SERVICE MANUAL

Tigercat 635C SKIDDER

Issue 2.0, NOVEMBER 2008

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 ............................................................................................................................ 9
OIL COOLER/RADIATOR AND CROSS-FLOW FAN ........................................................ 10
STEERING AND CENTER JOINT ..................................................................................... 11
GRAPPLE , ARCH AND BOOM ....................................................................................... 12
WINCH ............................................................................................................................. 13
DOZER BLADE ................................................................................................................ 14
AXLES AND DIFFERENTIAL LOCKS ............................................................................... 15

EARLIER MACHINES (6350501 TO 6350530) LATER MACHINES (6350531 TO 6351000)

IMPORTANT IMPORTANT

12 VOLT 24 VOLT
ELECTRICAL SYSTEM ELECTRICAL SYSTEM
635C-SM00

635C Available Literature

Tigercat
®
Operator's Manual, English ............................... Part No. 25729A
Service Manual, English (This Manual) ............. Part No. 25730A
Parts Catalog, English ........................................ Part No. 25728A Tigercat Industries Inc.
P.O. Box 544
Paris, Ontario
Canada N3L 3T6
Tel: (519) 442-1000
Fax: (519) 442-1855
Tigercat 635C Skidder Introduction

ii
Tigercat
Tigercat 635C635C
SkidderSkidder Introduction

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 635C Skidder serial numbers
6350501 to 6351000.
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 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.

iii
Tigercat 635C Skidder Introduction
S.A.E. STANDARDS
ROLL-OVER PROTECTION STRUCTURES (ROPS)
FALLING OBJECTS PROTECTION STRUCTURES (FOPS)
OPERATOR PROTECTION STRUCTURES (OPS)
* MODIFICATIONS AND REPAIRS:

The integrity of the ROPS, FOPS, OPS structure and its continued ability to provide the level of protection
it was designed for could be seriously affected by any modifications to the structure, its mounting or to the
chassis to which it is attached.
Tigercat emphasizes that the certification of approval of the ROPS, FOPS, OPS structure will become
void if any such modifications take place.
Tigercat may officially grant approval for modifications only by:
i) Written approval of repairs or modifications signed by the Tigercat Engineering Manager; or
ii) Approved modifications officially released by Tigercat.
Both of the above are provided that the work is carried out in the factory approved manner.
Unauthorized modifications and/or repairs made or contributed to by a customer or a Tigercat distributor
may result in creating a dangerous situation and therefore the customer or Tigercat distributor will be
considered to have assumed the risk involved or be negligent in creating this situation.
Tigercat will not be held responsible for situations arising from having created unauthorized
modifications/changes to the structure.
Operator's cabs are designed to ROPS, FOPS, OPS standards so that they will withstand force and
absorb energy during a roll-over (ROPS), when resisting the impact of a falling object (FOPS) and
minimize the possibility of operator injury from penetrating objects (OPS). When a permanent deflection
of the structure occurs, the structure can no longer provide the original designed level of protection and
should be replaced. Attempts to straighten the structure, particularly by the application of heat, can
reduce still further the structures remaining capability to protect.
The mounting and the frame or chassis to which the cab is attached is considered an integral part of the
ROPS, FOPS, OPS and is included in the design, test and certification of the product.
Contact the Tigercat Service department before attempting any modifications or repair to roll-over
protective structures.
NOTICE OF
CERTIFICATION
Tigercat Industries Inc.
THIS STRUCTURE MEETS THESE
REQUIREMENTS OR
RECOMMENDED PRACTICES
MANUFACTURED BY
Tigercat Industries Inc.
Paris, Ont., Canada

ROPS SAE J1040 MAY94

FOPS SAE J231 JAN81

OPS SAE J1084 APR80

Tigercat Model 620/630

MAXIMUM
GROSS WEIGHT 47,000 lbs.

MANUFACTURERS
CERTIFICATION NO. 901099

6958A R03

iv
Tigercat 635C Skidder Introduction

NON-APPROVED FIELD PRODUCT CHANGES

The installation of any unauthorized attachment or changes made of any kind to this Tigercat product
could affect the product's ability to perform as originally intended. The product's integrity, stability and
safety could be at serious risk.
IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING
DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE
FACTORY APPROVED MANNER.
Official approval to make changes or install options is only as follows:
i) The relevant options for that product must be shown or listed on current Tigercat documentation
or literature such as a printed specification sheet, price list, parts manual, or product literature
issued by Tigercat.
ii) Approved options or product changes authorized in writing by the Tigercat Engineering Manager.
Authorization by any other person is unacceptable.
Unauthorized changes made or contributed to by a person or organization may result in creating a
dangerous situation and therefore the person or organization will be considered to have assumed the risk
involved or be negligent in creating this situation.
Weight is an important factor when considering the addition of options or an attachment, Refer to your
Tigercat distributor for information on maximum permissible operating weight and the effect the addition
of various options may have on your machine.
Tigercat will not be held responsible for any situation that may arise resulting from Non-approved Field
Product Changes to its product.
Should Tigercat become involved in a suit resulting from changes made to the product without proper
authorization by Tigercat as stated above, Tigercat will take whatever action is appropriate to protect its
interests.
The product warranty policy and the certification on any safety items installed on the modified product will
become NULL and VOID if the above policy is not adhered to as specified.
Non-approved product changes also nullify warranties given to Tigercat by its component manufacturers.

Tigercat Industries Inc.

v
Tigercat 635C Skidder Introduction

vi
Tigercat 635C Skidder

SECTION 1 - SAFETY
MARCH 2008
Read and understand this Safety section prior to operating any equipment.
Read and understand all manuals for any attachments or accessories.
CONTENTS - SECTION 1
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
ELECTRICAL SYSTEM VOLTAGE ............................................................................... 1.2
EMERGENCY CAB EXITS ............................................................................................ 1.7
EXHAUST FUMES ....................................................................................................... 1.14
FIRE PREVENTION ..................................................................................................... 1.17
DRY CHEMICAL CLEANUP PROCEDURES .......................................................... 1.21
FIRE PREVENTION GUIDELINES .......................................................................... 1.17
WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED ................................. 1.20
WHAT TO DO TO PREPARE FOR A MACHINE FIRE ............................................ 1.18
WHAT TO DO WHEN A MACHINE FIRE OCCURS ................................................ 1.19
FIRST AID ...................................................................................................................... 1.4
FLUID INJECTION INJURY ......................................................................................... 1.15
FLUID LEAKS .............................................................................................................. 1.11
GREASE INJECTION INJURY .................................................................................... 1.16
HYDRAULIC PRESSURE HAZARD ............................................................................ 1.11
LOOSE CLOTHING HAZARD ..................................................................................... 1.12
PARKING THE MACHINE ............................................................................................. 1.8
PROTECTIVE CLOTHING ............................................................................................. 1.3
SAFETY PRECAUTIONS, GENERAL ........................................................... 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
VOLTAGE, ELECTRICAL SYSTEM .............................................................................. 1.2
WELDING, PRIOR TO ................................................................................................. 1.10
WORKING WITH OIL .................................................................................................... 1.4
Tigercat 635C Skidder Safety

SAFETY SYMBOLS GENERAL

SAFETY PRECAUTIONS
Please note the voltage of electrical system in use
on the machine you are operating or servicing.
EARLIER MACHINES (6350501 TO 6350530)

IMPORTANT
This safety alert symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
The safety alert symbol identifies important safety
12 VOLT
messages on machines, safety signs, in manuals,
or elsewhere. When you see this symbol, be alert
ELECTRICAL SYSTEM
to the possibility of personal injury or death.
Follow the instructions in the safety message. LATER MACHINES (6350531 AND UP)

Understanding Signal Words

IMPORTANT

DANGER
24 VOLT
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
ELECTRICAL SYSTEM
or serious injury.
Remember that safety is a prime responsibility of
all.
WARNING
To minimize the risks and promote safety at all
times, this section of the operator’s manual
WARNING indicates a potentially hazardous details a number of safety rules which should
situation which, if not avoided, could result in always be followed and obeyed.
death or serious injury. Always read the operator’s manual before
operating the machine. Pay close attention to
CAUTION WARNINGS and HAZARD identifications.

CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury.

Study all the safety messages in this manual and

on the labels on the machine carefully.
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.

1.2
Tigercat 635C Skidder Safety
Do not jump off the machine at any time.
GENERAL Do not try to climb onto or off of a moving
SAFETY PRECAUTIONS machine.
Do not let an untrained person operate the Do not use the joystick as a handle when entering
machine. 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 1 foot.

WARNING

Use recommended protective clothing and safety

devices such as gloves, safety boots, safety hat,
goggles, and ear protection when necessary. Avoid mounting or dismounting the machine
These safety rules highlight both general and in areas with slippery surfaces. Dry, deice,
specific measures that the operator should be clean up or cover slippery surfaces with an
familiar with and adhere to. More specific anti-slip material before mounting or
measures are illustrated with pictograms which dismounting the machine.
may also be attached to the machine in locations
pertinent to their respective message. Keep
safety labels in good condition. Repair or replace WARNING
damaged labels.
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.

WARNING

It is not recommended to walk on machine

surfaces that are not designated walking
Wear suitable hearing protective device such as areas.
earmuffs or earplugs to protect against noise. No attempt should be made to walk on angled
Prolonged exposure to loud noise can cause steel surfaces or surfaces that are irregular
permanent hearing loss. in shape.
Walking surfaces on the machine must be
covered with anti-slip materials to provide a
safe foot hold and prevent slipping.
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.

Always use the handrails and steps provided

when mounting and dismounting from the
machine.
1.3
Tigercat 635C Skidder Safety
Check all fluid levels.
GENERAL SAFETY PRECAUTIONS
Do not operate the machine with any of the
continued
exhaust system, safety covers, or other devices
To reduce risk of fire, machines should be removed.
completely cleaned of debris at least daily, Do not operate the machine with the cab retaining
particularly around the engine exhaust pins removed. Always install retaining pins and
components. Hydraulic oil leaks, excess grease, fasten front guards to cab roof after lowering the
fuel and oil accumulation (including spillage) cab.
should be eliminated immediately, always shut off
engine before cleaning machine..
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
Keep a first aid kit in an easily accessible location
unusual wear, to ROPS, FOPS, OPS structures.
on the vehicle at all times.
The machine should be inspected daily for signs
Working with oil
of fluid leaks, damage, unusual wear, or faulty
operation. Repair or replace malfunctioning parts Direct contact with oil implies a risk of skin
and systems immediately. complaints (example: eczema). Strict hygiene
should always be observed.
Check window and door guards for damage.
Some advice which should be observed:
Check protective windows for cracks, a damaged
window has reduced strength to stop flying • Oils used in this machine may be hot enough
objects. All damaged windows must be replaced to cause serious burns.
with original equipment. • Avoid contact with oil, particularly heated oil.
Check windows for scratching, crazing and • Oil on the skin should be washed off
cloudiness that could impair clear visibility all immediately with soap and water.
around the machine. • Wear protective gloves. Hands should be
clean before putting on gloves. Apply
Do not operate the machine with any defective or
protective cream to the hands to make
inoperable components.
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 635C Skidder Safety
If State/Provincial, local or job site regulations
GENERAL SAFETY PRECAUTIONS require even greater safety distances than stated
continued above, adhere strictly to these regulations for your
The following procedures are recommended when own protection.
inspecting equipment that has been subjected to If the machine must be transported, make sure
high temperatures such as fire: that it is adequately secured to the transporting
• Visually inspect any seals or gaskets which vehicle. Refer to vehicle moving instructions in
have suffered from heat; they will appear black SECTION 2 of the OPERATOR'S MANUAL.
and sticky. Stopping the engine immediately after it has been
• If these are found, Do Not Touch!!! working under load can result in overheating and
premature wear of the engine components. Reduce
• Determine the material composition of any
engine speed to LOW IDLE and let run for
seals or gaskets, If fluro-elastomer seals
approximately 5 minutes to allow gradual
(Viton, fluorel, or tecmoflon) have been used,
dissipation of heat and also to reduce turbo
the affected area must be decontaminated
speed. This will also prevent loss of coolant by
before undertaking further work. Natural rubber
after boil and possible hot spot damage to the
and nitrile materials are not hazardous.
engine.
• Disposable heavy duty gloves (neoprene) must Even though the brakes are fully engaged, block
be worn and the affected area decontaminated the wheels to prevent movement during transport.
by washing thoroughly with limewater (Calcium
Hydroxide solution). Install articulation lock whenever the machine is
to be transported.
• Any cloths, residue and gloves must be safely
discarded after use.
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 Be aware when performing service and
Maintain a charged fire extinguisher on the vehicle maintenance tasks that surfaces and grab
at all times and KNOW HOW TO USE IT. handles in and around the engine and cooling
system may become very hot when the engine
Do not carry passengers either in the cab or has been running. Contact with hot surfaces may
anywhere else on the machine. The vehicle seating cause injury.
accommodation is for one operator only.
Comply with instructions in this manual and also
Do not allow anyone to operate the machine who your company’s regulations for the operation of
may not be physically fit or who may be under the this machine.
influence of alcohol or drugs.
Read, understand and follow all general safety
When operating the machine, ensure there is precautions specified by grapple head
adequate clearance on both sides and above the manufacturer.
machine or any of its attachments. Additional
clearance may be necessary where the ground is Access to a cell phone or radio to call for
uneven. assistance in an emergency is advised. Be aware
that signal strength for cell phones and radios
Extreme caution should be exercised when changes with terrain and location.
approaching any area where overhanging electrical
powerlines are present. Serious injury or death by
electrocution can result if the machine or any of its WARNING
attachments are not kept a safe distance from Engine exhaust, some of its constituents, and
these lines. certain vehicle components contain or emit
Maintain a distance of 10 ft (3m) between the chemicals known to the State of California to
machine or boom and any power line carrying up to cause cancer and birth defects or other
50,000 volts or less plus 1/2 inch (10mm) for each reproductive harm.
additional 1,000 volts above the 50,000 volt level.
1.5
Tigercat 635C Skidder 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
WARNING work area. Use horn to warn bystanders before
Battery posts, terminals and related accessories moving the machine.
contain lead and lead compounds, chemicals When using a signal person, keep the person in
known to the State of California to cause cancer view at all times. Always be sure the signal
and birth defects or other reproductive harm. person is clear before backing up.
Wash hands after handling.
To avoid backover accidents:
If acid is accidentally splashed into your eyes,
• Always look around before you back up. Be
flush immediately with clean water and get
sure that everyone is clear.
medical attention.
• Keep reverse warning alarm in working
Do not attempt to charge a frozen battery; it can condition. The reverse warning alarm must
explode. sound when the machine is moving in
Disconnect battery before working on electrical reverse.
systems. Remove ground terminal first when • Use a signal person when backing up if view
disconnecting. Connect ground terminal last is obstructed. Always keep the signal person
when reconnecting. in view.
Do not short out battery terminals for any reason. • Learn the meaning of all flags, signs and
Serious burns or an explosion can result. markings on the job site and who is
responsible for signalling.
• Keep windows, mirrors and lights in good
condition.
CAUTION
• Dust, heavy rain, fog, snow etc. can reduce
Lead-acid batteries contain sulfuric acid visibility. As visibility decreases, reduce
which can severely damage eyes or skin on speed and use proper lighting.
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
Tigercat 635C Skidder Safety
Before moving the machine to the worksite, check
OPERATING to ensure that all doors, panels, and access
covers are installed properly and secured.
SAFETY PRECAUTIONS
CAB EXITS
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.

Shut off engine when refuelling - DO NOT refuel 3. Sliding windows in the cab doors, this is a
the engine while smoking or near open flame or third cab exit for use if the cab doors become
sparks. blocked.

Check that no other personnel have moved into a It is important that the operator of the machine
hazardous area before starting the machine. be familiar with these emergency exits and how to
use them.
Sound the machine horn before starting the
machine. All three exits should be checked to make sure
that they are operational and will function in an
emergency.

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
The operator's seat is equipped with a lap belt. using the exterior handle and once using the
Use this restraint system at all times when interior latch handle.
operating the machine.
For additional information, refer to EMERGENCY
EXITS in SECTION 3 of the OPERATOR'S
MANUAL.
Skidder operations should only be performed
from the operator’s seat.
Secure loose items in the 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 Make sure that all safety screens and guards are
SECTION 2 of the OPERATOR’S MANUAL. installed and properly secured.
Never use a liquid staring aid to start an
engine.

