Tigercat 635 SKIDDER SERVICE MANUAL – PDF DOWNLOAD

Description

Tigercat 635 SKIDDER SERVICE MANUAL – PDF DOWNLOAD

DESCRIPTION:

Tigercat 635 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 635 Skidder.
• The operator’s manual will assist the operator with the techniques of proper and safe operation of the
  Skidder. The service manual contains safety guidelines, a preventive maintenance schedule and
  servicing procedures to ensure optimum machine performance.
• Section 1 in both the operator’s manual and the service manual contains safety information that must be
  followed. As well, throughout the rest of the manuals WARNING and CAUTION notices are displayed
  where necessary, drawing attention to possible hazards when performing certain procedures.
• Only trained personnel should be allowed to operate or work on the machine.
• The phrase “and up” appearing in this manual after the serial number implies that the related
  information is current for any machine serial number HIGHER than the serial number preceding the “and
  up”.
• Tigercat reserves the right to make changes to the machine after this manual release date that may not
  immediately appear in this manual.

TABLE OF CONTENTS:

Tigercat 635 SKIDDER SERVICE MANUAL – PDF DOWNLOAD

635 SERVICE ISSUE 2.0………………………………………. 1
INTRODUCTION…………………………………………… 3
S.A.E. STANDARDS……………………………………….. 4
NON-APPROVED FIELD PRODUCT CHANGES……………………….. 5
SECTION 1 – SAFETY…………………………………………. 7
ARTICULATION LOCK ……………………………………… 16
battery disconnect switch ………………………………. 13
CAB SAFETY CABLE ………………………………………. 17
CAB SUPPORT BRACE ……………………………………… 17
cooling system ………………………………………… 15
exhaust fumes …………………………………………. 18
FIRE PREVENTION………………………………………… 7
FIRE PREVENTION GUIDELINES ………………………….. 19
WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE ………….. 20
WHAT TO DO AFTER A FIRE …………………………….. 21
WHAT TO DO IN CASE OF A MACHINE FIRE …………………. 20
first aid …………………………………………….. 10
Fluid leaks …………………………………………… 15
Hydraulic Pressure hazard ………………………………. 15
loose clothing hazard ………………………………….. 16
PARKING THE MACHINE ……………………………………. 13
protective clothing ……………………………………. 9
SAFETY PRECAUTIONS, GENERAL …………………………….. 10
SAFETY PRECAUTIONS, OPERATING …………………………… 12
SAFETY PRECAUTIONS, SERVICING …………………………… 15
SAFETY SYMBOLS ………………………………………… 8
Signal Words ………………………………………….. 8
SECTION 3 – LUBRICATION & MAINTENANCE………………………… 23
AIR CLEANER MAINTENANCE ………………………………… 38
AIR CONDITIONING SYSTEM, CHECKING ……………………….. 44
APPROVED HYDRAULIC OILS ………………………………… 29
CENTER JOINT…………………………………………… 49
LUBRICATION ……………………………………….. 49
MAINTENANCE ……………………………………….. 49
EMERGENCY EXITS, CHECK MONTHLY ………………………….. 25
FILTERS……………………………………………….. 32
AXLE RETURN FILTERS ………………………………… 37
CHARGE PRESSURE FILTER – DRIVE PUMP ………………….. 35
CHARGE PRESSURE FILTER – FAN DRIVE PUMP ………………. 35
ENGINE AIR INTAKE ………………………………….. 38
FUEL FILTER/WATER SEPARATOR …………………………. 32
FUEL TANK STRAINER …………………………………. 33
HYDRAULIC OIL DOUBLE FILTERS ………………………… 34
HYDRAULIC TANK BREATHER FILTER ………………………. 37
FIRE PREVENTION ……………………………………….. 25
GENERAL MAINTENANCE ……………………………………. 25
GRAPPLE SNUBBER MAINTENANCE …………………………….. 40
HOUR METER ~ MAINTENANCE ……………………………….. 24
LUBRICATION AND SERVICE POINTS ………………………….. 31
