A AD610C-02

main control VALVE

END SECTION (INTERNAL PILOT SUPPLY)

630C-162

The control valve is located on the rear chassis above the rear axle and under the cover plate.

HIGH PRESSURE SUPPLY

This control valve consists of an inlet section; three spool sections; and an end section with integrated pilot supply.

REDUCING VALVE AND PRESSURE RELIEF (PILOT SUPPLY)

The inlet section receives oil from the pump and supplies the control valve sections through the pressure gallery. For this application the inlet section is also used to direct oil back to tank via the T2 port. The end section internal and external ports have been plugged so that oil is internally redirected back to the T2 port of the inlet section.

The inlet section also includes a plug which separates the pressure gallery and the free flow gallery for closed center operation of the valve.

The inlet section is equipped with relief valve which acts as a main relief control valve.

The end section contains the internal pilot pressure supply used to operate the spools.

The internal pilot pressure supply is a valve function which acts as both a reducing valve and a pressure relief valve. A separate safety valve prevents maximum reduced pressure from being exceeded. Pilot pressure of 35 bar (508 psi) is generated by the pressure reducing valve and is available in the pilot gallery for operation of spool sections. A pilot pressure connection at port PS provides pilot pressure for external use (if required by machine options). Tank ports T1, T3 and TP are plugged to redirect tank oil back to the inlet section port T2.

SAFETY VALVE

COARSE FILTER WITH BY-PASS (FOR PILOT SUPPLY)

INTERNAL PILOT PRESSURE SUPPLY

END SECTION (INTERNAL PILOT SUPPLY)

630C-40

manual override

630c-218a

12.2

PILOT PRESSURE CONNECTION FOR EXTERNAL USE

manual override

Tigercat AD610C Carrier

Crane (Attachment Pressure)

Spool sections are equipped with double acting three position spools blocked in the neutral position. Spool sections are operated by electrohydraulic proportional spool actuators with spring centering. Each solenoid valve is equipped with manual override and air bleeding functions. Each spool section's pressure gallery is fitted with a load-hold check valve to prevent load sinking of a heavy load while a light load is operated.

controlled. The dozer, winch and attachment pressure spool sections are equipped with pressure relief cartridges on both the A and B sides. All relief valves are cartridge style, factory set for each function and nonadjustable.

Spool limiting set screws are factory set for all spool sections. (Factory settings are: dozer section 6mm from the end of the screw to the tightened jam nut, all other sections 10 mm)

Pressure relief ports in each spool are equipped differently according to the machine function PORT RELIEF & ANTICAVITANTION VALVE

HIGH PRESSURE SUPPLY

LOAD HOLD CHECK VALVE DOUBLE ACTING SPRING CENTRED SPOOL

ELECTRO HYDRAULIC SPOOL ACTUATOR

INTERNAL PILOT PRESSURE SUPPLY

SPOOL SECTION

630C-39

manual override

SERVICE PORT B

LOAD HOLD CHECK VALVE

SERVICE PORT A

ELECTRO HYDRAULIC SPOOL ACTUATOR PORT B

manual override

ELECTRO HYDRAULIC SPOOL ACTUATOR PORT A

PILOT OIL RESTRICTOR

PILOT OIL RESTRICTOR 'x' set screw adjustment

spool limiting set screw

spool limiting set screw

PORT B RELIEF VALVE CARTRIDGE

DOUBLE ACTING SPRING CENTRED SPOOL

NOTE: CROSS SECTION VIEW TOWARD END SECTION 630C-163

CROSS SECTION OF SPOOL SECTIONS 12.3

PORT A RELIEF VALVE CARTRIDGE

Tigercat AD610C Carrier

Crane (Attachment Pressure)

OPERATING DESCRIPTION

CONTROL VALVE CHARACTERISTICS

Oil is supplied by a variable displacement piston pump (main pump) via the priority valve. The priority valve directs oil to the control valve (dozer, winch, attachment pressure). The control valve is equipped with an inlet relief valve which acts as a main relief.

•

Control Pressure Relief : 500 psi (34 Bar) (Non-Adjustable)

• Start of Control : 0 gpm / 580 mA / 102 psi (0 L/min / 580mA / 7 Bar) • End of Control: 46.5 US gpm /1450 mA /348 psi

(176 L/min / 1450mA /24 Bar)

Oil enters the inlet section and is allowed to pass through the closed center spool sections to the end section and is prevented from returning to tank by a plugs in the T1, T3 and TP ports.