WARNING

1.7
Tigercat 635C Skidder Safety
When parking the machine:
OPERATING SAFETY PRECAUTIONS
continued • Park on level ground ONLY and engage
parking brake
Do not open an escape hatch or the cab doors to
increase ventilation when operating the machine. • Do not park on a hillside or incline.
• Before leaving the operator's cab, engage the
parking brake and lower the grapple and
dozer blade onto the ground.
• Stop the engine and release pilot system
pressure by performing the following steps:
1. Fully apply brake foot pedal 50 times or
more.
2. Pressure may remain in the system
Keep the cab doors closed when driving or after completing all of the above steps.
steering the machine to prevent accidental entry Use caution when loosening hydraulic
of branches and debris into the cab. connections.
Keep the cab doors closed and use seat belt
when driving or steering the machine to prevent
being thrown from the operator's cab.
Never operate the winch from the ground. Control
it only from the operator’s seat.

• Turn the master disconnect switch off if the

vehicle is to be parked for an extended period
of time (Example - overnight).

Never use the parking brake to slow down or stop

the machine except in an emergency.
Keep the brakes properly adjusted at all times.
Always rest the grapple and dozer blade on the
ground when operation is stopped, regardless if
the engine is running or shut off.
Never work alone. Regularly inform other crew When the engine is running, DO NOT allow
members of your intentions, location and length of anyone in areas of the machine where they may
time to perform duties. be crushed by moving components.
Park machine at least 50 feet (15 meters) away Maintain a safe operating distance between the
from other equipment and in a cleared area. In the machine and workers and all other personnel. It
event of a fire, this distance will minimize the is the duty of the operator to ensure that no
chance of the fire spreading to other equipment. person approach the machine while in use, the
Before leaving the operator's cab, engage the risk zone is 60 m (200 ft).
parking brake and lower the grapple and dozer
blade onto the ground.
If out of the operator’s cab for an extended period
shut the machine off.

1.8
Tigercat 635C Skidder Safety

OPERATING SAFETY PRECAUTIONS

CAUTION
continued
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.
Before moving the machine, lift the grapple and
dozer blade off the ground and keep them high
enough to clear obstacles such as stumps.
Check for correct tire air pressure. If the pressure
is too low it will result in swaying. If the pressure
Never operate the boom or grapple over the is too high it will result in bouncing.
heads of bystanders.
If the machine is to travel on public roads, use
When reeling in winch cable, make sure all accessory lights (when installed) and other
personnel are far enough away in case of rolling caution devices to alert operators of other
logs or whipping cables. vehicles of your presence. Ensure your machine
Use only prearranged and approved signalling meets all regulatory requirements.
practices. When transporting the machine, ensure that
Obey flagger’s signal and signs enough clearance is available on both sides and
above the machine or any of its attachments to
Operate the machine only from a seated position
avoid contact with power or telephone lines,
in the operator’s seat.
bridge structures, etc.
Do not carry passengers either in the cab or
Before transporting the machine check to ensure
anywhere else on the machine.
that all doors, panels and access covers are
If vision is limited by dust, smoke, fog or snow, installed properly and secured.
stop the machine until visibility is restored.
Read, understand and follow all general safety
Do not work below or behind a skidder parked on precautions specified by grapple head
a grade. manufacturer.
When working on slopes, travel straight up or
down the slope to prevent roll-over.
NEVER travel across a STEEP slope or side hill:
• If you travel across a MODERATE slope,
NEVER make an uphill turn as this could
cause a tip-over situation.
• Keep load low and close to skidder for best
stability.
• A load of logs will change the handling and
stability of the skidder.
• Always be prepared to dump the load in case
of emergency.
• Never approach an unstable log from the
downhill side.
• Do not winch in a load at a sharp angle. This
could cause your machine to tip over.
• Do not overload your skidder as this can
create an unstable condition and cause a
roll-over.

1.9
Tigercat 635C Skidder Safety
be made available at the welding location.
SERVICING Care must be taken in attaching the welding
SAFETY PRECAUTIONS machine grounding clamp so current does not
pass through bearings, especially the centre joint
bearing.
Also, turn off the master disconnect switch and
disconnect the positive (+) battery cable from both
batteries.
This machine is equipped with sensitive electronic
control equipment, prior to welding:-
EARLIER MACHINES (6350501 TO 6350530)

Conduct maintenance inspections at least as IMPORTANT

frequently as recommended in section 3 of the
OPERATOR'S MANUAL.
When servicing or repairing equipment, shut the
engine down, and disconnect the positive (+)
12 VOLT
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

ENGINE CPU DISCONNECT

635C-01 -LEFT SIDE OF ENGINE

Before performing maintenance or repair work on

any equipment, consult the manufacturer’s
instruction manual and follow recommended
procedures.
The radiator and the engine cooling system DISCONNECT
ENGINE GROUND
should be cleaned and serviced daily to maintain
moderate engine temperatures.
This machine is equipped with a reversible
cooling fan to facilitate cleaning of the radiator/oil ENGINE GROUND
DISCONNECT -
cooler/charge air cooler assembly and engine
compartment doors. Exercise care when working 630C-135
•• RIGHT SIDE OF
ENGINE
in this area with the engine running. If the FAN
Disconnect the engine CPU (Central Processing
CONTROL SWITCH is in the AUTOMATIC
Unit) by unplugging the two multipin connectors
position, the fan could turn ON and/or go into
from the left side of the engine. (Applicable on
CLEAN mode at any time when the engine is
QSC and QSL9 engines only).
running.
Also disconnect the engine ground connection at
Prior to welding on any part of the machine, it
the chassis.
should be cleaned and a fire extinguisher should

1.10
Tigercat 635C Skidder Safety

SERVICING SAFETY PRECAUTIONS WARNING

continued
Diesel fuel or hydraulic fluid under pressure
LATER MACHINES (6350531 AND UP) can penetrate the skin and cause serious
personal injury, blindness, or death. If any
fluid is injected into the skin, it must be
IMPORTANT
surgically removed within a few hours by a
doctor familiar with treating this type of injury.

24 VOLT
ELECTRICAL SYSTEM

•• •• 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.
DISCONNECT 4 PIN DISCONNECT THE TWO
ENGINE POWER MULTI-PIN PLUGS FROM
CONNECTOR THE ENGINE CPU

ENGINE CPU DISCONNECT

630C-242 -LEFT SIDE OF ENGINE

Pressure can be maintained in a hydraulic system

long after the power source and pump have been
shut down. Lower grapple and dozer blade to the
ground and relieve trapped pressure from brake
DISCONNECT
ENGINE GROUND accumulator before performing work on
components, or disconnecting any hoses. For the
procedure on how to RELIEVE PRESSURE, refer
to PARKING THE MACHINE in THIS SECTION.

ENGINE GROUND
• DISCONNECT -
RIGHT SIDE OF
630C-243 ENGINE

Disconnect the engine CPU (Central Processing

Unit) by unplugging the four pin engine power
connector and the two multipin connectors from Explosive release of fluids from pressurized
the left side of the engine. cooling system can cause serious burns.
Also disconnect the engine ground connection at Shut off engine. Only remove coolant filler cap
the chassis. when cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve pressure
before removing completely.

1.11
Tigercat 635C Skidder Safety
Do not change any pressure or relief setting
SERVICING SAFETY PRECAUTIONS unless Tigercat authorized instruction has been
continued obtained.
Use the proper tool for the job. Repair or replace
WARNING worn or damaged tools including lifting
equipment immediately.

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.
Keep your hands, feet, head, and loose clothing
• Use a thermometer to check surface and away from power driven parts. Tie long hair
system temperatures to ensure it is safe to behind your head. Remove rings and other
begin service work. jewellery to prevent electrical shorts and
entanglement in moving parts.
• DO NOT begin service work until the
surface or system temperature has cooled
down to below 100°F (38°C)!

SAFETY7

Always be aware of machine pinch points that

could cause injury. Never place body parts within
the range of motion of the working parts of the
machine.
Always wear your safety gloves when handling
cables, chains or logs.

1.12
Tigercat 635C Skidder Safety

SERVICING SAFETY PRECAUTIONS

continued
QUICK
ACCESS
DOOR

••
SAFETY
CABLE

•• HYDRAULIC
••
HOOD TILT
CYLINDER

ARTICULATION 635C-12 TILT OUT HOOD - OPEN

LOCK
Before working in engine area, machine must be
parked on level ground. The tilt out hood should
ALWAYS be opened FULLY. The hydraulic
• cylinder is used to open and close the hood and
CAB AT FULL TILT SUPPORTED must not be used as a support. Refer to
630C-126 BY SAFETY CABLE TILTING THE HOOD in SECTION 3 of THIS
MANUAL for complete instructions.

SUPPORT
BRACE
••
ARTICULATION
LOCK

ARTICULATION LOCK
TILTED CAB 630C-51 IN LOCKED POSITION
SUPPORTED BY
630C-124 •• SUPPORT BRACE
Before working in the centre joint area, install the
Before working under cab, machine must be frame articulation lock between the frames to
parked on level ground. Cab must be fully tilted prevent accidental articulation and injury. Always
with safety cable completely tight or cab support replace the lock bar in its storage position after
brace must be installed between frame and cab to use.
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. DO NOT work below or behind a machine
that is parked on a grade.
Never stand under an object supported with
hydraulics. Always use safety stands or a locking
device. WARNING
Failure to follow all of the above instructions
CAUTION could result in serious injury or death from
Do not open cab doors or window screens crushing.
when machine cab is tilted . The doors and
screens are heavy and will swing out with
considerable force.
1.13
Tigercat 635C Skidder Safety

SERVICING SAFETY PRECAUTIONS CAUTION

continued
The engine compartment access panels are
bolted in place, with the exception of the
quick access panel(s). Whenever bolts are
removed panels can fall during the process
of removing them from the machine. Once
the UPPER DOOR is removed (and the bolts
on the lower panel removed) the LOWER
PANEL is not fully supported and it is not
safe to apply any weight or pressure to the
20231A R1
panel, as it may fall out of the remaining
supports. Do not use LOWER PANELS with
All handles should be hand tight only at all bolts removed as hand grips, when
times. This is particularly important for easy servicing the machine.
access to the pressurized water system in the
event of a fire or other emergency. Refer also to
FIRE PREVENTION in THIS SECTION.
QUICK ACCESS TWO BOLTS
INSTALLED
LIFT OUT PANEL ON QUICK
WITH T-HANDLE
•• ACCESS
PANEL FOR

• • TRANSPORT
ONLY

BOLT ON • ••
ACCESS
PANELS
•
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.
630C-09 ACCESS PANELS RIGHT SIDE
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.

BOLT ON
• ••
ACCESS
PANELS

630C-10
ACCESS PANELS LEFT SIDE

Dispose of fluids properly.

Do not pour fluids into the ground, stream, pond.
Before draining any fluids, know the proper way to
dispose of them.

1.14
Tigercat 635C Skidder Safety

SERVICING SAFETY PRECAUTIONS WARNING

continued
Diesel fuel or hydraulic fluid under pressure
FLUID INJECTION INJURY
can penetrate the skin and could result in
Hydraulic and diesel fuel systems on forestry death or serious injury. If any fluid is injected
machines operate at very high pressures, often under the skin, a medical doctor familiar with
207 bar (3000 psi) and above. If a loose the treatment of this type of injury must
connection or a defect in a hose should occur, a surgically remove it within a few hours.
fine, high velocity stream of fluid will result. Even
In the event of any suspected fluid injection
for systems pressurized to as little as 7 bar (100
injury
psi), this fluid stream can penetrate human skin
as if it were a hypodermic needle. • 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.
Initially, an accidental fluid injection beneath the Always wear thick protective gloves.
skin may only produce a slight stinging sensation. • Be sure to wear safety goggles for eye
There is a danger that you will tend to ignore this, protection.
thinking that it will get better with time. Most often,
• Keep all body parts well away from the area
it does not! Within a very short time the wound
being investigated for leaks.
may begin to throb painfully, indicating that tissue
damage has already begun. • Use the end of a long piece of wood to move
hoses or other obstacles.
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 • Place the end of a long piece of wood in the
of this type of injury must surgically remove it suspected path of any fluid stream. Never use
within a few hours. any part of your body.
Time becomes critical as tissue damage • Recognize that the source of the leak and the
progresses rapidly. The longer you delay getting fluid streaming from it may be very small and
professional medical attention, the more damage not easily visible. You may only be able to see
can occur. the fluid that accumulates as a result of the
fluid stream.
Although fluid injection accidents are rare, the
resulting injury has on occasion required the When performing any service work
amputation of a finger, a hand or in some cases • Stop the engine and relieve all diesel fuel or
the entire limb. The longer the delay in getting hydraulic pressure before disconnecting any
professional medical aid, the further up the limb lines or otherwise working on the system.
the tissue damage can spread. An injury of this • Never grab any hydraulic or diesel fuel
type can become very serious or even fatal if not connectors or hoses when they are subjected
dealt with promptly and properly. 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.

1.15
Tigercat 635C Skidder 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 635C Skidder Safety
4. Clean out all accumulated forest debris
(twigs, pine needles, branches, bark, leaves,
FIRE PREVENTION 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.
5. Inspect the machine regularly for any signs
of diesel fuel or hydraulic system leakage.
When working in a forest environment, it is Check for worn or eroded fuel or hydraulic
impossible to prevent combustible debris from lines before starting up any equipment.
collecting in tight corners of the machine. This 6. Clean up any grease, diesel fuel, hydraulic
debris, in itself, may cause a fire; however, when and lubricating oil accumulation and
mixed with fuel, oil or grease in a hot or confined spillage immediately.
place, the danger of fire is greatly increased.
7. Steam clean the engine, transmission,
The following fire prevention guidelines should be
brake, fuel and hydraulic tank compartments
used to supplement the operator’s fire prevention
of all equipment at least once a month or
efforts. In no case should the guidelines be used,
more frequently when working in logging
or assumed, as replacements for diligent operator
conditions where large amounts of
efforts at preventing fires.
combustible forest debris are present.
The following guidelines will help to keep your
equipment up and running efficiently and keep the 8. Use only nonflammable solutions for
risk of fire to a minimum. cleaning the machine and components.
1. Maintain a CHARGED fire extinguisher on 9. Inspect the exhaust system daily for any
the machine at all times and KNOW HOW TO signs of leakage. Check for worn, cracked,
USE IT. broken or damaged pipes or muffler. Also
check for missing or damaged bolts or
2. Remove debris and blow out dust regularly
clamps. Should any exhaust leaks or
from the air intake doors, engine radiator and
defective parts be found, repairs must be
charge air cooler, hydraulic oil cooler, diesel
made immediately. Engine exhaust leaks can
fuel cooler and air conditioning condenser core
cause fires. Do not operate the machine until
to prevent overheating of the engine and
the exhaust leak is repaired.
hydraulics and to maintain efficient operation of
the machine. Refer to CLEANING A/C 10. During daily operation of the machine, the
CONDENSER, OIL COOLER AND RADIATOR occurrence of exhaust leaks are usually
in SECTION 2 of the OPERATOR’S MANUAL. accompanied by a change or increase in
engine exhaust noise levels. These audible
3. Blow off all forest debris and fine organic
warnings cannot be ignored. Should any
material accumulated near hot engine
exhaust leaks occur during operation, the
exhaust components (turbocharger and
machine must be shut down immediately
exhaust manifold as well as exhaust pipes and
and not put back to work until the necessary
muffler) at the completion of each work shift or
repairs have been completed.
more frequently when working in logging
conditions where large amounts of combustible 11. Park the machine at least 50 feet away
forest debris are present. Visual inspection from other equipment at the end of each shift.
after blow off to ensure thorough cleanliness is
12. Never leave the machine parked with
vital. Engine exhaust systems provide
boom, arch or blade suspended off the
numerous small pockets where saw dust, small
ground. Should their supporting hydraulic
wood chips and other flammable forest debris
hoses burn through during a fire, pressurized
can gather. Even small accumulations close to
hydraulic oil may be injected into the fire and
hot exhaust components can ignite and
the boom, arch or blade will fall rapidly to the
smolder. If dislodged this smoldering debris
ground.
can fall into other areas of the machine and
thereby spread a fire.

1.17
Tigercat 635C Skidder Safety
17. AFTER transporting (trucking) a machine
FIRE PREVENTION from one job site to the next, open all doors
continued and access panels and blow off any debris
that may have repositioned itself onto the
13. Turn the battery disconnect switch to OFF engine and exhaust parts due to wind
at shut down to de-energize all electrical turbulence caused by the journey.
circuits.
18. Before starting repair work, such as
14. Remain with the machine for at least 45 welding, the surrounding area should be
minutes at the end of operations while the cleaned and a fire extinguisher should be
machine cools. close by.
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

• 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.
15. Remove all keys, lock equipment and fuel
Dry chemical extinguishers should be rated
cap at the end of operations to reduce the risk
ABC and pressurized water extinguishers
of vandalism.
should be rated A.
16. Be cautious when smoking. An open Class A fires involve ordinary combustibles
flame, a lighted cigarette, etc., should not be such as wood, cloth, paper, rubber and many
permitted around any vehicle, especially plastics, Class B fires occur with flammable
during fuelling operations or when the fuel liquids such as diesel fuel, oil and grease and
system is open to the atmosphere or when Class C fires apply to energized electrical
servicing batteries. equipment.