NEW MACHINE MAINTENANCE ………………………………… 24
FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT ……….. 24
INITIAL PRE-DELIVERY INSPECTION ……………………… 24
TIGHTENING POINTS ………………………………….. 24
OIL LOST FROM LEAKAGE ………………………………….. 24
PRESSURIZED WATER SYSTEM MAINTENANCE …………………….. 42
REAR (BOGIE) AXLE ……………………………………… 50
BOGIE HOUSINGS (2 FILLING POINTS) ……………………. 51
DIFFERENTIAL (1 FILLING POINT) ………………………. 50
DRAINING AND REFILLING BOGIE AXLE ……………………. 50
PLANETARY DRIVES (4 FILLING POINTS) ………………….. 51
REPLACING THE ENGINE SERPENTINE BELT …………………….. 54
SCHEDULED MAINTENANCE ………………………………….. 26
FREQUENTLY ………………………………………… 26
8 HOURS …………………………………………… 26
48 HOURS ………………………………………….. 27
125 HOURS …………………………………………. 27
250 HOURS …………………………………………. 27
500 HOURS …………………………………………. 27
1000 HOURS ………………………………………… 28
SERVICE AND LUBRICATION POINTS ………………………….. 31
SPEED CONTROL LEVER ADJUSTMENT ………………………….. 55
STARTUP PROCEDURE AFTER MAJOR MAINTENANCE ………………… 52
TILTING THE CAB ……………………………………….. 46
TORQUE CHART ………………………………………….. 56
TORQUE CHART, GENERAL ………………………………….. 57
WHEELS, INSTALLING …………………………………….. 24
WINCH LUBRICATION – LANTEC ONLY …………………………. 48
SECTION 5 – PILOT SYSTEM……………………………………. 59
CHARGE PRESSURE FILTER …………………………………. 61
CIRCUIT DESCRIPTION (6350111 TO 6350134) …………………. 62
CIRCUIT DESCRIPTION (6350135 TO 6350499) …………………. 64
CIRCUIT DIAGRAM (6350111 TO 6350134) …………………….. 63
CIRCUIT DIAGRAM (6350135 TO 6350499) …………………….. 65
PILOT MANIFOLD ………………………………………… 61
PRESSURE SETTINGS ……………………………………… 66
SECTION 6 – ELECTRICAL, GAUGES AND ALARMS…………………….. 67
FAN CONTROLLER RELAY ASSEMBLY……………………………. 67
LATER MACHINES ONLY WITH FAN CONTROL SWITCH (FDC) ……… 75
FUSE AND RELAY PANEL …………………………………… 74
GAUGES AND ALARMS ……………………………………… 76
SCHEMATIC DIAGRAM (6350101 to 6350134) …………………… 68
SCHEMATIC DIAGRAM (6350135 TO 6350499) …………………… 71
SENSOR DETAILS ………………………………………… 76
SWITCH AND SENSOR LOCATIONS……………………………… 67
EARLIER MACHINES WITH FAN CONTROL LEVER ………………. 77
LATER MACHINES WITH FAN CONTROL SWITCH (FDC) ………….. 78
troubleshooting and testing …………………………….. 76
wire colour code chart …………………………………. 74
SECTION 7 – ENGINE START AND STOP……………………………. 79
DRIVE PREVENT VALVE ……………………………………. 81
FUEL CONTROL VALVE …………………………………….. 81
MAIN PUMP UNLOADING VALVE ………………………………. 81
START CIRCUIT DESCRIPTION……………………………….. 79
EARLIER DESIGN (6350101 TO 6350134) ………………….. 80
LATER DESIGN – WITH LOW OIL PRESSURE SHUT-DOWN…………. 79
(6350135 TO 6350499) ……………………………. 84
START CIRCUIT DIAGRAM…………………………………… 79
SERIAL NUMBERS 6350101 TO 6350134 ……………………. 82
SERIAL NUMBERS 6350135 TO 6350499 ……………………. 86
START MOTOR AND SOLENOID ……………………………….. 81
START SOLENOID RELAY …………………………………… 84
TACHOMETER SET-UP ……………………………………… 88
SECTION 8 – DRIVE………………………………………….. 89
circuit description ……………………………………. 90
DRIVE SYSTEM…………………………………………… 89
CHECK VALVE ……………………………………….. 99
DRIVE CIRCUIT DIAGRAM……………………………….. 89
SAUER PUMP AND REXROTH MOTORS …………………….100
DRIVE FOOT CONTROL VALVE ……………………………. 96
DRIVE MOTOR DESCRIPTION …………………………….. 94
DRIVE PREVENT VALVE ………………………………… 97
DRIVE PUMP DESCRIPTION – SAUER PUMP ………………….. 91
DRIVE SPEED CONTROL VALVE …………………………… 98
hydraulic set-up – SAUER pump/ rexroth motors………….. 89