Internal pilot pressure supply is generated by a pressure reducing valve in the end section for use in operating the spool sections. If none of the functions of the control valve are in use there will be no oil flow through the valve, therefore oil flow to the control valve will be regulated to zero as the piston pump de-strokes to a zero angle.

• Coil Resistance : 5.4 ohms Control Valve Characteristics

Flow gpm

50 45 40 35 30 25 20 15 10

Each electro-hydraulically controlled spool section has a closed centered 3-position spool with spring centering. When a function is brought into use the electrical current from the computer control system creates a magnetic force proportional to the current supplied within the solenoid. Refer also to CONTROL VALVE CHARACTERISTICS in THIS SECTION. The solenoid shifts the actuator and allows the spool to be shifted by internal pilot pressure applied to the end of the spool. Shifting the spool directs oil from the pressure gallery to operate the function required. Return oil from the function in use is directed through the control valve to the inlet section T2 port where it returns to tank.

When more than one function is operating at the same time there will be reduced flow to each.

5 0 0

200

400

600 800 (107) (164)

1000 1200 1400 1600 (220) (277) (334) (390)

Control Current mA Control Presure (psi)

To prevent over pressurizing of the operating circuits, some of the work ports in the spool sections have a port relief valve cartridge. All relief valves are cartridge style, factory set for each function and nonadjustable. All relief valves are anti-cavitation relief valves.

CONTROL VALVE ELECTRICAL SCHEMATIC ad610c-10

12.4

Tigercat AD610C Carrier

oil OUT

Crane (Attachment Pressure)

oil IN

front

inlet section

a

DOZER

b

a

WINCH

b

a

ATTACHMENT PRESSURE

b

END section

AD610C-02

main control VALVE

12.5

Tigercat AD610C Carrier

Crane (Attachment Pressure) Place in the PARKING BRAKE OFF position to DISENGAGE the parking brake.

NOTE: The parking brake must be DISENGAGED to DRIVE the machine. If the engine is started with the parking brake/unlock-activate crane switch is not in the parking brake ON position an interlock will be triggered to prevent accidental movement of the machine, the switch must be cycled to release the interlock.

NOTE ALSO: The interlock system prevents the machine from being driven and function controls from being operated while the parking brake is ENGAGED. As part of the interlock system this machine automatically engages the parking brake whenever a cab door is open. This prevents accidental or improper operation of the controls from anywhere but the operator's seat.

unlock-activate crane switch AD610C-02

CONTROL PANEL

PARKING BRAKE / UNLOCK-ACTIVATE CRANE SwITCH / P /

Refer also to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ INTERLOCK SYSTEM or COMPUTER ~ MESSAGES AND WARNINGS - INFORMATION ~ INTERLOCK SYSTEM in SECITION 6 of THIS MANUAL. Refer also to START CIRCUIT DIAGRAMS in SECTION 7 or ELECTRICAL SCHEMATICS in SECTION 6 of THIS MANUAL for more detailed information.

This is a three position switch, labelled / P / (UNLOCK-ACTIVATE CRANE/PARKING BRAKE ON/PARKING BRAKE OFF).

Place in the UNLOCK-ACTIVATE CRANE position to unlock the crane from its stowed position and activate the crane hydraulic controls.

In addition the parking brake will engage, the front axle oscillation lock will be activated and the full main pump pressure will be available to the crane functions.

Note also that when the crane is activated machine drive, steering and dozer functions are locked out. Attempting to activate any of these functions will trigger a message on the computer control system. Refer to COMPUTER ~ MESSAGES AND WARNINGS - INFORMATION ~ INTERLOCK SYSTEM - CRANE NOT STOWED in THIS SECTION. Place in the P PARKING BRAKE ON position to ENGAGE the parking brake. The parking brake icon on the main menu of the computer display will be illuminated when the parking brake is engaged. Note that only margin pressure is available from the main pump when the parking brake switch is in this position.

12.6

Tigercat AD610C Carrier

ad610cSH12

Crane (Attachment Pressure)

CIRCUIT SCHEMATIC 12.7

Tigercat AD610C Carrier

Crane (Attachment Pressure)

CIRCUIT DESCRIPTION Oil is supplied by a variable displacement piston pump (main pump) via the priority valve. The priority valve directs oil to the control valve (winch, dozer, attachment pressure). The control valve is equipped with an inlet relief valve which acts as a main relief.