1.18
Tigercat 635C Skidder Safety
• Ensure that all information necessary for you to
FIRE PREVENTION immediately contact all sources of help (local
continued fire department, etc) in the event of a fire
emergency is recorded and readily available at
• Ensure that the nozzle of any hand held all times.
extinguisher and pressurized water system
WHAT TO DO WHEN A MACHINE FIRE OCCURS
available on the machine and at the work site
fits within the access holes in the doors of the • If operating the machine when a fire occurs:
machine.
1. Lower all working attachments to the
• Ensure that your fire detection system* is in ground.
working order. Refer to FIRE DETECTION
2. Shut the engine off.
SYSTEM in SECTION 2 of the OPERATOR’S
MANUAL. 3. Activate the fire suppression system**.
• Ensure that your fire suppression system** is 4. Radio or call for help. Be certain to report a
charged and in working order. Refer to FIRE fire immediately.
SUPPRESSION SYSTEM in SECTION 2 of
5. Exit the machine taking fire extinguisher
the OPERATOR’S MANUAL.
and pressurized water system hose (if
• Ensure that you are familiar with the applicable) with you.
recommended procedures for fire contained
6. At all times ensure your own personal
in the emergency action plan of your
safety and the safety of anyone that may be
company.
in the area. Approach any fire with extreme
• Ensure that you follow all national, state / caution. All fires can be very dangerous and
provincial and local regulations dealing with life threatening.
fire fighting in effect in your specific
7. Only if you can safely do so, turn OFF the
geographic region. Regulations will vary from
battery disconnect switch.
region to region but most will usually require
that: • Before deciding to fight the fire, be certain that:
1. Workers assigned to fire fighting duties 1. The fire is small and not rapidly spreading.
must be physically capable of performing 2. There is always a clear, safe escape route
them safely and effectively. to your back.
2. Workers designated to use fire fighting 3. You have received training in the use of the
equipment as part of an emergency action available fire extinguishing systems and are
plan must receive full and proper training confident that you can operate them
from a qualified instructor. effectively.
3. Whenever portable fire extinguishers are • Be aware that engine coolant , diesel fuel or
provided for use in the workplace, training hydraulic hoses could fail during a fire. If this
must be provided to familiarize workers happens, hot coolant, fuel or oil could possibly
with the general principles of fire be ignited by the fire.
extinguisher use and the hazards involved
with fire fighting. • If in any doubt about whether or not to fight the
fire – DON’T. Instead stand well clear of the fire
4. Training must be provided upon initial and wait for help to arrive.
employment and at least annually
thereafter. • If possible a dry chemical fire extinguisher or

• Ensure that after you have received the fire suppression system** should be used first
training as outlined above, that you know how to fight a machine fire. Then immediately
to use the fire extinguisher, the pressurized afterwards use the pressurized water hose
water system (if applicable) and the fire supplied with the machine (if applicable) or a
pressurized water extinguisher (if available). A
suppression system** on your machine.
fire suppressed by dry chemical may re-ignite
There is not enough time available to read from the heat retained by any debris in the
instructions during a fire emergency. area. The water will cool the area, reducing the
chances of re-ignition.

1.19
Tigercat 635C Skidder Safety
WHAT TO DO AFTER A MACHINE FIRE HAS
FIRE PREVENTION OCCURRED
continued
• Before returning the machine to work.
• Use the PASS method. This is the most 1. Ensure that the cause of the fire is
effective use of a fire extinguisher. determined and all appropriate repairs are
completed.
• Pull the pin at the top of the extinguisher
that keeps the handle from being pressed. 2. Ensure that the fire detection system* or
Break the plastic seal as the pin is pulled.
the fire suppression system** is properly
• Aim the nozzle at the base of the fire. Do serviced and in working order (if
not aim the nozzle at the flames. In order applicable).
to put out the fire, you must extinguish the
fuel, not the flames. Hose nozzles are 3. Ensure that all extinguishers used in
often clipped to the extinguisher body. fighting the fire are replaced or recharged.
Release the hose before taking aim. • Notify your equipment dealer and / or
• Squeeze the handle to release the Tigercat Industries Inc. by completing an
pressurized extinguishing agent. The incident report, Tigercat form number 5101.
handle can be released at any time to stop
the discharge.
*NOTE: Fire detection systems are offered by
Tigercat as an optional installation on some
• Sweep from side to side at the base of the Tigercat product lines. Please disregard any
fire until the fire is completely out or the references made to fire detection systems if not
fire extinguisher is empty 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.

TYPICAL FIRE EXTINGUISHER

20229A 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.

1.20
Tigercat 635C Skidder Safety
DRY CHEMICAL CLEANUP PROCEDURES 3. In areas exposed to heat during the fire, the
dry chemical powder will melt forming a coating
Both ABC dry chemical fire extinguishers and fire
that cakes or crusts on all surfaces.
suppression systems discharge a chemical
powder to extinguish the fire. The chemical To break down the caked dry chemical, spray
makeup and the small particle size of the powder or wash these areas with a 50/50 mixture of
as well as the force of the discharge all contribute hot water and isopropyl alcohol. Allow this
to the fire fighting capability. These same mixture to stand in place for several minutes.
characteristics also permit the powder to
The caked dry chemical when exposed to
penetrate into and fully cover all components in
moisture is also mildly acidic. Therefore when
the vicinity of the discharge.
the break down procedure has been
The following are recommendations for the completed, follow this immediately with the
cleanup and neutralizing of areas exposed to dry neutralizing procedure as described in step 2.
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.

1.21
Tigercat 635C Skidder Safety

1.22
Tigercat 635C Skidder
SECTION 3 - LUBRICATION & MAINTENANCE
MARCH 2008

CONTENTS - SECTION 3
AIR CLEANER MAINTENANCE .................................................................. 3.30
AIR CONDITIONING SYSTEM, CHECKING ............................................... 3.40
APPROVED HYDRAULIC OILS
AXLE CIRCUIT ......................................................................................... 3.15
MAIN HYDRAULIC SYSTEM .................................................................... 3.14
ARTICULATION LOCK ................................................................................ 3.46
CAB SAFETY CABLE .................................................................................. 3.44
CAB SUPPORT BRACE .............................................................................. 3.44
CENTER JOINT
LUBRICATION .......................................................................................... 3.47
MAINTENANCE ........................................................................................ 3.47
EMERGENCY EXITS, CHECK MONTHLY .................................................... 3.8
FILTERS
AXLE PRESSURE FILTER ....................................................................... 3.29
CHARGE PRESSURE FILTER ................................................................. 3.29
FUEL FILTER/WATER SEPARATOR ............................................ 3.24, 3.26
HYDRAULIC OIL TRIPLE ELEMENT FILTERS ........................................ 3.28
SECONDARY FUEL FILTER/WATER SEPARATOR ............................... 3.25
SERVICING GUIDELINES FOR OIL FILTERS ......................................... 3.29
FIRE PREVENTION ....................................................................................... 3.9
FRONT AXLE OIL LEVEL CHECK AND AXLE CIRCUIT FILL ................... 3.54
GENERAL MAINTENANCE ................................................................... 3.8, 3.9
GRAPPLE SNUBBER MAINTENANCE ................................... 3.34, 3.35, 3.36
HOUR METER ~ MAINTENANCE ................................................................. 3.3
LUBRICATION AND SERVICE POINTS
(6350501 TO 6350530) ............................................................................. 3.16
(6350531 TO 6350534) ............................................................................. 3.18
(6350535 TO 6350620) ............................................................................. 3.20
(6350621 AND UP) ................................................................................... 3.22
NEW MACHINE MAINTENANCE .................................................................. 3.3
FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT .................. 3.3
INITIAL PRE-DELIVERY INSPECTION ...................................................... 3.3
OIL LOST FROM LEAKAGE .......................................................................... 3.8
OIL SAMPLE COLLECTION PROCEDURES ................................................ 3.5
OIL SAMPLING PROGRAM .......................................................................... 3.6
PRESSURIZED WATER SYSTEM MAINTENANCE ................................... 3.38
REAR (BOGIE) AXLE
DRAINING AND REFILLING BOGIE AXLE
6350501 TO 6350534 ........................................................................... 3.50
6350535 AND UP .................................................................................. 3.52
SLEW BEARING LUBRICATION ............................................................. 3.53
Tigercat 635C Skidder Lubrication and Maintenance

SCHEDULED MAINTENANCE ...................................... 3.10, 3.11, 3.12, 3.13

FREQUENTLY .......................................................................................... 3.10
8 HOURS .................................................................................................. 3.10
48 HOURS ................................................................................................ 3.10
125 HOURS .............................................................................................. 3.11
250 HOURS .............................................................................................. 3.12
500 HOURS .............................................................................................. 3.12
1000 HOURS ............................................................................................ 3.13
SEASONAL .............................................................................................. 3.13
SERVICE AND LUBRICATION POINTS
(6350501 TO 6350530) ............................................................................. 3.16
(6350531 TO 6350534) ............................................................................. 3.18
(6350535 TO 6350620) ............................................................................. 3.20
(6350621 AND UP) ................................................................................... 3.22
STARTUP PROCEDURE AFTER MAJOR MAINTENANCE
6350501 TO 6350530 ............................................................................... 3.56
6350531 AND UP ..................................................................................... 3.59
TILTING THE HOOD AND CAB .................................................................. 3.42
TILTING THE CAB ................................................................................... 3.44
TILTING THE HOOD ................................................................................ 3.42
TORQUE CHART ........................................................................................ 3.61
TORQUE, FLUID CONNECTIONS .................................................... 3.62, 3.65
TORQUE SPECIFICATIONS - GENERAL ................................................... 3.62
WEIGHTS OF COMMERCIAL WOOD ........................................................ 3.66
WHEELS, INSTALLING ................................................................................. 3.3
WINCH MAINTENANCE - ALLIED ONLY ................................................... 3.48

3.2
Tigercat 635C Skidder Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE

FOR 635C SKIDDER

NEW MACHINE MAINTENANCE

*INITIAL PRE-DELIVERY INSPECTION:-
PERFORM THE INITIAL PRE-DELIVERY INSPECTION
USING Tigercat FORM NUMBERS 5281 AND 5283;
"PDI AND 50-100 HOUR INSPECTION REPORT"

*FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT:-

WITH THE OWNER'S MECHANIC PRESENT,
PERFORM AN INSPECTION AND SERVICE
ACCORDING TO THE Tigercat FORM NUMBERS 5281 AND 5283;
"PDI AND 50-100 HOUR INSPECTION REPORT"
THIS MUST BE COMPLETED WITHIN THE FIRST 50-100 HOUR TIME FRAME.

*IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY,

THIS REPORT MUST BE COMPLETED AND RETURNED TO
Tigercat Industries Inc. WARRANTY DEPARTMENT.

TIGHTENING POINTS FOR:- IMPORTANT!

THE FIRST 50-100 HOUR INSPECTION WHEELS:
REPORT:~ When installing wheels, ensure that all paint has
All hydraulic connections been removed from the mating surfaces of both
Hose clamps the wheel disc and the flange of the axle to ensure
metal to metal contact.
Center joint pin securing bolts
For more complete instructions also refer to
Transmission securing bolts
section 15 of the service manual.
Engine mounting bolts
Axle mounting bolts HOUR METER ~ MAINTENANCE:
Wheel retaining bolts Check the hour meter on a regular basis to
Cab securing bolts determine your scheduled maintenance times.
Pin retainers The intervals and times on the scheduled
maintenance chart in this manual are for normal
Any other loose nut, bolt or fitting
operating conditions.
If your machine is being operated in difficult or
NOTE: Use of filters other than genuine Tigercat severe conditions, you should service your
replacement filters is not recommended. 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 635C Skidder 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.

635C Models Recommended Testing Schedule

Loca tion First Sa m ple Follow -up Sa m ple s
Hydraulic Oil 100 Hours Every 1000 Hours or 6 Months
Transmission 100 Hours Every Oil Change (500 Hours or 3 Months)
Bogie Axle 100 Hours Every Oil Change (1000 Hours or 6 Months)
Front Axle Circuit 100 Hours Every 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 follow-
up 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 635C Skidder Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM

OIL SAMPLE COLLECTION PROCEDURES
Fill out the Sample Information Form (SIF)
completely and accurately. When taking multiple
HYDRAULIC
oil samples, fill out all of the required SIF forms in SAMPLE VALVE
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.
The accuracy of the lab analysis results is very OS MAIN 630C HYDRAULIC OIL
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
HYDRAULIC
lab. To be able to accurately compare and trend SAMPLE VALVE
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 AXLE
FILTER
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 OS AXLE 630C AXLE HYDRAULIC OIL
sample bottle.
Hydraulic Oil Samples:
• Avoid contamination of the sample – replace
the sample bottle cap immediately after filling • Hydraulic oil samples should be taken from the
the bottle to approximately ¾ full. circulating oil flow at operating temperature,
with no functions actuated, using sample
All samples taken should be immediately valves that are permanently located on the
forwarded to the lab for processing. machine whenever possible.
Contact your Tigercat dealer to purchase additional • To obtain a representative oil sample, sample
or replacement hydraulic sample valves or drain valves must be purged before the actual oil
plugs. sample is taken. Drain a minimum of 3 or 4
In cases where oil samples must be pumped or ounces of oil into a separate container and
otherwise drawn out of a reservoir or housing, a discard this oil using approved recycling
hand operated oil suction pump is also available methods.
from your Tigercat dealer. • Replace the dust cover on the sample valve
immediately after taking the oil sample and
sealing the sample bottle.

3.5
Tigercat 635C Skidder Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM

Transmission and Bogie 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 SAMPLE LOCATION /
TRANSMISSION DRAIN
draining oil to obtain a representative sample. 630C-100 TRANSMISSION OIL

3.6
Tigercat 635C Skidder Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM

DIFFERENTIAL
SAMPLE LOCATION/
DRAIN PLUG
(1 PLACE)
BOTTOM OF
DIFFERENTIAL
NOT VISIBLE IN THIS
ILLUSTRATION
••
••

BOGIE HOUSING
SAMPLE LOCATION /
••
DRAIN PLUG
(2 PLACES - LOWER)
ONE SAMPLE FROM
EACH HOUSING

EARLIER DESIGN
635C-18 BOGIE AXLE - 3 SAMPLE LOCATIONS 6350501 TO 6350534

DIFFERENTIAL
SAMPLE LOCATION/
DRAIN PLUG
(1 PLACE)
BOTTOM OF
DIFFERENTIAL
NOT VISIBLE IN THIS
ILLUSTRATION

•
••

BOGIE HOUSING
SAMPLE LOCATION /
DRAIN PLUG
(2 PLACES - LOWER)
ONE SAMPLE FROM
EACH HOUSING •• LATER DESIGN
6350535 AND UP
625C-94 BOGIE AXLE - 3 SAMPLE LOCATIONS

3.7
Tigercat 635C Skidder Lubrication and Maintenance

GENERAL

Inspect the EXHAUST SYSTEM DAILY for

CAUTION any signs of LEAKAGE. Check for worn,
cracked, broken, or damaged pipes or muffler.
All handles, steps and platforms must be kept Also check for missing or damaged bolts or
free of grease, oil, fuel, mud, snow and ice. clamps. Should any exhaust leaks or defective
parts be found, repairs must be made
Clean around filler caps before checking or immediately. Engine exhaust leaks can cause
adding fluids fires, DO NOT OPERATE the machine until
Release hydraulic pressures and clean around the exhaust leak is repaired.
hydraulic fittings before breaking connection. During daily operation of the machine, the
Plug or cap immediately occurrence of exhaust leaks are usually
Clean up spills as soon as possible accompanied by a change or increase in
engine exhaust noise levels. These audible
Always use clean oil and containers warnings cannot be ignored. Should any
Drain dirty oil while still warm exhaust leaks occur during operation, the
machine must be shut down immediately and
Do not exceed recommended fluid levels not put back to work until the necessary
Service all hydraulic filters after the failure of a repairs have been completed.
pump, motor, cylinder or valve. Failures of this Always have a fire extinguisher at hand
nature could contaminate the entire hydraulic
For safety; when leaving the cab or leaving
system
machine unattended or during service, always
Top up diesel fuel AT END OF Each shift to lower grapple and dozer blade to the ground
reduce contamination by condensation
For safety, always block or support grapple and
Clean up oil spills on walking surfaces and top dozer blade when working under them.
of engine enclosure immediately
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 Alternate exit routes are provided: the sliding
prevent arcing across machined surfaces or windows in the cab doors. These are only to be
through bearings used if the cab doors cannot be opened.
Clean away all branches, bark and chips. It is therefore essential that these emergency exits
Clean up all traces of oil to avoid fires 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

3.8
Tigercat 635C Skidder 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.

3.9
Tigercat 635C Skidder Lubrication and Maintenance

SCHEDULED MAINTENANCE

FREQUENTLY:~ • Lubricate arch cylinders and pivots, 12-fittings,

purge
• Operate the reversible fan to clear debris
• Lubricate dozer blade cylinders and pivots,
from the engine cooling air intake door
6-fittings, purge
screens. It may also be necessary to
manually check for possible restriction • Lubricate grapple snubbers, 4-fittings, purge
depending upon operating conditions in • Lubricate grapple, 8-fittings, purge
your area. • Lubricate grapple yoke, 4-fittings, purge
Clean:~
EVERY 8 HOURS (EVERY SHIFT):~ • Potentially damaging limbs or sticks from
machine
• Perform "frequently" maintenance check,
• A/C condenser, oil cooler, radiator refer to
And in addition:~
CLEANING A/C CONDENSER AND
• Check engine coolant level
COOLING ASSEMBLY in SECTION 2 of the
• Check engine oil level OPERATOR'S MANUAL.
• Drain engine fuel filter/water separator
Check:~
• On machines (6350501 to 6350530) drain • For leakage around hydraulic components and
secondary fuel filter/water separator flexible hoses. See "Oil lost from leakage"
• Check air intake precleaner, clean as required chart.
• Check air cleaner unloader valve • For loose nuts, bolts and fittings
• Check engine air filter restriction indicator • Condition and tension of fan belts.
• Check hydraulic oil level • Exhaust system for leaks.
• Check winch sump oil level • Water pressure (60 psi) for pressurized water
• Check transmission oil level with dipstick system.

