Tigercat 604 604C CABLE SKIDDER SERVICE MANUAL – PDF DOWNLOAD

Description

Tigercat 604 604C CABLE SKIDDER SERVICE MANUAL – PDF DOWNLOAD

DESCRIPTION:

Tigercat 604 604C CABLE SKIDDER SERVICE MANUAL – PDF DOWNLOAD

INTRODUCTION :

An Operator’s manual, Service manual and a Parts catalog are provided by Tigercat to assist the dealer,
customer and operator in becoming familiar with the features of the 604/604C Cable Skidder.
Serial numbers:-
604 6040101 to 6040200
604C 6040201 and up

• The operator’s manual will assist the operator with the techniques of proper and safe operation of the
  Cable Skidder. The service manual contains safety guidelines, a preventive maintenance schedule and
  servicing procedures to ensure optimum machine performance.
• Section 1 in both the operator’s manual and the service manual contains safety information that must be
  followed. As well, throughout the rest of the manuals WARNING and CAUTION notices are displayed
  where necessary, drawing attention to possible hazards when performing certain procedures.
• Only trained personnel should be allowed to operate or work on the machine.
• The information contained in this manual is current at time of printing. Improvements to the machine are
  on-going and may not be covered, therefore in these cases contact your Tigercat dealer for the
  appropriate information.
• The phrase “and up” appearing in this manual after the serial number implies that the related
  information is current for any machine serial number HIGHER than the serial number preceding the “and
  up”.
• Tigercat reserves the right to make changes to the machine after this manual release date that may not
  immediately appear in this manual.

TABLE OF CONTENTS:

Tigercat 604 604C CABLE SKIDDER SERVICE MANUAL – PDF DOWNLOAD

604 604C SERVICE…………………………………………. 1
INTRODUCTION…………………………………………. 3
S.A.E. STANDARDS……………………………………… 4
NON-APPROVED FIELD PRODUCT CHANGES……………………… 5
SECTION 1 – SAFETY……………………………………….. 7
battery disconnect switch …………………………….. 14
Battery safety ………………………………………. 12
CAB EXITS …………………………………………… 13
CAB SAFETY CABLE …………………………………….. 19
CAB SUPPORT BRACE ……………………………………. 19
cooling system ………………………………………. 17
EMERGENCY CAB EXITS ………………………………….. 13
exhaust fumes ……………………………………….. 20
FIRE PREVENTION ……………………………………… 23
DRY CHEMICAL CLEANUP PROCEDURES ……………………. 27
FIRE PREVENTION GUIDELINES ………………………… 23
WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED ………… 26
WHAT TO DO TO PREPARE FOR A MACHINE FIRE ……………. 24
WHAT TO DO WHEN A MACHINE FIRE OCCURS ………………. 25
first aid …………………………………………… 10
FLUID INJECTION INJURY ……………………………….. 21
Fluid leaks …………………………………………. 17
GREASE INJECTION INJURY ………………………………. 22
Hydraulic Pressure hazard …………………………….. 17
loose clothing hazard ………………………………… 18
PARKING THE MACHINE ………………………………….. 14
protective clothing ………………………………….. 9
SAFETY PRECAUTIONS, GENERAL …………………………… 8
SAFETY PRECAUTIONS, OPERATING …………………………. 13
SAFETY PRECAUTIONS, SERVICING …………………………. 16
SAFETY SYMBOLS ………………………………………. 8
SIGNAL WORDS ………………………………………… 8
WELDING, PRIOR TO ……………………………………. 16
Working with oil …………………………………….. 10
SECTION 3 – LUBRICATION & MAINTENANCE………………………. 29
AIR CLEANER MAINTENANCE ………………………………. 54
AIR CONDITIONING SYSTEM, CHECKING ……………………… 60
APPROVED HYDRAULIC OILS……………………………….. 29
MAIN HYDRAULIC SYSTEM …………………………….. 41
ARTICULATION LOCK ……………………………………. 57
AXLE LEVEL CHECK, FILL………………………………… 29
AND DRAIN LOCATIONS ……………………………… 66
CAB SAFETY CABLE …………………………………….. 63
CAB SUPPORT BRACE ……………………………………. 63
CENTER JOINT…………………………………………. 57
LUBRICATION ……………………………………… 57
MAINTENANCE ……………………………………… 57
EMERGENCY EXITS, CHECK MONTHLY ………………………… 35
ENGINE AIR CLEANER……………………………………. 29
AIR CLEANER UNLOADER VALVE ………………………… 55
AIR INLET HOOD …………………………………… 54
FILTERS……………………………………………… 48
CHARGE PRESSURE FILTER ……………………………. 53
FUEL FILTER/WATER SEPARATOR ……………………….. 48
FUEL TANK STRAINER ……………………………….. 51
HYDRAULIC OIL DOUBLE FILTERS ………………………. 52
SERVICING GUIDELINES FOR OIL FILTERS ……………….. 53
FIRE PREVENTION ……………………………………… 35
GENERAL MAINTENANCE ………………………………….. 35
HOUR METER ~ MAINTENANCE ……………………………… 31
LUBRICATION AND SERVICE POINTS…………………………. 29
6040101 TO 6040200 ……………………………….. 43
6040201 TO 6040240 ……………………………….. 45
6040241 AND UP …………………………………… 47
NEW MACHINE MAINTENANCE ………………………………. 31
FIRST 50-100 HOUR INSPECTION AND SERVICE…………….. 29
REPORT ………………………………………. 31
INITIAL PRE-DELIVERY INSPECTION ……………………. 31
OIL LOST FROM LEAKAGE ………………………………… 32
OIL SAMPLE COLLECTION PROCEDURES ………………………. 33
OIL SAMPLING PROGRAM …………………………………. 32
PRESSURIZED WATER SYSTEM MAINTENANCE …………………… 58
SCHEDULED MAINTENANCE ………………………………… 37
FREQUENTLY ………………………………………. 37
8 HOURS …………………………………………. 37
48 HOURS ………………………………………… 37
125 HOURS ……………………………………….. 38
250 HOURS ……………………………………….. 38
500 HOURS ……………………………………….. 39
1000 HOURS ………………………………………. 39
2000 HOURS ………………………………………. 40
SEASONAL ………………………………………… 40
SERVICE AND LUBRICATION POINTS…………………………. 30
6040101 TO 6040200 ……………………………….. 43
6040201 TO 6040240 ……………………………….. 45
6040241 AND UP …………………………………… 47
STARTUP PROCEDURE AFTER……………………………….. 30
MAJOR MAINTENANCE ………………………………… 70
TILTING THE CAB ……………………………………… 62