Oil enters the inlet section of the control valve and is allowed to pass through the closed center spool sections to the end section and is prevented from returning to tank by a plugs in the T1, T3 and TP ports. Internal pilot pressure supply is generated by a pressure reducing valve in the end section for use in operating the spool sections.

The aerial device is provided with attachment pressure via the main control valve attachment pressure section.

Each electro-hydraulically controlled spool section has a closed centered 3-position spool with spring centering.

When the operator places the PARKING BRAKE/ UNLOCK-ACTIVATE CRANE SWITCH into the UNLOCK-ACTIVATE CRANE position a signal is sent to the computer control system (DIGITAL IN - PARK BRAKE SWITCH CRANE) The computer control system generates a signal (CURRENT OUT - CRANE ACTIVATE) which is sent out to a solenoid on the attachment pressure section of the control valve activating ATTACHMENT PRESSURE function.

When the ATTACHMENT PRESSURE function is activated electrical current from the computer control system creates a magnetic force proportional to the current supplied within the solenoid. The corresponding solenoid shifts the actuator and allows the spool to be shifted by internal pilot pressure applied to the end of the spool. Shifting the spool directs oil from the pressure gallery to aerial device. The attachment pressure section of the control valve is equipped with cartridge style relief valves to protect the circuit from over pressurizing.

Return oil is directed through the control valve to the inlet section T2 port where it returns to tank.

Refer also to SECTION 6 of THIS MANUAL for complete electrical schematics and more detailed information about the computer control system.

12.8

Tigercat AD610C Carrier

Crane (Attachment Pressure)

ILLUSTRATION NOT AVAILABLE AT THE TIME OF PRINTING

E620C-24

CIRCUIT diagram 12.9

Tigercat AD610C Carrier

Crane (Attachment Pressure)

PRESSURE checks and adjustments information NOT AVAILABLE AT THE TIME OF PRINTING

12.10

Tigercat AD610C Carrier SECTION 13 - WINCH

december 2009

CONTENTS - SECTION 13 ALLIED WINCH CIRCUIT DESCRIPTION............................................................................................ 13.6 CIRCUIT diagram....................................................................................................... 13.7 CIRCUIT SCHEMATIC................................................................................................... 13.8 CONTROL VALVE,........................................................................ See also SECTION 12 WINCH SECTION....................................................................................................... 13.2 CONTROL VALVE ELECTRICAL SCHEMATIC............................................................. 13.2 HYDRAULIC SCHEMATIC, CIRCUIT............................................................................ 13.8 MULTIFUNCTION MANIFOLD....................................................................................... 13.5 PRESSURE checks and adjustments................................................................ 13.9 WINCH CONTROL LEVER............................................................................................ 13.3 Winch - DP................................................................................................................... 13.4 WINCH SELECT SWITCH............................................................................................. 13.3

Tigercat AD610C Carrier

Winch

CONTROL VALVE The control valve is located on the rear chassis above the rear axle and under the cover plate.

oil OUT

This control valve consists of an inlet section; three spool sections; and an end section with integrated pilot supply.

oil IN

front

inlet section

For detailed information and an operating description of the control valve refer to CONTROL VALVE in SECTION 12.

a

DOZER

b

WINCH SECTION

a

WINCH

b

The winch spool section is equipped with pressure relief cartridges on both the A and B sides. All relief valves are cartridge style, factory set for each function and nonadjustable.

a

Spool limiting set screws are factory set for all spool sections. The factory setting for the winch section spool stops is 10mm from the end of the screw to the tightened jam nut. Refer also to CONTROL VALVE in SECTION 12.

ATTACHMENT PRESSURE

b

END section

AD610C-02

main control VALVE

CONTROL VALVE ELECTRICAL SCHEMATIC ad610c-10

13.2

Tigercat AD610C Carrier

Winch Place this switch in the (FREESPOOL) position to disconnect the drive motor from the drum in the winch and allow the cable to be freely pulled from the spool. Free spool must be turned off to activate a pull with the winch. The winch freespool icon on the main menu of the computer display will be illuminated when the winch selector switch is in the position.

NOTE: The winch freespool function cannot be activated when the winch cable is under load. The cable must be slack to activate winch freespool.

Refer also to WINCH CONTROL LEVER in THIS SECTION .

WINCH CONTROL LEVER Place the winch select switch (to the left of the lever) in the I (ON) position.

Pull and hold the winch control lever back to spool the winch cable IN. winch select switch AD610C-02

Push and hold the winch control lever FORWARD to spool the winch cable OUT.

winch control lever

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

CONTROL PANEL

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

WINCH SELECT SWITCH This is a three position switch, O / I /

.