• Lubricate front axle pivot, 2-fittings, purge If the water system has been operated, refer to
PRESSURIZED WATER SYSTEM
• On machines 6350501 to 6350620 MAINTENANCE in THIS SECTION for refilling
Lubricate mid drive shaft 1-fitting, purge and charging instructions.
Note: Lubrication of mid drive shaft slip • Conduct an overall visual inspection.
joint should be done with machine fully • Refer to diesel engine service manual and
articulated. attachment manual for additional required
Lubricate rear drive shaft bearing, 2-fitting, maintenance at this scheduled time period.
purge
• On machines 6350621 and up
EVERY 48 HOURS:~
Lubricate mid drive shaft 1-fitting, purge
• Check the center joint for looseness. Refer to
Note: Lubrication of mid drive shaft slip
CENTER JOINT MAINTENANCE in THIS
joint should be done with machine fully
SECTION for instructions. If a problem is
articulated.
found corrective action should be taken
Lubricate rear drive shaft bearing, 1-fitting, immediately. Refer also to CENTER JOINT in
purge SECTION 11 of the SERVICE MANUAL for
• Lubricate center joint bearings, 2-fittings, more detailed checking and adjustment
purge procedures.
• Lubricate steering cylinder ends, 4-fittings,
purge

3.10
Tigercat 635C Skidder Lubrication and Maintenance

SCHEDULED MAINTENANCE
EVERY 125 HOURS:~ • Proper operation of pressurized water system.
• Perform "frequently" maintenance Refer to PRESSURIZED WATER SYSTEM
MAINTENANCE in THIS SECTION.
• Perform 8 hour maintenance
Visually check for damage to:~
And in addition:~
• Arch and pivot linkage
• On machines 6350501 to 6350620
• Front and rear frame
Lubricate front drive shaft, 1-fitting, purge
• Center joint area
• On machines 6350621 and up
• Attachment
Lubricate front drive shaft, 1-fitting, purge
Make repairs immediately
Lubricate mid rear drive shaft, 1-fitting,
purge Visually inspect for:~
• Frayed electrical wiring and hydraulic hose
• Lubricate grapple rotator shaft, 3-fittings,
5-shots • Wear in any other components
• Carry out A/C system inspection; Refer to AIR Clean/replace:~
CONDITIONING SYSTEM, CHECKING in THIS • Refer to diesel engine service manual and
SECTION attachment manual for additional required
maintenance at this scheduled time period.
Check:~
• Check axle circuit reservoir oil level (in front
axle). Refer to FRONT AXLE OIL LEVEL
CHECK AND AXLE CIRCUIT FILL in THIS
SECTION.
• On machines 6350501 to 6350534
Check oil level in bogie axle differential and
housings, 1-place
Check oil level in bogie axle planetary
drives, 4-places
• On machines 6350535 and up
Check oil level in bogie axle, 1-place
• 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.
• Charge Air Cooler for damage, wear, cracks, or
leaks and repair immediately.
• Fluid level in batteries unless maintenance free
• Engine rpm.
• All hydraulic pressures
• Hydraulic pump and motor securing bolts
• Check fuel tank filler screen
• Torque tightening points as per new machine
maintenance.

3.11
Tigercat 635C Skidder Lubrication and Maintenance

SCHEDULED MAINTENANCE
EVERY 250 HOURS:~ EVERY 500 HOURS:~
• Perform "frequently" maintenance • Perform "frequently" maintenance
• Perform 8 hour maintenance • Perform 8 hour maintenance
• Perform 125 hour maintenance • Perform 125 hour maintenance
And in addition:~ • Perform 250 hour maintenance
• On machines 6350501 to 6350530 replace the And in addition:~
engine fuel filter/water separator and the • Replace air intake safety element
secondary fuel filter/water separator
• Replace axle pressure filter †
• On machines 6350531 and up replace the
• Replace hydraulic oil triple element filters
primary fuel filter and the secondary fuel filter/
(3 elements) †
water separator
2 white, high performance element.
• Replace coolant corrosion resistor
1 blue, water absorbing element.
• Replace air intake primary element
• Replace charge pressure filter †
• On machines 6350501 to 6350510
• Replace oil in transmission
Lubricate bogie axle slewing rings,
• Lubricate drive coupling, 3-fittings, purge
12-fittings; 2-places
• Lubricate door hinges, 8-fittings
Note: Do not use a power greaser as it
will damage the seals. • Refer to diesel engine service manual and
attachment manual for additional required
• On machines 6350621 and up maintenance at this scheduled time period.
Check parking brake oil level
• Lubricate grapple pinion gear spline, 1-fitting,
5-shots, (Note: remove pipeplug to access)
• Clean and thoroughly inspect all surfaces of
the arch and boom for cracks. All cracks must
be properly repaired in their early stages. Note
that in most cases cracks will continue to grow
in size and often lead to major structural
damage. Failure to regularly inspect for
cracks and immediately repair the boom
system will void the structural warranty.
Contact your Tigercat dealer for specific
procedures required to correctly repair any
cracks found.
• 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.
3.12
Tigercat 635C Skidder Lubrication and Maintenance

SCHEDULED MAINTENANCE

EVERY 1000 HOURS:~ SEASONAL:~

• Perform "frequently" maintenance • Drain and refill hydraulic oil tank and front axle
• Perform 8 hour maintenance circuit with recommended hydraulic oil. Refer
to APPROVED HYDRAULIC OILS in THIS
• Perform 125 hour maintenance
SECTION also see SECTION 15 of the
• Perform 250 hour maintenance SERVICE MANUAL for axle draining
• Perform 500 hour maintenance procedure.

And in addition:~ • Drain and refill bogie axle differential, housings

• Replace air cleaner unloader valve and planetary drives. Refer to REAR (BOGIE)
AXLES in THIS SECTION. Refer also to
• Check center joint preload with a dial indicator. LUBRICATION AND SERVICE CHART in
Refer to CENTER JOINT ~ CHECKING THIS SECTION for recommended gear oils.
CENTER JOINT PRELOAD in SECTION 11 of
the SERVICE MANUAL. If a problem is found • Drain and refill pressurized water system.
corrective action should be taken immediately, Refer to PRESSURIZED WATER SYSTEM
refer to CENTER JOINT PRELOAD MAINTENANCE in THIS SECTION.
ADJUSTMENT in SECTION 11 of the
SERVICE MANUAL.
• Replace oil in winch sump
• On machines 6350621 and up
Replace oil in parking brake.
• Drain and refill pressurized water system.
Refer to PRESSURIZED WATER SYSTEM
MAINTENANCE in THIS SECTION.
• Drain and refill hydraulic oil tank and front axle
circuit with recommended hydraulic oil. Refer
to APPROVED HYDRAULIC OILS in THIS
SECTION also see SECTION 15 of the
SERVICE MANUAL for axle draining
procedure.
• Drain and refill bogie axle differential, housings
and planetary drives. Refer to REAR (BOGIE)
AXLES in THIS SECTION. Refer also to
LUBRICATION AND SERVICE CHART in
THIS SECTION for recommended gear oils.
• On machines 6350511 and up
Lubricate bogie axle slewing rings, 2-
fittings; 2-places . Refer to REAR (BOGIE)
AXLE~SLEW BEARING LUBRICATION in
THIS SECTION.
• Refer to diesel engine service manual and
attachment manual for additional required
maintenance at this scheduled time period.

3.13
Tigercat 635C Skidder Lubrication and Maintenance

APPROVED HYDRAULIC OILS

MAIN HYDRAULIC SYSTEM

Note that the 635C skidder has two separate hydraulic systems (the main hydraulic system and the axle
circuit). These two hydraulic systems require two different types of hydraulic oil that must not be
interchanged under any circumstances.
Use only one of the following oils to fill or replenish the MAIN HYDRAULIC SYSTEM.

®
HYDRAULIC OIL OPERATING RANGE Tigercat
(Not suitable for axle applications) OPERATING TEMP. RANGE
LOWEST START-UP TEMP.

HYDRAULIC OIL TEMPERATURE

-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100
˚C
OIL TYPE
-40 -20 0 20 40 60 80 100 120 140 160 180 200 220˚F
CITGO
MYSTICK HVI 32
MYSTICK HVI 46
MYSTICK HVI 68
CHEVRON
RYKON PREMIUM 32
RYKON PREMIUM 46
RYKON PREMIUM 68
ESSO / EXXON
UNIVIS N22
UNIVIS N32
UNIVIS N46
UNIVIS N68
IRVING OIL
HYDRAULIC LP 22
HYDRAULIC LP 32
HYDRAULIC LP 46
HYDRAULIC LP 68
MOBIL
MOBIL DTE 12M (ISO 22)
MOBIL DTE 13M (ISO 32)
MOBIL DTE 15M (ISO 46)
MOBIL DTE 16M (ISO 68)
PETRO-CANADA
HYDREX MV 22
HYDREX MV 36
HYDREX MV 60
SHELL
TELLUS T22
TELLUS T32
TELLUS T46
TELLUS T68
TEXACO
RANDO HDZ 22
RANDO HDZ 32
RANDO HDZ 46
RANDO HDZ 68

OPERATING MACHINE OUTSIDE LIMITS SHOWN WILL

CAUTION RESULT IN FAILURE OF HYDRAULIC COMPONENTS

5168AR03

3.14
Tigercat 635C Skidder Lubrication and Maintenance

APPROVED HYDRAULIC OILS

AXLE CIRCUIT
Note that the 635C skidder has two separate hydraulic systems (the main hydraulic system and the axle
circuit). These two hydraulic systems require two different types of hydraulic oil that must not be
interchanged under any circumstances.
Wet disk brakes in the axles require oil with specific properties to ensure reduced chatter and ensure
proper lubrication of mechanical components.
Use only one of the following oils to fill or replenish the AXLE HYDRAULIC CIRCUIT.

AXLE OIL
THE FLUID USED TO FILL OR REPLENISH
THE AXLES ON THIS MACHINE
MUST MEET JOHN DEERE SPECIFICATIONS
TYPE J20C (SUMMER) OR J20D (WINTER).
THE FOLLOWING ARE APPROVED BY Tigercat ®

FOR USE IN THIS MACHINE:

CHEVRON TRACTOR HYDRAULIC FLUID (SUMMER)
CITGO TRACTOR HYDRAULIC FLUID (33-310) (SUMMER)
IMPERIAL/ESSO HYDRAUL 56 (SUMMER)
HYDRAUL 50 (LOW VISC) WINTER)
SHELL DONAX TD (SUMMER)
DONAX TDL (WINTER)
SUN SUNFLEET TH FLUID (SUMMER)
JOHN DEERE TYPE J20C (HYGARD) (SUMMER)
TYPE J20D (HYGARD) WlNTER) 22874A R0

NOTE FOR MACINES EQUIPPED WITH REAR BOGIE AXLES: The axle circuit on this machine
includes the front axle only. Refer to FRONT AXLE OIL LEVEL CHECK AND AXLE CIRCUIT FILL in
THIS SECTION. For information regarding the rear (bogie) axle refer to REAR (BOGIE) AXLE in THIS
SECTION.

3.15
 Tigercat 635C Skidder Lubrication and Maintenance
MACHINE SERIAL NUMBERS (6350501 TO 6350530)

SEE CHART

21502BR3

3.16
 LUBRICATION AND SERVICE POINTS

Tigercat 635C Skidder Lubrication and Maintenance

Tigercat® Model 635C
SERVICE AND LUBRICATION POINTS
REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION
SERVICE EVERY CAPACITY
POINT NO.
SERVICE

ITEM DESCRIPTION

LITERS
1000 

USG

QTY
125 

250 

500 
8
1 COOLING SYSTEM CHK CHANGE COOLANT 46 12.2 60/40 ANTIFREEZE *
EVERY 2 YEARS
2 ENGINE OIL/FILTER CHK • • • SEE ENGINE MANUFACTURER'S
CUMMINS QSC SERIES • MAINTENANCE MANUAL FOR PROCEDURES,
3 FUEL FILTER/WATER SEPARATOR (ENGINE) DRN REP 1
3A SECONDARY FUEL FILTER DRN REP 1
4 COOLANT CORROSION RESISTOR REP 1
5 FUEL TANK FILLER SCREEN CHK 1
6 AIR INTAKE PRECLEANER CHK 1 CLEAN AS REQUIRED
AIR INTAKE PRIMARY ELEMENT REP 1 CHECK FILTER RESTRICTION
7
AIR INTAKE SAFETY ELEMENT REP 1 INDICATOR WITH ENGINE RUNNING
8 AIR CLEANER UNLOADER VALVE CHK REP 1 REFER TO SECTION 3 OF THE MANUAL
9 MAIN HYDRAULIC RESERVOIR CHK 102 27 1 DRAIN AND REFILL AS REQUIRED BY
(GAUGE ON TANK) SEASONAL OIL CHANGE * * *
(SEE HYDRAULIC OIL CHART)
10 AXLE RETURN FILTER REP 1 ALSO CHANGE WHEN REPAIRING A
† LEAKING OR FAILED AXLE
11 HYDRAULIC FILTER, FULL FLOW, INCLUDES:- REP 3 *NOTE: MUST USE 1 BLUE FILTER ELEMENT
1 BLUE WATER ABSORBING ELEMENT* † AND 2 WHITE FILTER ELEMENTS
2 WHITE HIGH PERFORMANCE ELEMENTS
12 CHARGE PRESSURE FILTER REP 1 CHECK FILTER RESTRICTION
† INDICATOR ON FILTER WITH ENGINE
RUNNING AT FULL AND WITH OIL FLOW
13 WINCH ALLIED CHK D/R 3.8 1.0 SEE WINCH MANUFACTURER'S
MAINTENANCE MANUAL
14 PRESSURIZED WATER SYSTEM CHK TEST D/R 52 13.7 SEASONAL DRAIN AND REFILL
15 TRANSMISSION CAST CHK D/R 6 1.6 1 FILL WITH MIL-L-2105C OR API-GL-5
LUBRICANT GRADE/WEATHER
TEMPERATURE:
BELOW -10Fº(-23ºC) USE 75W-90
UP TO 100ºF(38ºC) USE 80W-90
ABOVE 100ºF(38ºC) USE 85W-140
AXLES: FRONT 31.2 8.2 1 *** SEE AXLE OIL CHART
16 REFER TO SECTION 3 OF THE MANUAL
AXLE CIRCUIT RESERVOIR - FRONT AXLE CHK D/R
FOR CHECKING PROCEDURE.
17 BOGIE AXLE - DIFFERENTIAL CHK D/R FILL WITH MIL-L-2105C OR API-GL-5
126 33 1
18 BOGIE AXLE - HOUSINGS CHK D/R LUBRICANT GRADE/WEATHER TEMPERATURE:
BELOW -10Fº(-23ºC) USE 75W-90
19 BOGIE AXLE - PLANETARY DRIVES CHK D/R 5 1.3 4 UP TO 100ºF(38ºC) USE 80W-90
ABOVE 100ºF(38ºC) USE 85W-140
REFER TO MANUAL SECTION 3 FOR REAR
(BOGIE) AXLE FILLING PROCEDURE
20 BOGIE AXLE - SLEWING RINGS LITHIUM BASE EP2 GREASE ‹
EARLIER MACHINES 6350501 TO 6350510 LUB PURGE 24
LATER MACHINES 6350511 TO 6350530 LUB PURGE 4
21 AXLE-PIVOT (FRONT ONLY) LUB PURGE 2 LITHIUM BASE EP2 GREASE ‹
FRONT DRIVE SHAFT LUB PURGE 1 LITHIUM BASE EP2 GREASE ‹
MID DRIVE SHAFT LUB PURGE 1
22
**
REAR DRIVE SHAFTS: BEARINGS LUB PURGE 2
23 DRIVE COUPLING LUB PURGE 3 LITHIUM BASE EP2 GREASE ‹
CENTER JOINT LUB PURGE 2 LITHIUM BASE EP2 GREASE ‹
24 CENTER JOINT BEARING PRELOAD CHK CHK REFER TO SECTION 3 OF THE MANUAL
48  FOR DETAILS
25 STEERING CYLINDERS LUB PURGE 4 LITHIUM BASE EP2 GREASE ‹
26 DOUBLE ARCH CYLINDER & PIVOTS LUB PURGE 12 LITHIUM BASE EP2 GREASE ‹
27 DOZER BLADE CYLINDER & PIVOTS LUB PURGE 6 LITHIUM BASE EP2 GREASE ‹
28 GRAPPLE, Tigercat SEE LUBRICATION POINTS DIAGRAM
635CLUBCHART-21502BR3MOD.XLS 03/08