LOWERING THE CAB …………………………………. 65
RAISING THE CAB ………………………………….. 62
TORQUE CHART ………………………………………… 74
TORQUE, FLUID CONNECTIONS …………………………….. 76
TORQUE SPECIFICATIONS – GENERAL ……………………….. 75
WEIGHTS OF COMMERCIAL WOOD ……………………………. 78
WHEELS, INSTALLING …………………………………… 31
WINCH MAINTENANCE – ALLIED ONLY ……………………….. 68
SECTION 6 – ELECTRICAL AND COMPUTERS……………………….. 81
ALARMS AND GAUGES ……………………………………138
CHANNELS ……………………………………………102
INPUTS…………………………………………… 81
DIGITAL IN (DIN) ……………………………..102
FREQUENCY IN (FIN) ……………………………102
VOLTAGE IN (VIN) ……………………………..102
OUTPUTS………………………………………….. 81
CURRENT OUT (COUT) ……………………………102
DIGITAL OUT (DOUT) ……………………………102
PWM OUT (PULSE WIDTH MODULATION) ……………….102
COMPUTER…………………………………………….. 81
CONTROL SYSTEM ………………………………….. 83
IQAN CONTROL SYSTEM COMPONENTS ……………………. 83
COMPUTER SYSTEM OVERVIEW …………………………….. 83
CURRENT OUT – TROUBLESHOOTING FOR OPEN CIRCUITS …………102
DOWNLOADING APPLICATIONS FROM DEALER WEBSITE ……………121
ELECTRICAL KIT – SERVICE AND DIAGNOSTICS ……………….118
ELECTRICAL SYSTEM SCHEMATIC DIAGRAMS …………………..142
ERROR MESSAGES AND ALARMS……………………………… 81
FAULT CODES : ERROR MESSAGES ………………………117
MAIN SYSTEM ERRORS ……………………………….111
FAULT CODES : ERROR MESSAGES ………………………….117
ERROR :INPUT HIGH ………………………………..117
ERROR: INPUT LOW …………………………………117
ERROR: OUTPUT HIGH ……………………………….117
ERROR: OUTPUT LOW ………………………………..117
INTERPRETING ERROR MESSAGES ……………………….117
FAULT CODES, READING ACTIVE ENGINE CODES ………………. 95
FUSE AND RELAY PANELS…………………………………. 81
6040101 to 6040140 ……………………………….132
6040141 TO 6040200 ……………………………….135
6040201 AND UP …………………………………..136
GAUGES AND ALARMS ……………………………………138
GET APPLICATION ……………………………………..126
GET ERROR/EVENT LOG ………………………………….130
ID-TAG …………………………………………….. 93
INFORMATION CENTER -IQAN MDM COMPUTER DISPLAY ………….. 94
SYSTEM DIAGNOSTICS MENUS …………………………. 96
DIAGNOSTICS MENU DESCRIPTION ………………….. 97
DIAGNOSTICS MENU OPERATION ……………………. 99
SYSTEM WARNING MESSAGES …………………………..107
AIR INTAKE RESTRICTED SERVICE INTAKE TO CORRECT ….110
CHARGE FILTER IN BYPASS WARNING ………………..109
engine temperature warning …………………….108
hydraulic oil level low warning ………………..107
Hydraulic oil temperature warning ………………107
low coolant level warning ……………………..108
MODULE IS OFFLINE SYSTEM WARNING ……………….111
oil pressure warning ………………………….107
SERVICE USE ONLY (PROGRAM MODE) ………………..109
voltage warning ………………………………108
IQAN MODULES…………………………………………. 82
CONTROL SYSTEM OVERVIEW ………………………….. 83
IQAN CONTROL SYSTEM COMPONENTS ……………………. 83
MDM DISPLAY MODULE ………………………………. 85
XS-A0 CAB MODULE ………………………………… 86
XT2-A0 FRONT CHASSIS MODULE ………………………. 90
IQAN SOFTWARE ……………………………………….120
DOWNLOADING APPLICATIONS FROM DEALER WEBSITE ………..121
GET APPLICATION (DOWNLOAD FROM MDM)…………………. 82
USING A PC/LAPTOP …………………………….127
USING A PDA ………………………………….126
GET ERROR/EVENT LOG……………………………….. 82
USING A PC/LAPTOP …………………………….131
USING A PDA ………………………………….130
GRAPHING AND MEASUREMENT OF CHANNELS………………… 82
USING A PC/LAPTOP …………………………….129
USING A PDA ………………………………….128
IQAN DEVELOP G4 SOFTWARE UPGRADE (PSB 1739) …………120
PDA REGISTRATION …………………………………120
UPDATING THE IQAN APPLICATION………………………. 82
FROM A PC/LAPTOP ……………………………124
FROM A PDA …………………………………..122
MAIN SYSTEM ERRORS …………………………………..111
ENGINE RELATED J1939 CONNECTION ERRORS ……………..114
MDM MODULE BLANK SCREEN …………………………..111
MODULE IS OFFLINE ………………………………..111
XS-A0 MODULE OFFLINE ERROR ……………………….112
XT2-A0 MODULE OFFLINE ERROR ………………………113
MODULE IS OFFLINE ……………………………………111