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

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

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

AD610C-11

Refer also to WINCH SELECT SWITCH in THIS SECTION.

WINCH CONTROLS (SWITCH AND LEVER) ELECTRICAL SCHEMATIC 13.3

Tigercat AD610C Carrier

Winch

Winch - DP The recovery winch is located in the rear of the carrier.

Refer also to OPERATING WINCH in SECTION 2 of the OPERATOR'S MANUAL.

fill/level plug

Refer to WINCH LUBRICATION in SECTION 3 in THIS MANUAL. Refer to manufacturer's service manual for more information about the winch.

ad610c-06

13.4

recovery winch

drain plug

Tigercat AD610C Carrier

Winch

MULTIFUNCTION MANIFOLD

AD610C-200

MULTIFUNCTION manifold

AD610C-07

MULTIFUNCTION MANIFOLD ELECTRICAL SCHEMATIC

The multifunction manifold controls the front differential lock, rear differential lock and winch freespool functions.

This manifold contains a non-adjustable pressure relief valve and five solenoid operated pilot valves.

The pressure relief valve is used to provide pilot oil for use by the solenoid operated pilot valves in the manifold when a function is activated.

This manifold has two tank ports T and T1.

Coil resistance for all five solenoids is 33.8 ohms.

604-17

For information about the winch functions functions refer to SECTION 13 of THIS MANUAL.

13.5

MULTIFUNCTION MANIFOLD HYDRAULIC SCHEMATIC

Tigercat AD610C Carrier CIRCUIT DESCRIPTION Oil is supplied by a variable displacement piston pump (main pump) via the priority valve. The priority valve directs oil to the control valve (winch, dozer, attachment pressure). The control valve is equipped with an inlet relief valve which acts as a main relief.

Oil enters the inlet section of the control valve and is allowed to pass through the closed center spool sections to the end section. Each electrohydraulically controlled spool section has a closed centered 3-position spool with spring centering. Oil is prevented from returning to tank by plugs in the T1, T3 and TP ports. Internal pilot pressure supply, which is used to operate the spool sections, is generated by a pressure reducing valve located at the end section of the control valve.

A hydraulic winch motor is used to drive the winch during the winding IN/OUT of the cable. The hydraulic winch motor receives oil from the main pump via the winch spool section in the control valve.

Winch Oil is supplied to the multifunction manifold from the main pump via the pilot manifold. The multifunction manifold is equipped with a pressure reducing valve and pressure relief valve which provide pilot oil to all functions.

Winch freespool is controlled by the winch select switch. When the winch control switch is placed in the WINCH FREESPOOL position a signal (DIGITAL IN - Winch Freespool) is sent to the computer control system and second signal is sent directly to the winch freespool solenoid coil. The winch freespool icon on the main menu of the computer display will be illuminated when the winch selector switch is in the position. The pilot signal from the multifunction manifold releases the freespool clutch, allowing the cable to unwind freely.

Refer also to SECTION 6 of THIS MANUAL for complete electrical schematics and more detailed information about the computer control system.

When the operator places the winch select switch in the ON position and operates the the winch control lever back or forward a signal (DIGITAL IN - Winch Freespool and VOLTAGE IN - Winch Lever ) is sent to the computer control system.

The computer control system generates a signal (DIGITAL OUT - Winch In or Winch Out) which is sent to a winch in solenoid on the winch section of the control valve activating the WINCH IN or WINCH OUT function.

When the WINCH IN or WINCH OUT function is activated, an electrical current from the computer control system creates a magnetic force proportional to the current supplied within the solenoid. The corresponding solenoid shifts the actuator and allows the spool to be shifted by internal pilot pressure applied to the end of the spool. Shifting the spool directs oil from the main pump to the winch motor. Return oil is directed through the control valve to the inlet section T2 port where it returns to tank. The winch section of the control valve is equipped with a cartridge style relief valve on both the A side and B side to protect the winch circuit from over pressurizing.