3.17
Tigercat 635C Skidder Lubrication and Maintenance
MACHINE SERIAL NUMBERS (6350531 TO 6350534)

4 FTG/1000

3.18
 Tigercat 635C Skidder Lubrication and Maintenance
Tigercat® Model 635C
SERVICE AND LUBRICATION POINTS
REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION
SERVICE EVERY CAPACITY
POINT NO.
SERVICE

ITEM DESCRIPTION

LITERS
1000 

USG

QTY
125 

250 

500 
8
1 COOLING SYSTEM CHK CHANGE COOLANT 46 12.2 60/40 ANTIFREEZE *
EVERY 2 YEARS
2 ENGINE OIL/FILTER CHK • • • SEE ENGINE MANUFACTURER'S
CUMMINS QSC SERIES • MAINTENANCE MANUAL FOR PROCEDURES,
CAPACITIES AND REPLACEMENT INTERVALS
3 FUEL FILTER/WATER SEPARATOR (ENGINE) DRN REP 1
3A SECONDARY FUEL FILTER REP 1
4 COOLANT CORROSION RESISTOR REP 1
5 FUEL TANK FILLER SCREEN CHK 1
6 AIR INTAKE PRECLEANER CHK 1 CLEAN AS REQUIRED
AIR INTAKE PRIMARY ELEMENT REP 1 CHECK FILTER RESTRICTION
7
AIR INTAKE SAFETY ELEMENT REP 1 INDICATOR WITH ENGINE RUNNING
8 AIR CLEANER UNLOADER VALVE CHK REP 1 REFER TO SECTION 3 OF THE MANUAL
9 HYDRAULIC RESERVOIR CHK 102 27 1 D/R AS REQUIRED BY SEASONAL OIL CHANGE
(GAUGE ON TANK) ***
(SEE HYDRAULIC OIL CHART)
10 AXLE PRESSURE FILTER REP 1 ALSO CHANGE WHEN REPAIRING A
† LEAKING OR FAILED AXLE
11 HYDRAULIC FILTER, FULL FLOW, INCLUDES:- REP 3 *NOTE: MUST USE 1 BLUE FILTER ELEMENT
1 BLUE WATER ABSORBING ELEMENT* † AND 2 WHITE FILTER ELEMENTS
2 WHITE HIGH PERFORMANCE ELEMENTS
12 CHARGE PRESSURE FILTER REP 1 CHECK FILTER RESTRICTION
† INDICATOR ON FILTER WITH ENGINE
RUNNING AT FULL AND WITH OIL FLOW
13 WINCH ALLIED CHK D/R 3.8 1.0 REFER TO WINCH MAINTENANCE IN SECTION
3 OF MANUAL. SEE ALSO WINCH
MANUFACTURER'S MANUAL
14 PRESSURIZED WATER SYSTEM CHK TEST D/R 52 13.7 SEASONAL DRAIN AND REFILL
15 TRANSMISSION CAST CHK D/R 6 1.6 1 FILL WITH MIL-L-2105C OR API-GL-5
LUBRICANT GRADE/WEATHER
TEMPERATURE:
BELOW -10Fº(-23ºC) USE 75W-90
UP TO 100ºF(38ºC) USE 80W-90
ABOVE 100ºF(38ºC) USE 85W-140
AXLES: FRONT 31.2 8.2 1 *** SEE AXLE OIL CHART
16 REFER TO SECTION 3 OF THE MANUAL
AXLE CIRCUIT RESERVOIR - FRONT AXLE CHK D/R
FOR CHECKING PROCEDURE.
17 BOGIE AXLE - DIFFERENTIAL CHK D/R FILL WITH MIL-L-2105C OR API-GL-5
126 33 1
18 BOGIE AXLE - HOUSINGS CHK D/R LUBRICANT GRADE/WEATHER TEMPERATURE:
BELOW -10Fº(-23ºC) USE 75W-90
19 BOGIE AXLE - PLANETARY DRIVES CHK D/R 5 1.3 4 UP TO 100ºF(38ºC) USE 80W-90
ABOVE 100ºF(38ºC) USE 85W-140
REFER TO MANUAL SECTION 3 FOR REAR
(BOGIE) AXLE FILLING PROCEDURE
20 BOGIE AXLE - SLEWING RINGS LUB PURGE 4 LITHIUM BASE EP2 GREASE ‹
21 AXLE-PIVOT (FRONT ONLY) LUB PURGE 2 LITHIUM BASE EP2 GREASE ‹
FRONT DRIVE SHAFT LUB PURGE 1 LITHIUM BASE EP2 GREASE ‹
MID DRIVE SHAFT LUB PURGE 1
22
**
REAR DRIVE SHAFTS: BEARINGS LUB PURGE 2
23 DRIVE COUPLING LUB PURGE 3 LITHIUM BASE EP2 GREASE ‹
CENTER JOINT LUB PURGE 2 LITHIUM BASE EP2 GREASE ‹
24 CENTER JOINT BEARING PRELOAD CHK CHK REFER TO SECTION 3 OF THE MANUAL
48  FOR DETAILS
25 STEERING CYLINDERS LUB PURGE 4 LITHIUM BASE EP2 GREASE ‹
26 DOUBLE ARCH CYLINDER & PIVOTS LUB PURGE 12 LITHIUM BASE EP2 GREASE ‹
27 DOZER BLADE CYLINDER & PIVOTS LUB PURGE 6 LITHIUM BASE EP2 GREASE ‹
28 GRAPPLE, Tigercat SEE LUBRICATION POINTS DIAGRAM
635CLUBECHART-31643BR01MOD.XLS 03/08

3.19
Tigercat 635C Skidder Lubrication and Maintenance
MACHINE SERIAL NUMBERS (6350535 TO 6350620)

3.20
Tigercat 635C Skidder Lubrication and Maintenance
Tigercat® Model 635C
SERVICE AND LUBRICATION POINTS
REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION
SERVICE EVERY CAPACITY
POINT NO.
SERVICE

ITEM DESCRIPTION

1000 

LITERS
125 

250 

500 

USG

QTY
8
CHANGE COOLANT
1 COOLING SYSTEM CHK 46 12.2 60/40 ANTIFREEZE *
EVERY 2 YEARS

ENGINE OIL/FILTER CHK • SEE ENGINE MANUFACTURER'S

2
CUMMINS QSC SERIES • • • MAINTENANCE MANUAL FOR PROCEDURES,
CAPACITIES AND REPLACEMENT INTERVALS

3 FUEL FILTER/WATER SEPARATOR (ENGINE) DRN REP 1

3A SECONDARY FUEL FILTER REP 1
4 COOLANT CORROSION RESISTOR REP 1
5 FUEL TANK FILLER SCREEN CHK 1
6 AIR INTAKE PRECLEANER CHK 1 CLEAN AS REQUIRED
AIR INTAKE PRIMARY ELEMENT REP 1 CHECK FILTER RESTRICTION
7
AIR INTAKE SAFETY ELEMENT REP 1 INDICATOR WITH ENGINE RUNNING

8 AIR CLEANER UNLOADER VALVE CHK REP 1 REFER TO SECTION 3 OF THE MANUAL
DRAIN AND REFILL AS REQUIRED BY
HYDRAULIC RESERVOIR
9 CHK 102 27 1 SEASONAL OIL CHANGE ***
(GAUGE ON TANK)
(SEE HYDRAULIC OIL CHART)
REP ALSO CHANGE WHEN REPAIRING A
10 AXLE PRESSURE FILTER 1
† LEAKING OR FAILED AXLE

HYDRAULIC FILTER, FULL FLOW, INCLUDES:- *NOTE: MUST USE 1 BLUE FILTER ELEMENT
REP
11 1 BLUE WATER ABSORBING ELEMENT* 3 AND 2 WHITE FILTER ELEMENTS
†
2 WHITE HIGH PERFORMANCE ELEMENTS
CHECK FILTER RESTRICTION
REP INDICATOR ON FILTER WITH ENGINE
12 CHARGE PRESSURE FILTER 1
† RUNNING AT FULL AND WITH OIL FLOW

REFER TO WINCH MAINTENANCE IN SECTION 3

13 WINCH ALLIED CHK D/R 3.8 1.0 OF MANUAL. SEE ALSO WINCH
MANUFACTURER'S MANUAL
14 PRESSURIZED WATER SYSTEM CHK TEST D/R 52 13.7 SEASONAL DRAIN AND REFILL
FILL WITH MIL-L-2105C OR API-GL-5
LUBRICANT GRADE/WEATHER
TEMPERATURE:
15 TRANSMISSION CAST CHK D/R 6 1.6 1
BELOW -10ºF(-23ºC) USE 75W-90
UP TO 100ºF(38ºC) USE 80W-90
ABOVE 100ºF(38ºC) USE 85W-140
31.2 8.2
AXLES: FRONT 1 *** SEE AXLE OIL CHART
16 REFER TO SECTION 3 OF THE MANUAL
AXLE CIRCUIT RESERVOIR - FRONT AXLE CHK D/R FOR CHECKING PROCEDURE.

FILL WITH MIL-L-2105C OR API-GL-5

17 BOGIE AXLE - DIFFERENTIAL CHK D/R LUBRICANT GRADE/WEATHER TEMPERATURE:
BELOW -10ºF(-23ºC) USE 75W-90
246 65 3 UP TO 100ºF(38ºC) USE 80W-90
ABOVE 100ºF(38ºC) USE 85W-140
18 BOGIE AXLE - HOUSINGS CHK D/R REFER TO MANUAL SECTION 3 FOR REAR
(BOGIE) AXLE FILLING PROCEDURE

LITHIUM BASE EP2 GREASE

19 BOGIE AXLE - SLEWING RINGS LUB PURGE 4
REFER TO MANUAL SECTION 3 FOR PROCEDURE

20 AXLE-PIVOT (FRONT ONLY) LUB PURGE 2 LITHIUM BASE EP2 GREASE ‹

FRONT DRIVE SHAFT LUB PURGE 1

21 LUB LITHIUM BASE EP2 GREASE ‹

MID DRIVE SHAFT PURGE 1
**
REAR DRIVE SHAFTS: BEARINGS LUB PURGE 2

22 DRIVE COUPLING LUB PURGE 3 LITHIUM BASE EP2 GREASE ‹

CENTER JOINT LUB PURGE 2 LITHIUM BASE EP2 GREASE ‹
23 CHK REFER TO SECTION 3 OF THE MANUAL
CENTER JOINT BEARING PRELOAD CHK
48  FOR DETAILS

24 STEERING CYLINDERS LUB PURGE 4 LITHIUM BASE EP2 GREASE ‹

25 DOUBLE ARCH CYLINDER & PIVOTS LUB PURGE 12 LITHIUM BASE EP2 GREASE ‹
26 DOZER BLADE CYLINDER & PIVOTS LUB PURGE 6 LITHIUM BASE EP2 GREASE ‹
27 GRAPPLE, Tigercat SEE LUBRICATION POINTS DIAGRAM

635CLUBECHART-37769BR1.XLS 03/08
3.21
Tigercat 635C Skidder Lubrication and Maintenance
MACHINE SERIAL NUMBERS (6350621 AND UP)

3.22
Tigercat 635C Skidder Lubrication and Maintenance

635C LUBCHART - 40825BENG.XLS 03/08

3.23
Tigercat 635C Skidder Lubrication and Maintenance
FILTERS Changing the filter:
1. Park machine on level ground, install
IMPORTANT articulation lock bar, lower dozer and grapple
Failure to service and replace filters at the to the ground, stop engine, engage parking
proper intervals specified in the brake and block wheels.
manufacturer's manuals, could cause damage 2. Wipe clean the area around the filter and
to the machine and result in the product head.
warranty becoming NULL and VOID. Check
Tigercat parts catalog for replacement filters. 3. Use filter drain to drain fuel out of the filter for
approximately 5 seconds. This will prevent
FUEL FILTER/WATER SEPARATOR fuel from running over the top of the filter when
(CUMMINS QSC ENGINE) it is removed.
SERIAL NUMBERS 6350501 TO 6350530 4. Disconnect the water in fuel sensor from the
This is a combination unit, with a replaceable fuel wiring harness.
filter with drain valve and a reusable water in fuel 5. Place rags below to catch the spillage of fuel.
sensor. For service and replacement intervals
see SERVICE AND LUBRICATION POINTS in 6. Wearing face protection (in case of a fuel
THIS SECTION. Refer also to engine spray) unscrew the old filter. Dispose of any
manufacturer's manual for more detailed fuel properly .
information. 7. Remove the water in fuel sensor from the fuel
filter. Dispose of the fuel filter properly.
FUEL FILTER/
SECONDARY
WATER 8. Install the water in fuel sensor in the new filter.
FUEL FILTER/
WATER SEPARATOR (Inspect water in fuel sensor for damage and
SEPARATOR (ENGINE)
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
DRAIN TAP
specified by the filter manufacturer. Note:
Mechanical overtightening can damage the
filter element.
•
DRAIN TAP
FUEL WATER SEPARATORS 12. Connect water in fuel sensor to the wiring
635C-15 (6350501 TO 6350530) harness.
13. Start the engine and check for leaks. Refer to
WARNING STARTING ENGINE in SECTION 2 of the
OPERATOR'S MANUAL.
Drain fuel filter into a container and dispose
of all fluids properly. IMPORTANT
Filters that are an integral part of the engine
(fuel and lubricating oil) should be serviced
and replaced according to the engine
manufacturer's manual.

3.24
Tigercat 635C Skidder Lubrication and Maintenance
SECONDARY FUEL FILTER/WATER
SEPARATOR SECONDARY FUEL
FILTER/WATER
SEPARATOR
This is a combination unit, with a replaceable
fuel filter and a removable water sediment bowl INJECTOR PUMP
TEST PORT
on the bottom of the unit. The water sediment
bowl is only replaced if it becomes damaged or •• ••
non-functional. For service and replacement
intervals see SERVICE AND LUBRICATION
POINTS in THIS SECTION.
Changing the filter:
1. Park machine on level ground, install
articulation lock bar, lower dozer and grapple
to the ground, stop engine, engage parking
brake and block wheels.
2. Wipe clean the area around the filter and 635C-24 PRIME FUEL LINES
head. 15. Turn ignition switch to the ON position. Watch
hose until a steady stream of fuel begins. (If
3. Place rags below to catch the spillage of fuel.
the lift pump shuts off before a steady stream
4. Wearing face protection (in case of a fuel of fuel begins, the ignition switch may need to
spray) unscrew the old filter. be turned to the OFF position then back to
ON.)
5. Remove and discard the small 1” I.D. gasket
from the threaded extension on the filter head. 16. Once a steady stream of fuel begins remove
hose.
6. Remove the water sediment bowl from the
bottom of the old filter. Discard this gasket 17. Start the engine and check for leaks.
also. Dispose of old filter and any fuel
properly.
7. Clean the water sediment bowl.
8. Check the seating area for the gaskets on the
filter head and the water sediment bowl and
wipe clean.
9. Lubricate gasket for bottom of filter and water
sediment bowl with clean engine oil and
carefully hand tighten the water sediment
bowl onto the new filter. Close the water drain
valve.
10. Lubricate the new 1” I.D. gasket with clean
engine oil and install onto the threaded
extension on the filter head.
11. Lubricate the gasket on top of the new filter
with clean engine oil and pre-fill the filter
with clean fuel.
12. Screw the new filter on to the filter head until
the gasket makes contact with the seat and
then hand tighten an additional 3/4 turn only.
13. Fuel lines must be primed after changing the
secondary fuel filter.
14. Attach a quick connect fitting and hose to the
test port of the fuel injector pump. Place the
end of the hose in a suitable container to catch
fuel.