Drive Motor pressure Adjustment …………………..107
drive Pump Pressure Adjustment ……………………104
Motor Begin of displacement control Pressure ……….108
Motor Minimum displacement Adjustment ……………..107
Motor pressure override adjustment (P.O.R.) ………..111
FRONT AXLE …………………………………………….116
AXLE IDENTIFICATION …………………………………104
CAPACITY …………………………………………..118
DIFFERENTIAL AND DIFFERENTIAL LOCK ……………………116
DRAINING THE FRONT AXLE ……………………………..118
FILLING FRONT AXLE, ALTERNATIVE METHOD ……………….119
FILLING THE FRONT AXLE ………………………………118
OSCILLATION SHIM CHECK AND ADJUSTMENT (FRONT AXLE) ……..120
Service brakes (front axle only)……………………… 89
BRAKE BLEEDING ………………………………….118
BRAKE LINING INSPECTION ………………………….117
SERVICING BRAKES ………………………………..117
HYDRAULIC OIL HEATING PROCEDURE …………………………. 99
REAR (BOGIE) AXLE ………………………………………122
BOGIE HOUSINGS (2 FILLING POINTS) …………………….123
DIFFERENTIAL (1 FILLING POINT) ……………………….122
DIFFERENTIAL AND DIFFERENTIAL LOCK ……………………122
DRAINING AND REFILLING BOGIE AXLE …………………….122
PLANETARY DRIVES (4 FILLING POINTS) …………………..123
TEST DRIVE – SAUER pump and rexroth motors………………… 89
Begin of Displacement Control Pressure ………………..101
DIFFERENTIAL LOCKS ………………………………….102
GROUND SPEED ……………………………………….103
horsepower …………………………………………102
Motor Pressure Override (POR) ………………………..101
Steering Operation ………………………………….102
TRANSMISSION …………………………………………..115
TRANSMISSION IDENTIFICATION ……………………………..102
WHEEL INSTALLATION ……………………………………..124
TAPERED ASSEMBLY STUD ……………………………….124
SECTION 9 – BRAKES………………………………………….125
ACCUMULATOR…………………………………………….125
accumulator ………………………………………..126
CHARGING AND TESTING DEVICE ………………………….127
CHARGING THE ACCUMULATOR …………………………….127
CHECKING GAS PRESSURE ……………………………….126
BRAKES…………………………………………………125
ACCUMULATOR and SERVICE BRAKES ……………………….135
BRAKE PILOT VALVE …………………………………..126
Parking brake ………………………………………129
CHARGING VALVE, ACCUMULATOR ……………………………..127
CIRCUIT DIAGRAM…………………………………………125
(6350101 TO 6350134) ………………………………..130
(6350135 TO 6350499) ………………………………..131
DIFFERENTIAL LOCKS………………………………………125
ADJUSTING DIFFERENTIAL LOCK VALVES ……………………134
CIRCUIT DESCRIPTION …………………………………134
MAIN PUMP ……………………………………………..128
Multifunction Valve……………………………………..125
ADJUSTING HIGH PRESS RELIEF ………………………….132
DESCRIPTION ………………………………………..132
HIGH PRESSURE RELIEF ………………………………..132
Parking brake ………………………………………….129
SECTION 10-OIL COOLER/RADIATOR AND CROSS-FLOW FAN………………137
CROSS-FLOW FAN-FDC (6350136 TO 6350499) …………………..148
CIRCUIT DESCRIPTION …………………………………152
CIRCUIT DIAGRAM …………………………………….153
ELECTRONIC FAN DRIVE CONTROL (FDC)…………………….137
CHECK FOR TEMPERATURE SENSOR FAILURE ………………157
CHECK MINIMUM FAN SPEED WITH A/C “ON” AND NO A/C D ….157
CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY ENGINE ….158
CHECK VARIABLE FAN SPEED WHEN CONTROLLED BY HYDRAU ….159
FAN CONTROLLER RELAY ASSEMBLY ………………………..150
FAN DRIVE MOTOR …………………………………….151
FAN DRIVE PUMP ……………………………………..148
FAN DRIVE PUMP PRESSURE, CHECK ……………………….156
FAN PUMP forward and reverse MAX. DISPLACEMENT SET ……..154
FAN SPEED, MAX. FORWARD AND REVERSE …………………..154
FDC CONTROL ………………………………………..150
TROUBLE-SHOOTING GUIDE……………………………….137
FDC. OPERATION ………………………………….160
OVERHEATING PROBLEMS …………………………….160