13.6

Tigercat AD610C Carrier

Winch

ILLUSTRATION NOT AVAILABLE AT THE TIME OF PRINTING

CIRCUIT diagram 13.7

Tigercat AD610C Carrier

ad610cSH12

Winch

CIRCUIT SCHEMATIC 13.8

Tigercat AD610C Carrier

Winch

PRESSURE checks and adjustments information NOT AVAILABLE AT THE TIME OF PRINTING

13.9

Tigercat AD610C Carrier

Winch

13.10

Tigercat AD610C Carrier SECTION 14 - DOZER BLADE

december 2009

CONTENTS - SECTION 14 CIRCUIT DESCRIPTION............................................................................................... 14.6 CIRCUIT diagram....................................................................................................... 14.7 CIRCUIT SCHEMATIC................................................................................................... 14.5 CONTROL VALVE ELECTRICAL SCHEMATIC............................................................. 14.3 DOZER BLADE CONTROL LEVER............................................................................... 14.4 HYDRAULIC SCHEMATIC, CIRCUIT............................................................................ 14.5 PRESSURE checks and adjustments................................................................ 14.8

Tigercat AD610C Carrier

Dozer blade

14.2

Tigercat AD610C Carrier

Dozer blade

CONTROL VALVE The control valve is located on the rear chassis above the rear axle and under the cover plate.

oil OUT

This control valve consists of an inlet section; three spool sections; and an end section with integrated pilot supply.

oil IN

front

inlet section

For detailed information and an operating description of the control valve refer to CONTROL VALVE in SECTION 12.

a

DOZER

b

DOZER SECTION

a

WINCH

b

Pressure relief ports in the dozer spool section are equipped with pressure relief cartridges on both the A and B sides. All relief valves are cartridge style, factory set for each function and nonadjustable.

a

ATTACHMENT PRESSURE

b

END section

Spool limiting set screws are factory set for all spool sections. The factory setting for the dozer section spool stop is 6mm from the end of the screw to the tightened jam nut. (Decreasing spool stop setting slows down dozer blade movement.) the Refer also to CONTROL VALVE in SECTION 12.

AD610C-02

main control VALVE

CONTROL VALVE ELECTRICAL SCHEMATIC ad610c-10

14.3

Tigercat AD610C Carrier DOZER BLADE CONTROL LEVER

Dozer blade DOZER BLADE CONTROL LEVER Pull the lever BACK to RAISE

the dozer blade.

Push the lever FORWARD to LOWER dozer blade.

the

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

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

CAUTION

AD610C-01

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

RIGHT HAND ARM REST

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

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

14.4

Tigercat AD610C Carrier

ad610cSH12

Dozer blade

CIRCUIT SCHEMATIC 14.5

Tigercat AD610C Carrier

Dozer blade

CIRCUIT DESCRIPTION Oil is supplied by a variable displacement piston pump (main pump) via the priority valve. The priority valve directs oil to the control valve (winch, dozer, attachment pressure). The control valve is equipped with an inlet relief valve which acts as a main relief.

Oil enters the inlet section of the control valve and is allowed to pass through the closed center spool sections to the end section. Each electrohydraulically controlled spool section has a closed centered 3-position spool with spring centering. Oil is prevented from returning to tank by plugs in the T1, T3 and TP ports. Internal pilot pressure supply, which is used to operate the spool sections, is generated by a pressure reducing valve located at the end section of the control valve.

Two cylinders are used to move the dozer blade UP or DOWN. The dozer circuit receives hydraulic oil from the main pump.

When dozer function is not in use there is no oil flow through the dozer valve section and the pressure compensated main piston pump destrokes.

When the operator moves the dozer control lever forward or back a signal (VOLTAGE IN - Dozer Lever) is sent to the computer control system.

The computer control system generates a signal (CURRENT OUT – Dozer Up-/Dn+) which is sent out out to the a solenoid dozer section of the dozer control valve activating the DOZER UP or DOZER DOWN function.

When the DOZER UP or DOZER DOWN function is activated electrical current from the computer control system creates a magnetic force proportional to the current supplied within the solenoid. The corresponding solenoid shifts the actuator and allows the spool to be shifted by internal pilot pressure applied to the end of the spool. Shifting the spool directs oil from the pressure gallery to either end of the two cylinders to move the DOZER UP or DOWN. The dozer section of the control valve is equipped with cartridge style relief valves to protect the circuit from over pressurizing.

Return oil is directed through the control valve to the inlet section T2 port where it returns to tank.

Refer also to SECTION 6 of THIS MANUAL for complete electrical schematics and more detailed information about the computer control system.

14.6

Tigercat AD610C Carrier

Dozer blade

ILLUSTRATION NOT AVAILABLE AT THE TIME OF PRINTING

CIRCUIT diagram 14.7

Tigercat AD610C Carrier

Dozer blade

PRESSURE checks and adjustments information NOT AVAILABLE AT THE TIME OF PRINTING

14.8