3.25
Tigercat 635C Skidder Lubrication and Maintenance
FUEL FILTER/WATER SEPARATOR
(CUMMINS QSC ENGINE) IMPORTANT
SERIAL NUMBERS 6350531 AND UP Filters that are an integral part of the engine
This machine is equipped with two fuel filters. The (fuel and lubricating oil) should be serviced
secondary fuel filter is a combination unit, with a and replaced according to the engine
replaceable fuel filter with drain valve and a manufacturer's manual.
reusable water in fuel sensor. For service and
Changing the engine fuel filter:
replacement intervals see SERVICE AND
LUBRICATION POINTS in THIS SECTION. Refer 1. Park machine on level ground, install
also to engine manufacturer's manual for more articulation lock bar, lower dozer and grapple
detailed information. to the ground, stop engine, engage parking
brake and block wheels.
SECONDARY
FUEL FILTER/ 2. Wipe clean the area around the filter and
PRIMARY WATER
FUEL FILTER SEPARATOR 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
DRAIN TAP 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
FUEL WATER SEPARATOR filter.
630C-246 (6350531 AND UP) 7. Screw the new filter on to the filter head as
specified by the filter manufacturer. Note:
Mechanical overtightening can damage the
filter element.
WARNING 8. Operate the fuel lift pump to prime the fuel
Drain fuel filter into a container and dispose system by turning the ignition switch to the
of all fluids properly. RUN position, do not attempt to start the
engine. Cycle the lift pump several times by
turning the ignition switch to the OFF position,
waiting 10 seconds and turning the ignition
switch back to RUN again.
9. Start the engine and check for leaks. Refer to
STARTING ENGINE in SECTION 2 of the
OPERATOR'S MANUAL.

3.26
Tigercat 635C Skidder Lubrication and Maintenance
Changing the secondary fuel filter: FUEL TANK STRAINER
1. Park machine on level ground, install This is a stainless steel fuel strainer, screwed on to
articulation lock bar, lower dozer and grapple the inlet pipe of the engine fuel feed line inside at
to the ground, stop engine, engage parking the bottom of the fuel tank.
brake and block wheels.
Changing or cleaning the strainer:
2. Wipe clean the area around the filter and NOTE:
head. This should only be required if excessive
3. Use filter drain to drain fuel out of the filter for quantities of foreign material has built up
approximately 5 seconds. This will prevent inside the tank.
fuel from running over the top of the filter when 1. Park machine on level ground, install
it is removed. articulation lock bar, lower dozer and grapple
4. Disconnect the water in fuel sensor from the to the ground , stop engine, engage parking
wiring harness. brake and block wheels.
5. Place rags below to catch the spillage of fuel. 2. Drain the fuel tank. (plug in bottom)
6. Wearing face protection (in case of a fuel 3. Remove the round fuel tank cover plate and
spray) unscrew the old filter. Dispose of any “O” ring from the access hole.
fuel properly . 4. Before removing the strainer, clean any debris
7. Remove the water in fuel sensor from the fuel from the bottom of the tank and wipe it clean.
filter. Dispose of the fuel filter properly. 5. Remove the fuel strainer using the hex on the
8. Install the water in fuel sensor in the new filter. end of strainer. Carefully clean the strainer (it
(Inspect water in fuel sensor for damage and may be damaged by rough handling).
replace as required.) 6. Check for a buildup of foreign materials
9. Check the seating area for the o-ring on the where the strainer threads on to the pipe and
filter head and wipe clean. elbow.
10. Lubricate the o-ring on top of the new filter with 7. Reinstall the strainer using the hex on end.
clean engine oil. DO NOT PRE-FILL the new 8. Reinstall fuel tank cover plate with “O” ring.
filter.
9. Refuel and check for leaks. Start the engine
11. Screw the new filter on to the filter head as and check for leaks again.
specified by the filter manufacturer. Note:
Mechanical overtightening can damage the
filter element.
12. Connect water in fuel sensor to the wiring
harness.
13. Start the engine and check for leaks. Refer to
STARTING ENGINE in SECTION 2 of the
OPERATOR'S MANUAL.

3.27
Tigercat 635C Skidder Lubrication and Maintenance
HYDRAULIC OIL TRIPLE ELEMENT FILTERS Changing the filters:
1. Park machine on level ground, install
BLUE
ELEMENT articulation lock bar, lower dozer and grapple to
WATER
TRIPLE ABSORBING ground, stop engine, engage parking brake and
ELEMENT
FILTER SIGHT block wheels.
GAUGE
2. Wipe clean the area around the filter and head.

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

• 4. Wearing face protection (in case of an oil

spray), unscrew the old filter. Dispose of old
•
filter and any oil properly.
5. The new Tigercat filters are supplied with two
gaskets enclosed, examine the filter head
closely to determine which gasket should be
•• MAIN
used and follow the instructions to ensure
HYDRAULIC proper installation.
TANK
FILTER
•• HEAD
• •
•
CHARGE GASKET
AXLE PRESSURE
FILTER FILTER
• FILTER
HYDRAULIC TANK, FILTERS AND ELEMENT
635C-23 SIGHT GAUGE SQUARE SECTION GASKET INSTALLATION
FILTR_SEALS
The hydraulic oil cooling circuit contains a triple
filter head with a built in restriction indicator and a Square Section Gasket
25 psi (1.7 Bar) bypass valve. In the event of a Remove used gasket and clean groove in head.
clogged filter element or thicker oil on cold starts,
Apply clean oil to new gasket surfaces.
this bypass filter will open and redirect oil around
the filter element. When the filter elements Install new gasket into groove in filter head.
become restricted, the Red pop-up indicator will Screw on new filter until gasket makes contact.
show RED, indicating that the elements must be Tighten filter an additional 3/4 turn.
changed. It is recommended that all machines use
two different filter elements: DO NOT use bottom nut for filter installation or
damage/leakage may result. Bottom nut is to
2 white, Tigercat high performance, full flow assist in filter removal only.
hydraulic oil filter element
FILTER
1 blue, Tigercat water absorbing, full flow hydraulic HEAD
oil filter element. •
Refer to SCHEDULED MAINTENANCE and •
GASKET
SERVICE AND LUBRICATION POINTS in THIS
SECTION. • FILTER
ELEMENT

IMPORTANT
FILTR_SEALS 'O' RING GASKET INSTALLATION
Failure to service and replace filters at the
proper intervals specified in the z 'O' Ring Gasket
manufacturer's manuals, could cause damage Remove used gasket and clean gasket seat in
to the machine and result in the product head.
warranty becoming NULL and VOID. Check
Tigercat parts catalog for replacement filters. Apply clean oil to new gasket surfaces.
Install new gasket on inside lip of filter.

3.28
Tigercat 635C Skidder Lubrication and Maintenance
Screw on new filter until gasket makes contact.
Tighten filter until top edge makes metal to HYDRAULIC FILTER
metal contact with filter head. SERVICING GUIDELINES
(approximately 1 1/2 additional turns after
gasket contact) IMPORTANT
DO NOT use bottom nut for filter installation or
damage/leakage may result. Bottom nut is to
NEVER PRE-FILL
assist in filter removal only. HYDRAULIC FILTERS
6. Start the engine and check for leaks. Tigercat generally does not recommend the pre-
filling of spin-on filters due to the risk of damage to
CHARGE PRESSURE FILTER the hydraulic system caused by unfiltered oil.
The charge circuit contains a single element, full Unfiltered oil used to pre-fill filters enters directly
flow Tigercat hydraulic filter with a 50 psi (3.5 Bar) into the hydraulic circuit. Contaminants in unfiltered
third port bypass valve. When a restriction is oil can cause significant and costly damage to
encountered, the bypass valve diverts oil back to hydraulic valves, pumps and motors. The
tank via the third port to prevent unfiltered oil from cleanliness of hydraulic oil cannot be guaranteed
entering the charge circuit. unless it is always prefiltered before use.

AXLE PRESSURE FILTER

The hydraulic axle circuit is equipped with a full flow IMPORTANT
pressure filter with a 50 psi (3.5 Bar) third port Contaminated hydraulic fluid can lead to
bypass valve. When a restriction is encountered premature failure of hydraulic components
the bypass valve diverts oil back to the axle circuit and costly repairs. Filters must be replaced at
reservoir in the front axle to prevent unfiltered oil the recommended time intervals. Refer to
from entering the axle circuit. SCHEDULED MAINTENANCE in THIS
SECTION OF THIS MANUAL.
The axle return oil filters require changing every 500
Use of hydraulic oil filters other than the
hours and when repairing a leaking or failed axle.
Tigercat brand could lead to severe wear and
Changing a pressure filter: rapid failure of hydraulic system components.
1. Park machine on level ground, install
articulation lock bar, lower dozer blade to WARNING
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
spray), unscrew the filter.
WARNING, HOT HYDRAULIC OIL AND HOT
5. Drain filter and dispose of any oil properly. MACHINE SURFACES CAN CAUSE SERIOUS
6. Check the seating area on the filter head and BURNS!
wipe it clean.
• Before servicing the machine, allow the
7. This filter has an o-ring gasket. Replace o-ring hydraulic system and machine surfaces to
as required and apply hydraulic oil to the gasket cool down.
surface.
• Use a thermometer to check surface and
8. Screw on the new filter until the gasket makes system temperatures to ensure it is safe to
contact with the seat in the filter head. begin service work.
9. Hand tighten filter an additional 1/2 turn only.
• DO NOT begin service work until the
DO NOT use bottom nut for filter installation or surface or system temperature has cooled
damage/leakage may result. Bottom nut is to down to below 100°F (38°C)!
assist in filter removal only
10. Start the engine and check for leaks.

3.29
Tigercat 635C Skidder Lubrication and Maintenance
AIR CLEANER MAINTENANCE DISCHARGE
LOUVER
GUARD
(EARLIER
DESIGN
GUARD SHOWN)
•• •
•• INLET
AREA
INTAKE
AREA
•
••
AIR PRECLEANER
630C-14 (EARLIER MACHINES)

AIR INLET HOOD DISCHARGE

(EARLIER MACHINES) LOUVER
630C-234
GUARD
(LATER
DESIGN
SHOWN)
GUARD/
HOOD •• ••
INLET
•• AREA

•• EXTENSION ••
TUBE

• INTAKE
AREA
AIR PRECLEANER
630C-245 (LATER MACHINES)
AIR PRECLEANER (IF EQUIPPED)
AIR INLET HOOD The optional engine air precleaner cleans engine
630C-244 (LATER MACHINES) air before it reaches the air cleaner filter elements.
AIR INLET HOOD It removes contaminants such as dust, powder,
insects, rain and snow. The air precleaner should
The air inlet hood protects the air inlet from rain, be checked every 8 hours to make sure that
snow and debris. The air inlet hood should be foreign materials have not plugged the intake area
checked every 8 hours to make sure that foreign or the discharge louver area. Clean as required.
materials have not plugged air inlet area. Clean as
required.

3 3

630C-19 CENTRI® PRECLEANER OPERATION

3.30
Tigercat 635C Skidder Lubrication and Maintenance

IMPORTANT ENGINE ENGINE AIR

•
AIR PRECLEANER
The air inlet hood or air precleaner (if CLEANER
equipped) 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 630C-17 ENGINE AIR CLEANER
intake tube will lead to ingestion of dirt into
FILTER ENGINE
the engine which may result in engine failure. RESTRICTION AIR
INDICATOR 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.

IMPORTANT
For peak engine performance and maximum
fuel economy, please ensure that the air inlet
hood or air precleaner (if equipped) is
630C-15 ENGINE AIR CLEANER
regularly checked and cleaned as required.
All intake air tubes and clamps should be AIR CLEANER
thoroughly inspected on a regular basis and
any damaged or missing components should The air cleaner on this machine uses two filter
be replaced immediately. elements, a primary element and a safety element
accessible from the left side of the engine
OPERATION: compartment.
1. Air enters the precleaner. To ensure maximum engine protection, it is
2. Specially designed vanes move dirty air toward important that the elements be serviced correctly
the impeller. and at proper servicing intervals.
3. The spinning impeller spins the air creating A filter restriction indicator is mounted to the output
centrifugal force to separate contaminants side of the filter, this should show green when the
from the clean air. engine is running under load. Service is required if
4. Contaminants are blown out the discharge the indicator shows red. Later machines may be
louver. equipped with a filter restriction switch (not shown)
5. Clean air enters the intake to the air cleaner. used to send a signal to the computer control
system in the event of a filter restriction.

CAUTION
INSTALL AIR FILTER END CAP AS SHOWN

CLAMPING BOLT VERTICAL

UNLOADER VALVE IN THIS LOCATION

28047A R0

3.31 Continued on next page

Tigercat 635C Skidder Lubrication and Maintenance
Continued from previous page IMPROPER SERVICING
Engine exposure to dust during servicing is the
largest single reason for engine damage due to
dust.
UNLOADER VALVE
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.
OUTLET SAFETY
PRIMARY TUBE ELEMENT
630C-16 AIR CLEANER UNLOADER VALVE ELEMENT

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 630C-63 AIR FILTER ELEMENTS
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 SCHEDULED MAINTENANCE,
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.

3.32
Tigercat 635C Skidder Lubrication and Maintenance
IMPORTANT STEPS TO FOLLOW WHEN
CHANGING FILTER ELEMENTS
1. Release the cover latch gently to reduce the
amount of dust dislodged.
2. Avoid dislodging dust from filter element(s) by
gently pulling the element off the outlet tube.
3. Always clean the sealing surface of the outlet
tube before inserting a new filter element.
4. Always clean the inside of the outlet tube and
filter housing.
5. Check your old filter, It can help you detect
foreign material on the sealing surface that is
causing leakage.
NOTE: Filter elements should never be
cleaned and reused. Cleaning causes dust to
bypass the filter and be deposited on the inner
surface of the filter media. The dust is then
drawn directly into the engine.
6. Inspect the new filter for damage.
7. Insert the new filter properly. Apply pressure to
the outer rim of the filter not the flexible centre.
8. Check connections and ducts for air tight fit.
Ensure that all clamps, bolts and connections
are tight. Check rubber elbows for splits or
wear points Leaks here send dust directly to
the engine.

3.33
Tigercat 635C Skidder Lubrication and Maintenance
GRAPPLE SNUBBER MAINTENANCE

IMPORTANT
GREASE
All service points on snubbers must be FITTINGS
(1 PER
greased every shift (8 hours) to ensure a long • SNUBBER)
LINK
service life.