PDA REGISTRATION …………………………………….120
READING ENGINE FAULT CODES …………………………… 95
SWITCH AND SENSOR LOCATIONS……………………………. 82
6040101 TO 6040200 ……………………………….138
6040201 AND UP …………………………………..140
UPDATE APPLICATION …………………………………..122
WIRE COLOUR CODE CHART ……………………………….142
SECTION 7 – ENGINE START AND STOP…………………………..209
START CIRCUIT DESCRIPTION………………………………209
(6040201 AND UP) ………………………………..227
CLOSED CAB (6040101 TO 6040140) …………………..215
CLOSED CAB (6040141 TO 6040200) …………………..223
OPEN CAB (6040101 TO 6040140) …………………….211
OPEN CAB (6040141 TO 6040200) …………………….219
START CIRCUIT DIAGRAM………………………………….209
(6040201 AND UP) ………………………………..228
CLOSED CAB (6040101 TO 6040140) …………………..216
CLOSED CAB (6040141 TO 6040200) …………………..224
OPEN CAB (6040101 TO 6040140) …………………….212
OPEN CAB (6040141 TO 6040200) …………………….220
SECTION 8 – DRIVE…………………………………………231
AXLES ……………………………………………….248
BRAKE BLEEDING ……………………………………250
BRAKE LINING INSPECTION ……………………………250
DIFFERENTIAL AND DIFFERENTIAL LOCKS …………………248
LUBRICATION ………………………………………248
OSCILLATION SHIM CHECK AND ADJUSTMENT (FRONT AXLE) ……270
PLANETARY WHEEL END DISASSEMBLY AND REASSEMBLY ……….272
SERVICING BRAKES ………………………………….249
CAB SUPPORT BRACE …………………………………….261
CIRCUIT DESCRIPTION …………………………………..232
CIRCUIT DIAGRAM……………………………………….231
(6040101-6040111, 6040114-6040120,6040141,……………231
6040143-6040200) ………………………………242
(6040112-6040113, 6040121-6040140, 6040142) ………….243
(6040201 AND UP) ………………………………….242
CIRCUIT HYDRAULIC SCHEMATIC…………………………….231
(6040101-6040111, 6040114-6040120,6040141,……………231
6040143-6040200) ………………………………244
(6040112-6040113, 6040121-6040140, 6040142) ………….245
(6040113, 6040121, 6040125, 6040126) ………………..247
(6040201 AND UP) ………………………………….244
DRIVE MOTOR ………………………………………….236
DRIVE MOTOR SPEED VERIFICATION …………………………253
DRIVE PUMP …………………………………………..233
DRIVE PUMP PRESSURE CHECKS …………………………….252
HYDRAULIC OIL HEATING PROCEDURE ………………………..269
HYDROSTATIC SETUP PROCEDURE ……………………………254
SETUP PREPARATION …………………………………255
drive pump charge pressure …………………………256
drive pump HIGH PRESSURE RELIEF …………………….257
DRIVE PUMP POR ……………………………………259
Motor Begin of Displacement Control Pressure …………261
Motor Maximum Speed/Minimum Displacement …………….263
DRIVE MOTOR MAX CURRENT ……………………………267
DRIVE PUMP MAX CURRENT …………………………….265
MAXIMUM SPEED CONTROL DIAL …………………………….240
SPECIAL TOOLS FOR WHEEL END ASSEMBLY ……………………287
STARTUP PROCEDURE AFTER MAJOR MAINTENANCE. See SECTION 3…..231
TRANSMISSION …………………………………………241
TRAVEL/ENGINE SPEED PEDALS……………………………..231
EARLIER MACHINES ………………………………….238
LATER MACHINES ……………………………………239
SECTION 9 – BRAKES AND DIFFERENTIAL LOCKS……………………289
ACCUMULATOR…………………………………………..289
ACCUMULATOR ………………………………………295
CHARGING AND TESTING DEVICE ………………………..294
CHARGING THE ACCUMULATOR …………………………..295
CHECKING GAS PRESSURE ……………………………..295
CHARGING VALVE, ACCUMULATOR ……………………………295
CIRCUIT DESCRIPTION……………………………………289
6040101 TO 6040200 ………………………………..298
6040201 AND UP ……………………………………302
CIRCUIT DIAGRAM……………………………………….289
BRAKE AND DIFFERENTIAL LOCK CIRCUIT………………….289
6040101-6040111, 6040114-6040120, 6040141 ………..301
6040112-6040113, 6040121-6040140, 6040142 ………..299
6040143-6040200 ……………………………….301
6040201 AND UP ………………………………..303
CIRCUIT HYDRAULIC SCHEMATIC ……………………………297
CONTROL VALVE ………………………………………..293
CONTROL VALVE ELECTRICAL SCHEMATIC ……………………..293
LOAD SENSING………………………………………….289
LOAD SENSING BASIC DESCRIPTION ……………………..291
LOAD SENSING BASIC PRINCIPALS ………………………291