CROSS-FLOW FAN-LEVER OPERATED (6350101 TO 6350135) …………142
CIRCUIT DESCRIPTION AND OPERATION …………………….144
CIRCUIT DIAGRAM …………………………………….145
FAN DRIVE MOTOR …………………………………….143
FAN DRIVE PUMP ……………………………………..142
FAN DRIVE PUMP PRESSURE VERIFICATION ………………….147
FAN SPEED VERIFICATION / ADJUSTMENT …………………..146
OIL COOLER …………………………………………….138
OIL COOLER AND RADIATOR INSTALLATION ……………………..139
OIL COOLER CIRCUIT DESCRIPTION …………………………..140
OIL COOLER CIRCUIT DIAGRAM ………………………………141
SECTION 11 – STEERING AND CENTER JOINT………………………..161
CENTER JOINT……………………………………………168
checking center joint visually for looseness …………..168
checking the center joint preload …………………….170
center joint preload adjustment …………………..171
DIAGRAM ……………………………………………170
grease seals – ORIENTATION …………………………..171
IDENTIFYING EARLIER AND LATER BEARINGS ………………..169
lubrication ………………………………………..168
maintenance ………………………………………..168
IDENTIFYING EARLIER AND LATER BEARINGS ……………………169
PRIORITY VALVE …………………………………………164
STEER CONTROL VALVE …………………………………….162
STEERING……………………………………………….161
CIRCUIT DIAGRAM …………………………………….167
testing the Steering Operation …………………………..166
SECTION 12 – GRAPPLE, ARCH AND BOOM…………………………..173
CIRCUIT DESCRIPTION……………………………………..173
ARCH ………………………………………………179
ARCH/BOOM ………………………………………….185
grapple open/close ………………………………….193
GRAPPLE ROTATE – TIGERCAT GRAPPLE……………………..173
WITH DANFOSS MOTOR ………………………………192
WITH WHITE HYDRAULICS MOTOR ………………………192
CIRCUIT DIAGRAMS………………………………………..173
ARCH/boom ………………………………………….184
GRAPPLE ……………………………………………191
SINGLE ARCH ………………………………………..178
GRAPPLE CONTROL VALVE……………………………………173
dual FUNCTION ARCH SECTION …………………………..182
grapple rotate and open/close SECTIONs ………………..189
SINGLE FUNCTION ARCH SECTION …………………………176
grapple snubber maintenance See SECTION 3………………….173
JOYSTICK CONTROL VALVE, arch and grapple ………………….175
PORT RELIEF VALVE DESCRIPTION (GRAPPLE VALVE) ……………..199
ADJUSTING PROCEDURE …………………………………198
PRESSURE SETTINGS……………………………………….173
DUAL ARCH/BOOM ……………………………………..185
GRAPPLE ROTATE – DANFOSS MOTOR ………………………195
GRAPPLE ROTATE – WHITE HYDRAULICS MOTOR ………………194
GRAPPLE OPEN/CLOSE ………………………………….196
SINGLE ARCH ………………………………………..179
RELIEF VALVES…………………………………………..173
ADJUSTING PROCEDURE …………………………………198
SNUBBER MAINTENANCE – GRAPPLE See SECTION 3………………..173
SECTION 13 – WINCH………………………………………….201
CONTROL LEVER valve …………………………………….203
GRAPPLE CONTROL VALVE……………………………………201
WINCH SECTION ………………………………………204
LANTEC WINCH……………………………………………201
CIRCUIT DESCRIPTION …………………………………206
CIRCUIT DIAGRAM (6350101 to 6350134) ………………….207
CIRCUIT DIAGRAM (6350135 TO 6350499) …………………209
Winch ……………………………………………..206
WINCH MOTOR ………………………………………..206
PRESSURE SETTINGS……………………………………….201
WINCH IN PORT RELIEF ADJUSTMENT ………………………210
WITHOUT WINCH IN PORT RELIEF, NON- ADJUSTABLE ………….210
SECTION 14 – DOZER BLADE…………………………………….213
CIRCUIT DESCRIPTION …………………………………….218
circuit diagram ………………………………………..219
CONTROL LEVER PILOT VALVE ……………………………….215
DOZER CONTROL VALVE …………………………………….216
OPERATING DESCRIPTION ……………………………….217
pressure settings ………………………………………220

IMAGES PREVIEW OF THE MANUAL:

TIGERCAT 635 SKIDDER SERVICE MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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