QUADCO MODEL 300 SNUBBER

USED ON TIGERCAT GRAPPLES
In this model the snubbers are independent of the
link. Separate snubbers provide snubbing action
in two directions. There 1 grease fitting on each
snubber for daily lubrication of the sleeves and
housings. Grapple installations use 4 model 300
SPRING
snubbers depending on the type of grapple and WASHER FRICTION
SLEEVE
yoke used. Be sure to lubricate all the grapple
snubbers on your machine. • ••
ADJUSTING SNUBBER TENSION
Tension is adjusted by tightening the end cap bolt. •
Tighten the end cap bolt only 1/2 turn at a time
until the desired tension is achieved.
Note: Overtightening may result in grapple •
stiffness and reduced friction sleeve life. Applying
too much pressure may press the spring washer END CAP BOLT
flat causing all tension to be lost.
CY045 QUADCO MODEL 300 SNUBBER

3.34
Tigercat 635C Skidder Lubrication and Maintenance
FRICTION SLEEVE REPLACEMENT
CROSS GROOVE
QUADCO MODEL 300 SNUBBERS POSITION LINED UP
WITH WEAR BLOCK
1. Park machine on level ground, install
articulation lock bar, lower dozer and grapple
to ground, stop engine, engage parking brake WEAR SLOT

• • ••
and block wheels. SPRING
WASHER
2. Remove the snubber end cap bolt, end cap,
bearing, spring washer and housing. END CAP • •• CORE
ASSEMBLY

3. Remove the friction sleeve from the core • •• FRICTION

SLEEVE
assembly using a pry bar on each side to
loosen it. Note: Loctite® is used for friction
• HOUSING

sleeve installation. Heat may be required to

loosen the sleeve for removal.
• BEARING

END CAP BOLT

4. Clean the core assembly to remove any CY045 QUADCO MODEL 300 SNUBBER
Loctite® residue.
5. Apply a thin coat of Loctite® 620 retaining
compound (or equivalent) to the core
assembly and to the inner side of the new
friction sleeve.
6. Position the friction sleeve so that the cross
groove will be lined up with the wear block
wear slot (Model 300) as shown. Push the
friction sleeve onto core assembly.
Check again to be sure the friction sleeve is
positioned correctly as shown. Correct
positioning of the cross groove is required to
ensure proper snubber lubrication and long
service life.
7. Apply moly-based grease to the outer friction
sleeve surface. Use a generous amount of
grease.
8. Reinstall the housing, spring washer, bearing,
end cap and end cap bolt.
9. Allow the Loctite® to cure for at least 30
minutes before operating the machine.

3.35
Tigercat 635C Skidder Lubrication and Maintenance
ESCO CRG SNUBBER ASSEMBLY
USED ON TIGERCAT GRAPPLES
In this model the snubbers are part of the link. Two
separate snubbers provide snubbing action in two
directions. There are 7 grease fittings on each
snubber assembly for daily lubrication. Be sure to
lubricate all the grapple snubbers on your
machine.
Proper lubrication prevents excessive clutch wear.

IMPORTANT
All service points on snubbers must be 625C-12 SNUBBER ASSEMBLY
greased every shift (8 hours) to ensure a long
service life.

ADJUSTING SNUBBER TENSION

Each snubber should be adjusted such that:
• It is capable of stopping the grapple within one
full swing.
Snubbers that are too loose can allow the
grapple to swing violently and cause damage
to the grapple and/or other machine
components.
• It is capable of holding the grapple at
approximately a 5° angle.
Snubbers that are overtightened can reduce
the effect of lubricating grease and cause
premature clutch wear.
PROCEDURE
Tension is adjusted by removing shims from the
snubber.
1. Park machine on level ground, install
articulation lock bar, lower dozer and grapple
to ground, stop engine, engage parking brake
and block wheels.
2. Remove one shim at a time to increase
snubber friction.
One split shim at a time can be removed from
each snubber without completely removing
the end caps. Remove 3 bolts on the left side
then loosen 3 bolts on the right side of the
snubber enough to separate the end cap from
the housing to remove one half of the shim.
Reinstall bolts and tighten in a crisscross
pattern.
3. Fill snubber with grease until grease comes
out the exhaust port.

3.36
Tigercat 635C Skidder Lubrication and Maintenance

SNUBBER
HOUSING

••

GREASE SPLINED
FILL PORT SHAFT

•• • •
GREASE
EXHAUST
PORT

FRICTION ALIGN TAB

PLATE
• ON SHIMS
WITH TAB ON
•• END CAP

REACTION
PLATE

•
•• ••
BELLEVILLE
WASHERS ••
•
SHIMS
•
O-RING ••
END CAP

625C-01 ESCO CRG SNUBBER ASSEMBLY

3.37
Tigercat 635C Skidder Lubrication and Maintenance
PRESSURIZED WATER SYSTEM SYSTEM TEST
MAINTENANCE This system should be tested once every month
WATER DOZER BLADE by turning the shut-off valve ON and expelling
•• CONTROL
VALVE • water from the hose end nozzle. A very forceful
discharge of water should be obtained. If the water
does not come out with force (with pressure gauge
• reading 60 psi) the system needs to be PURGED.
Refer to PURGING PRESSURIZED WATER
• SYSTEM in THIS SECTION.
WATER TANK 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
HOSE STORAGE
CHARGE procedure should be carried out yearly.
COMPARTMENT
FILL & CHARGE PRESSURIZED
WATER SYSTEM
635C-19
PRESSURIZED WATER SYSTEM 1. Open water shut off valve and completely
A water tank is incorporated into the dozer blade discharge all water and compressed air from
and is pressurized to 60 psi (4 Bar) . A valve the tank via the hose end nozzle.
controls the flow of water from the tank to a hose
located in the hose storage compartment on the CAUTION
dozer blade. Tank capacity is 13.7 US gal (52 L). Never remove fill plug before depressurizing
The control valve incorporates an air charge valve, tank or injury may result. This fill plug
a pressure gauge and a relief valve on the outlet incorporates a vent hole to release air
side of the valve. A ball valve is installed on the pressure from the tank before the threads
outlet side of the valve and is used to shut off the disengage. Do not replace this fill plug with
water supply to the hose. This ball valve should be any substitute.
in the OFF position when the system is not in use.
2. Slowly unscrew fill plug two full turns. Any
The pressure gauge on the valve should read remaining air in the tank will be heard expelling
60 psi(4 Bar) check system pressure daily. from the special fill plug. Do not remove fill
plug until all air has been expelled.

WATER TANK

PRESSURE FILL PLUG

GAUGE

OUTLET
•• CONNECTION
•
•
•• •
AIR CHARGE •• DOZER BLADE
VALVE •
WATER SHUT-OFF 150-8A PRESSURIZED WATER SYSTEM
VALVE (SHOWN OFF)

620C-42 WATER CONTROL VALVE 3. Close water shut off valve.

Refer also to FIRE PREVENTION in SECTION 1 4. Fill tank with clean water.
of THIS MANUAL. When temperatures below 32°F (0°) are
anticipated, use a 60/40 solution of Nontoxic
R. V. Antifreeze or other suitable antifreeze.
Antifreeze solution must meet GM 6038M
specifications.

3.38
Tigercat 635C Skidder Lubrication and Maintenance
NOTE: Most Nontoxic R.V. Anti freeze PURGING PRESSURIZED WATER SYSTEM
solutions contain corrosion and algae
inhibitors, it is therefore suggested that this Purging should be carried out whenever the flow of
solution be added to the water on a continual water does not forcefully discharge from the end
basis regardless of temperature conditions. of the hose with the pressure gauge reading 60 psi
(4 Bar).
5. Install fill plug in tank.
1. Open water shut off valve and completely
NOTE: This is a special plug designed to discharge all water and compressed air from
withstand pressurization of the water tank. the tank via the hose end nozzle.
Do not substitute.
6. Pressurize the system to 60 psi (4 Bar) as CAUTION
indicated on pressure gauge by connecting an
air hose to air charge valve beside the Never remove fill plug before depressurizing
pressure gauge. tank or injury may result. This fill plug
incorporates a vent hole to release air
7. Open the water shut off valve. pressure from the tank before the threads
8. Discharge about 1/2 US gal (2 L) of fluid into disengage. Do not replace this fill plug with
an empty antifreeze jug or other suitable any substitute.
container. 2. Slowly unscrew fill plug two full turns. Any
There will be significant foaming as the fluid is remaining air in the tank will be heard expelling
discharged into the jug. Continue until a very from the special fill plug. Do not remove fill
forceful flow is obtained and any plug until all air has been expelled.
contamination that may have been in the tank 3. Close the water shut off valve and add
is flushed from the system. 2 US gal (8 L) of CLEAN water to the tank.
9. Check fluid in the jug for contamination. If fluid 4. Install the fill plug
is dirty dispose of it properly.
NOTE: This is a special plug designed to
10. Close the water shut-off valve. withstand pressurization of the water tank.
11. Release pressure and fluid from the hose. Do not substitute.
12. Pressurize the system to 60 psi (4 Bar) as 5. Pressurize the system to 60 psi (4 Bar) as
indicated on pressure gauge by connecting an indicated on pressure gauge by connecting an
air hose to air charge valve beside the air hose to air charge valve beside the
pressure gauge. 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.

3.39
Tigercat 635C Skidder Lubrication and Maintenance
CHECKING THE AIR CONDITIONING
SYSTEM IMPORTANT
Any service work must be performed by It is recommended that during cold weather
authorized A/C technicians. The system should when the A/C system is not in use, that it be
be charged with R134a refrigerant only. PAG run for a period of 5 minutes every 2 weeks.
(polyalkeylene glycol) oil should be present in the This will circulate oil to all components of the
system and must be used on 'O' rings and fittings A/C system.
during assembly.

A/C SYSTEM TOTAL CAPACITIES CAUTION

R134a REFRIGERANT PAG OIL Use compressed air for cleaning only when
(polyalkylene glycol) the machine is cold to avoid the risk of fire
1.59 kg (3 lbs 8 oz) 0.25 kg (9 oz) caused by debris contacting hot surfaces.
If using compressed air for cleaning, use at
The compressor and charge valves are accessed 30psi or less.
from the left side engine compartment. The Always use personal protective equipment
receiver dryer is mounted in the compartment to guard against flying debris.
behind the right cab door, on the outside of the
cab.
CAUTION
Perform following inspection along with 125
Avoid the risk of fire caused by debris
HOURS inspection outlined in SCHEDULED
accumulating on surfaces that may become
MAINTENANCE in THIS SECTION.
hot during machine operation. Always use
a. Check re-circulating and fresh air filters in care when cleaning to ensure that debris
operator's cab. Refer to SECTION 2 of the removed from one area of the machine does
OPERATOR'S MANUAL. not accumulate on other areas of the
machine.

i. Check to see that compressor clutch will

•• engage.*

SIGHT GLASS
CHECK A/C INDICATES
CONDENSER CONDITION OF
CORE CHARGE
•
•• BINARY SWITCH,
CHECK A/C SYSTEM
PROTECTION
630C-62 CONDENSER CORE
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
MOISTURE INDICATOR
coil located inside the A/C-heater unit and also BLUE - OK.
PINK - REPLACE DRYER,
the inside of the A/C-heater unit. Clean as RECHARGE SYSTEM
required.
d. Check and adjust compressor drive belt
tension. •
e. Check all A/C hoses for kinks.*
f. Run air conditioning system for 3 - 5 minutes. A/C RECEIVER/DRYER

g. Check air temperature exiting vents in cab.

h. Listen to compressor and blower motor for
abnormal noises.* 870-D43 A/C RECEIVER/DRYER
3.40
Tigercat 635C Skidder Lubrication and Maintenance
j. 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.

3.41
Tigercat 635C Skidder Lubrication and Maintenance
TILTING THE HOOD AND CAB OPENING THE TILT OUT HOOD
1. Position the Skidder on level ground.
WARNING
2. Lower the Grapple and Dozer to the ground.
Before tilting the cab or hood, ensure that the
machine is parked on level ground. Lower the 3. Engage parking brake and turn ignition off.
dozer blade and grapple on to the ground. 2 BOLTS (ONE ON
EACH SIDE)
Engage the parking brake and turn the SECURE HOOD
IN PLACE DURING
ignition switch off. OPERATION
MAINTENANCE
A single hand pump is used to tilt both the hood ACCESS PANEL

and the cab. The tilt out hood and cab tilt functions
can be performed together or separately. ••
To operate both the tilt out hood and cab tilt
functions together ensure that the tilt out hood
locking bolts, cab securing pins and canopy sweep
bolts have been removed. Refer to TILTING THE
••
HOOD and TILTING THE CAB in THIS SECTION.
When the two functions are performed together
the hood open/close function will occur first 635C-14 TILT OUT HOOD - CLOSED
followed by the cab raise/lower function. 4. Ensure that the quick access door located on
To operate the tilt out hood function only ensure the left side of the tilt out hood is securely
that the cab locking pins are securely in place. latched and remove the hood securing bolts (2
Refer to TILTING THE HOOD in THIS SECTION. bolts).

To operate the cab tilt function only ensure that the 5. Open the lower compartment door in the right
tilt out hood securing bolts are securely in place. hand step below the cab door to access the
Refer to TILTING THE CAB in THIS SECTION. hood and cab tilt hand pump.

PUMP HANDLE

PUMP LEVER
SHOWN IN
• "RAISE"/"OPEN"
POSITION
• ••

PUMP

HAND PUMP FOR

630C-60 HOOD TILT AND CAB TILT

The hood and cab tilt circuit is closed and does not
normally require scheduled maintenance other PUMP CONTROL LEVER IN
than lubrication of cylinders and pivot points. 630C-137 RAISE CAB/OPEN HOOD POSITION
Tigercat recommends the use of DEXTRON III
TYPE transmission fluid in this circuit (total circuit 6. Turn the lever on the pump manifold to RAISE
capacity 2 L [0.5 US gal]). The fill port is located (pointing in).
on the pump.
CAUTION
Keep hands away from the locking bolt area.

7. Insert handle into pump and pump in a steady

manner to raise the hood to the tilt out
position. The pump handle is stored on the
inside of the access door.

3.42
Tigercat 635C Skidder Lubrication and Maintenance
CLOSING THE TILT OUT HOOD
QUICK
ACCESS 1. Clear the area under the hood of obstructions.
DOOR
and secure all lines and wires.
••

PUMP LEVER

HYDRAULIC
• SHOWN IN
"LOWER"/"CLOSE"
POSITION
HOOD TILT
CYLINDER
•
635C-12 TILT OUT HOOD - OPEN

8. The tilt out hood should ALWAYS be opened

FULLY. The hydraulic cylinder is used to open
and close the hood and must not be used as a
support.
PUMP CONTROL LEVER IN
630C-138 LOWER CAB/CLOSE HOOD POSITION
CAUTION
2. Turn the lever on the pump manifold to
Always open tilt out hood FULLY, hood tilt LOWER (pointing out)
cylinder fully extended, to ensure the hood is
properly supported. Never work under an 4. Pump the handle in a steady motion to close
object supported by hydraulics. the hood.

CAUTION
Keep hands away from engine enclosure area
as hood is being lowered.
5. Watch closely for pinching of lines and wires.
6. When fully lowered, insert hood securing bolts
and tighten (2 bolts).
7. Turn the lever on the pump manifold inwards
and store the pump handle on the access
door.
Continued on next page

3.43
Tigercat 635C Skidder Lubrication and Maintenance
Continued from previous page 6. Open the lower compartment door in the right
RAISING THE CAB hand step below the cab door to access the
cab tilt hand pump.
1. Position the Skidder on level ground.
2. Lower the Grapple and Dozer to the ground.
3. Engage parking brake and turn ignition off.
PUMP LEVER
4. Remove the canopy sweep bolts at the cab. SHOWN IN
"RAISE"/"OPEN"
(4 bolts) POSITION

5. Remove the right side Cab Locking Pins. (2

•
pins) This is done by first removing the
locking bolts. (2 bolts)
CANOPY
SWEEP
BOLTS

•
•
PUMP CONTROL LEVER IN
630C-137 RAISE CAB/OPEN HOOD POSITION

7. Turn the lever on the pump manifold to RAISE

(pointing in).
8. Insert handle into pump and pump in a steady
manner to raise the cab to the tilt position.
630C-46
The pump handle is stored on the inside of the
access door.

CAUTION
Keep hands away from the locking pin area.
As the cab passes "top dead centre" it will
slowly move on its own to the full extent of
the safety cable. DO NOT PUMP BEYOND
LIMIT OF SAFETY CABLE.

9. Insert CAB SUPPORT BRACE for partial tilt.

Secure brace at each end with the cab locking
630C-48X pins. Full tilt is limited to the length of the
safety cable and is beyond centre of gravity.
The cab will stay at this limit provided Skidder
is on level ground.

WARNING
• •
Before working under cab;
Machine must be parked on level ground.
CAB LOCKING PINS AND BOLTS
Cab must be fully tilted with safety cable
630C-47
completely tight, or cab support brace must
be installed.