LOAD SENSING OPERATING TIPS ………………………..292
MAIN PUMP ……………………………………………290
MULTIFUNCTION MANIFOLD ………………………………..296
PARKING BRAKE – HYDRAULIC………………………………289
SPRING APPLIED HYDRAULIC RELEASE ……………………304
PRESSURE CHECKS……………………………………….289
BRAKE PRESSURE REGULATION ………………………….310
PRESSURE SETTINGS, MAIN PUMP …………………………..309
PRIORITY VALVE. See SECTION 11………………………….289
SERVICE BRAKES………………………………………..289
BRAKE PEDAL VALVE …………………………………294
REAR AXLE BRAKE. See SECTION 8………………………289
SECTION 10-OIL COOLER……………………………………..313
CIRCUIT DESCRIPTION……………………………………313
OIL COOLER ……………………………………….318
CIRCUIT DIAGRAM……………………………………….313
FAN CIRCUIT (OPTIONAL)……………………………..313
6040201 AND UP ………………………………..323
OIL COOLER CIRCUIT…………………………………313
6040101-6040111, 6040114-6040120, 6040141 ………..320
6040112-6040113, 6040121-6040140, 6040142 ………..319
6040143-6040200 ……………………………….320
6040201 AND UP ………………………………..320
CIRCUIT HYDRAULIC SCHEMATIC…………………………….313
OIL COOLER CIRCUIT ………………………………..321
COOLING PUMP ………………………………………..315
FILTER, HYDRAULIC DOUBLE ELEMENT ……………………….316
FLOW CONTROL VALVE ……………………………………317
HYDRAULIC OIL TANK, MAIN ………………………………316
OIL COOLER/ RADIATOR/ cHARGE AIR COOLER …………………314
SUCTION STRAINER ……………………………………..317
VARIABLE PITCH FAN (OPTIONAL – 6040201 AND UP)……………313
ADDING OIL TO FAN …………………………………326
CHECKING OIL LEVEL ………………………………..325
CIRCUIT DIAGRAM …………………………………..323
DRAINING OIL FROM FAN ……………………………..326
FAN LUBRICATION AND SERVICE INTERVALS ……………….324
FAN OPERATION …………………………………….322
LUBRICATION AND SERVICE INTERVALS …………………..324
MAINTENANCE CHECK LIST …………………………….326
OIL SPECIFICATION …………………………………325
REMANUFACTURING …………………………………..324
REMOVE DEBRIS DURING OPERATION USING THE……………..313
CLEAN FUNCTION ………………………………..322
SECTION 11 – STEERING AND CENTER JOINT………………………327
CENTER JOINT………………………………………….336
CHECKING CENTER JOINT VISUALLY FOR LOOSENESS …………336
CHECKING THE CENTER JOINT PRELOAD……………………327
CENTER JOINT PRELOAD ADJUSTMENT …………………337
DIAGRAM ………………………………………….337
GREASE SEALS – ORIENTATION …………………………338
LUBRICATION ………………………………………336
MAINTENANCE ………………………………………336
PRIORITY VALVE ……………………………………….331
STEER CONTROL VALVE……………………………………327
METERED STEERING ………………………………….328
QUICK STEER ………………………………………330
STEERING……………………………………………..327
CIRCUIT DIAGRAM …………………………………..335
CIRCUIT HYDRAULIC SCHEMATIC ………………………..334
TESTING THE STEERING OPERATION …………………………339
SECTION 13 – WINCH………………………………………..341
ALLIED WINCH………………………………………….341
CIRCUIT DESCRIPTION ……………………………….350
CIRCUIT DIAGRAM …………………………………..351
CIRCUIT HYDRAULIC SCHEMATIC ………………………..353
PRESSURE REDUCING VALVE – DRAG BRAKE OPTIONAL ………..348
WINCH ……………………………………………349
CONTROL VALVE ………………………………………..342
CONTROL VALVE CHARACTERISTICS ………………………….344
CONTROL VALVE ELECTRICAL SCHEMATIC ……………………..344
MULTIFUNCTION MANIFOLD ………………………………..345
PRESSURE CHECKS……………………………………….341
WINCH IN …………………………………………354
WINCH CONTROL LEVER …………………………………..346
SECTION 14 – DOZER BLADE…………………………………..357
CIRCUIT DESCRIPTION …………………………………..362
CIRCUIT DIAGRAM ………………………………………363
CONTROL VALVE ………………………………………..359
CONTROL VALVE ELECTRICAL SCHEMATIC ……………………..359
DOZER CONTROL LEVER …………………………………..360
HYDRAULIC SCHEMATIC, CIRCUIT …………………………..365
PRESSURE CHECKS……………………………………….357
DOZER UP/DOWN RELIEFS ……………………………..366

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TIGERCAT 604 604C CABLE SKIDDER SERVICE MANUAL – PDF DOWNLOAD:

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