3.44
Tigercat 635C Skidder Lubrication and Maintenance

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.
LOWERING THE CAB
1. Clear the area under the cab of obstructions
and secure all lines and wires.
2. If the Cab Support Brace was used, you may
have to take the weight off of it by slightly
CAB SUPPORT BRACE raising the cab before removing it.
311-13 STORED UNDER SEAT

CAB
CAB SUPPORT
BRACE (3291B).
LOCKING
PIN •
MUST USE CAB & PUMP LEVER
CHASSIS LUGS SHOWN IN
SHOWN "LOWER"/"CLOSE"
POSITION
•
•
ARTICULATION
LOCK CAB
LOCKING
PIN ••
PARTIAL TILT WITH
630C-124 •• CAB SUPPORT BRACE PUMP CONTROL LEVER IN
LOWER CAB/CLOSE HOOD POSITION
630C-138

3. Turn the lever on the pump manifold to

LOWER (pointing out)
CAB SAFETY
CABLE (3361B)
CAUTION
Keep hands away from the locking pin area as
the cab is being lowered.
••
4. Pump the handle in a steady motion lower the
cab.
ARTICULATION
LOCK 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)
CAB AT FULL TILT SUPPORTED
630C-126 BY SAFETY CABLE 7. Turn the lever on the pump manifold inwards
and store the pump handle on the access door.
8. Close and lock the lower door.
WARNING
9. Replace the Canopy Sweep Bolts. (4 bolts)
If cab safety cable is damaged or lost, it must
be replaced immediately with Tigercat PART
NO. 3361B. DO NOT attempt to work under a
raised cab supported only by the hydraulic
cylinder or a substitute device.
3.45
Tigercat 635C Skidder Lubrication and Maintenance
ARTICULATION LOCK
1. Position machine on level ground and steer
machine into a straight ahead position.
2. Lower grapple and dozer blade to the ground,
engage parking brake, stop engine and
remove ignition key.

ARTICULATION
LOCK

•
•
RETAINING PINS
•
REAR CHASSIS

ARTICULATION LOCK
630C-52 STORED POSITION

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

ARTICULATION LOCK
630C-51 IN LOCKED POSITION

3.46
Tigercat 635C Skidder Lubrication and Maintenance
CENTER JOINT
MAINTENANCE OF CENTER JOINT
Maintenance in this area is usually limited to:
a) Regular lubrication of the two center joint
grease fittings to purge the pivot bearings of
debris and water. Refer to SERVICE AND
LUBRICATION POINTS in THIS SECTION for
lubrication intervals. Use only high quality,
lithium based EP2 grease containing
molybdenum disulphide.
b) Visually checking the center joint pivot for
looseness every 48 hours. With an observer
on the ground, keeping well clear of the center
joint area, perform the following test to check
for looseness of center joint.
1. Have operator lift the dozer blade off the
ground and then rapidly raise and lower
blade several times to "bounce" machine.
2. As machine bounces, check for motion
between the front and rear chassis frame
lugs. Also check for a "clunking" sound at
the center joint area.
3. Movement between front and rear chassis
lugs or clunking of the pivot indicates a
loose joint and preload must be checked.
Refer SECTION 11 of the SERVICE
MANUAL for more information.

REAR
CHASSIS

CHECK FOR
MOVEMENT IN FRONT
THIS JOINT AREA CHASSIS

DIG-003
CENTER JOINT PRE-LOAD CHECK

3.47
Tigercat 635C Skidder Lubrication and Maintenance
WINCH MAINTENANCE - ALLIED ONLY MAINTENANCE
LUBRICATION Maintenance of the winch is limited to the hydraulic
system maintenance of the skidder itself.
Refer to the manufacturer's maintenance and
service manual for information on your winch. Periodically check the winch, control valve, and
connecting hoses for damage or hydraulic oil
The sump holds 1.0 U.S. Gal. (3.8 litres).
leakage. If any problems are found, they should be
The oil supplied is Esso Hydraul 56 (Summer) or corrected before operating the winch.
Esso Hydraul 50 (Winter). Use these oils or the
equivalent.
Oil should be changed every 1000 hrs, depending
on use.
The oil level should be checked every day (if the
winch is being used) before starting the machine.

AIR BREATHER/FILLER CAP

•
ADJUST THE WINCH
630C-08 FREESPOOL TENSION

ADJUST THE WINCH FREE-SPOOL TENSION

If the winch cable requires too little effort to pull it
from the cable drum, the tension can be adjusted
172- WINCH LUBRICATION as follows:
6
• Loosen the lockscrew.
• Tighten the adjusting nut to increase the
• tension and/or loosen it to decrease it.
• Tighten the locknut.
OIL LEVEL PLUG
172-8

The oil level should be up to the oil level check

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

3.48
Tigercat 635C Skidder Lubrication and Maintenance
CABLE
RETAINER CABLE
PLATE GROOVE

•• ••

INSTALLING THE WINCH MAINLINE

INSTALLING THE WINCH MAINLINE

WARNING
Installing the winch mainline as follows will
provide a safety break-away feature. If the
load should fall down a hillside, the operator
should IMMEDIATELY put the winch control in
FREESPOOL position. This will allow the
cable to unwind freely from the cable drum
and break away from the winch, preventing
the machine from being pulled over.

• Start the engine and rotate the winch cable

drum so that the cable and ferrule groove in
the inside, left hand wall of the drum is at the
top and shut down engine.
• Remove the cable retainer plate capscrews
and retainer plate from the cable drum.
• Insert the cable ferrule into the groove in the
drum and hold the cable against the drum.
• Install the retaining plate and capscrews to
hold the cable in place.
• Start the engine and winch in the cable onto
the drum.

3.49
Tigercat 635C Skidder Lubrication and Maintenance
REAR (BOGIE) AXLE DIFFERENTIAL AND BOGIE HOUSINGS
(6350501 TO 6350534) (1 FILLING POINT)
The bogie axle has 5 separate oil reservoirs. Each 1. Note that the bogie housings must be level to
reservoir must be filled separately to get the drain and refill them properly.
proper level of lubrication in the bogie axle.
2. Before draining the oil from the bogie
Refer to SERVICE AND LUBRICATION POINTS housings, the axle should sit for at least 30
CHART in THIS SECTION for differential oil minutes so that contaminants in the oil can
capacity and recommended gear oils. settle in the oil pan.
DRAINING AND REFILLING 3. Remove the DIFFERENTIAL AND BOGIE
BOGIE AXLE HOUSINGS FILL/LEVEL PLUG.
• Park the machine on level ground. 4. Remove the BOGIE HOUSING DRAIN
PLUGS (2 per housing – lower plugs) and
• Stop the engine and engage parking brake.
drain the oil into a suitable container for
• The bogie axle must be level in order to drain disposal.
and refill it properly.
5. Remove the DIFFERENTIAL DRAIN PLUG
• Note that it will be necessary to reposition the and drain the oil into a suitable container for
wheel hubs when draining and refilling the disposal.
planetary drives.
6. Clean any fillings from the five drain plugs.
• The oil must be warm before draining and
7. Replace the DIFFERENTIAL DRAIN PLUG
refilling.
and the BOGIE HOUSING DRAIN PLUGS (2
• Clean around all fill, level and drain plugs per housing – lower plugs)
before removing them.

•
DIFFERENTIAL AND
BOGIE HOUSINGS
FILL/LEVEL PLUG
•• (1 PLACE)

PLANETARY
FILL PLUG
(4 PLACES)
BOGIE HOUSING
DRAIN PLUG
(4 PLACES - LOWER) •
PLANETARY
LEVEL/DRAIN
PLUG
(4 PLACES) •• WHEEL HUB IN
PLANETARY
FILL POSITION

635C-18 BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

3.50
Tigercat 635C Skidder Lubrication and Maintenance
8. Refill the differential and bogie housings with
new oil until the level reaches the bottom of the
DIFFERENTIAL AND BOGIE HOUSINGS
FILL/LEVEL PLUG.
Refer to SERVICE AND LUBRICATION
POINTS CHART in THIS SECTION for oil
capacity. Refer to Bogie Axle Service and
Repair Manual for recommended gear oils.
9. Replace the DIFFERENTIAL AND BOGIE
HOUSINGS FILL/LEVEL PLUG.
PLANETARY DRIVES (4 FILLING POINTS)
10. Position the wheel hub for draining the
planetary, with the drain plug in the lowest
possible position as shown.
11. Remove the PLANETARY FILL PLUG.
12. Remove the PLANETARY DRAIN/LEVEL
PLUG and drain the oil into a suitable
container for disposal.
13. Reposition the wheel hub for filling the
planetary, with the PLANETARY DRAIN/LEVEL
PLUG at 9 o’clock and the fill plug at 1 o’clock
as shown.
14. Refill the planetary with new oil until the level
reaches the bottom of the PLANETARY
DRAIN/LEVEL PLUG. (Note: To get a correct
filling level the wheel hub must be in the
planetary fill position as shown.)
Refer to SERVICE AND LUBRICATION
POINTS CHART in THIS SECTION for
differential oil capacity. Refer to Bogie Axle
Service and Repair Manual for recommended
gear oils.
15. Repeat steps 10 to 14 for each of the four
planetary drives.
AFTER DRAINING AND REFILLING
16. Check all drain, fill and level plugs for leaks.

3.51
Tigercat 635C Skidder Lubrication and Maintenance
REAR (BOGIE) AXLE BOGIE AXLE FILL (3 FILLING POINTS)
(6350535 & UP) 1. Note that the bogie housings must be level to
The bogie axle oil reservoirs (differential, bogie drain and refill them properly.
housings and planetaries are all connected and 2. Before draining the oil from the bogie
can be are at 3 locations to get the proper level housings, the axle should sit for at least 30
of lubrication in the bogie axle. minutes so that contaminants in the oil can
Refer to SERVICE AND LUBRICATION POINTS settle in the oil pan.
CHART in SECTION 3 for differential oil capacity 3. Remove the DIFFERENTIAL FILL/LEVEL
and recommended gear oils. PLUG and the BOGIE HOUSINGS FILL/
DRAINING AND REFILLING LEVEL PLUGS (1 per housing).
BOGIE AXLE 4. Remove the BOGIE HOUSING DRAIN
• Park the machine on level ground. PLUGS (2 per housing) and drain the oil into
a suitable container for disposal.
• Stop the engine and engage parking brake.
5. Remove the DIFFERENTIAL DRAIN PLUG
• The bogie axle must be level in order to drain and drain the oil into a suitable container for
and refill it properly. disposal.
• Note that it will be necessary to reposition the 6. Clean any filings from the five drain plugs.
wheel hubs when draining and refilling the
planetary drives. 7. Replace the DIFFERENTIAL DRAIN PLUG
and the BOGIE HOUSING DRAIN PLUGS (2
• The oil must be warm before draining and per housing – lower plugs)
refilling.
8. Refill the differential and bogie housings with
• Clean around all fill, level and drain plugs new oil until the level reaches the bottom of
before removing them. the FILL/LEVEL PLUGS.
Refer to SERVICE AND LUBRICATION
POINTS CHART in SECTION 3 for
differential oil capacity and recommended
gear oils.

••
DIFFERENTIAL
•
FILL/LEVEL PLUG
(1 PLACE)

• BOGIE HOUSINGS
FILL/LEVEL PLUG
(2 PLACES)

BOGIE HOUSING
DRAIN PLUG
(4 PLACES )

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

625C-94 (6350535 & UP)

3.52
Tigercat 635C Skidder Lubrication and Maintenance
9. Replace the DIFFERENTIAL FILL/LEVEL
PLUG and the BOGIE HOUSINGS FILL/
LEVEL PLUGS.
10. Check all drain, fill and level plugs for leaks.
11. Run axle for at least 10 minutesto remove
trapped air in confined spaces.
12. Recheck oil level and top up as necessary.

SLEW BEARING LUBRICATION -

BOGIE AXLES
The slew bearing has a lifetime lubrication in the BOGIE 2
raceway grease chamber and needs no service.
The only service work is the replacement of soiled Then open the opposite outlet plug (also pos. 92
grease in pre-chamber (buffer chamber). covered with white plastic cap).
Grease with a hand grease gun, at both grease
nipples per side, until grease squeezes out thumb
wide from the outlet opening (pos. 92). Then close
this outlet hole with plug and cap.
Grease with a hand grease gun, at both grease
nipples per side. When grease squeezes out from
buffer grease
the gap, the gap has sealed itself with grease all
chamber
the way around the circumference. Leave the
excess grease built up to protect against dirt.
Cover the grease nipples with plastic caps.

BOGIE 1

Clean the area around the grease nipples and

outlet plugs (pos. 90/92).

BOGIE 3

Open outlet plug, first the one on side A (pos. 92;

covered with white plastic cap).
Fill at both grease nipples per side (pos. 90;
covered with white plastic caps) standard grease.
Lubricate with hand grease gun until grease
squeezes out thumb wide from the outlet opening
(pos. 92). Then close this outlet hole with plug and
cap.

3.53
Tigercat 635C Skidder Lubrication and Maintenance
FRONT AXLE OIL LEVEL CHECK FRONT AXLE OIL LEVEL CHECK
AND AXLE CIRCUIT FILL 1. Park machine on level ground, install
The 635C is equipped with an axle hydraulic circuit articulation lock bar, lower dozer blade to the
which is completely separate from all other ground, stop engine, engage parking brake
hydraulic circuits. The front axle acts as a and block wheels. Place drain pan or other
reservoir for the axle hydraulic circuit. suitable container under the front axle.
Always keep the axle hydraulic circuit filled to the FILL LEVEL PLUGS
correct level. A low axle hydraulic oil level can
result in severe damage to the axle pump.
Refer also AXLE CIRCUIT RESERVOIR - FRONT •• •
AXLE in SECTION 2 of THE OPERATOR'S
MANUAL.
Before starting work, read and follow all “servicing
safety precautions” as listed in SECTION 1 of
FRONT AXLE OIL LEVEL FILL PLUGS
THIS MANUAL. 630C-132

Refer to APPROVED HYDRAULIC OILS ~ AXLE 2. Using a 1/2” square drive bar, remove one of
CIRCUIT in THIS SECTION for a list of approved the fill level plugs from the front axle.
hydraulic oils. *NOTE: Some later SWEDA front axles are
equipped with a dipstick to check oil level.
IMPORTANT 3. Oil level should reach the bottom of the oil fill
level plug (* or lowest dipstick marking if
Note that the 635C skidder has two separate equipped. Note that a slight overfill indicated
hydraulic systems (the main hydraulic by the dipstick is OK if the level plug indicates
system and the axle circuit). These two OK).
hydraulic systems require two different types
of hydraulic oil that MUST NOT BE If the oil is correct :
INTERCHANGED under any circumstances. Re-plug the fill level hole. Proceed to Step
Always use the correct type of hydraulic oil 14.
for the circuit you are filling. Refer to If the oil is too high:
APPROVED HYDRAULIC OILS in THIS
SECTION. Let the oil drain out of the axle until the
level is correct. Re-plug the fill level hole.
Perform this procedure only when the axle is cold. Proceed to Step 14.
If the oil is too low:
Oil must be added. Continue with the
procedure.
If you have an oil fill pump follow steps 4 through
8.
If you are filling from gallon or quart jugs follow
Steps 9 through 13.

Dispose of all fluids properly.

DIPSTICK

•• *NOTE:
SOME LATER SWEDA
FRONT AXLES ARE
EQUIPPED WITH A
DIPSTICK TO CHECK
OIL LEVEL.

LATER SWEDA AXLE WITH DIPSTICK

620C-103 FRONT AXLE ONLY
3.54
Tigercat 635C Skidder Lubrication and Maintenance
FILLING FRONT AXLE CIRCUIT FILLING FRONT AXLE CIRCUIT
USING AN OIL FILL PUMP WITHOUT AN OIL FILL PUMP
NOTE: This filling procedure should be used only NOTE: This filling procedure should be used only to
to top up the axle hydraulic oil level. If differential top up the axle hydraulic oil level. If differential lock
lock function has been affected by extremely low function has been affected by extremely low axle
axle hydraulic oil levels refer to FRONT AXLE OIL hydraulic oil levels refer to FRONT AXLE OIL FILL in
FILL in SECTION 15 of the SERVICE MANUAL for SECTION 15 of the SERVICE MANUAL for a more
a more detailed filling procedure. detailed filling procedure.

HIGH FLOW REMOVE AND

RETURN LINE CAP SUCTION
(BETWEEN LINE AND INSERT
FRONT AXLE FUNNEL HERE
AND BULKHEAD)

NOTE 630C

•
SHOWN SOME
HOSES SHOWN
•
ARE NOT USED
ON 635C
FILLING AXLE CIRCUIT MODEL
630C-235 USING AN OIL FILL PUMP FILLING AXLE CIRCUIT
4. Disconnect the high flow return line (between 630C-151
WITHOUT AN OIL FILL PUMP
front axle and bulkhead) at the bulkhead. Cap
the bulkhead fitting to avoid contamination of 9. Disconnect the axle pump suction line at the axle
the axle hydraulic circuit. cover bulkhead as shown.

5. Connect the line from the oil fill pump to the 10. Cap the hose to avoid contamination of the axle
return line. hydraulic circuit.

6. Pump oil into the front axle until it begins to 11. Using a funnel with a flexible hose, use gallon or
flow from the fill level hole. quart jugs to add oil to the axle until it begins to
flow from the fill level hole.
Oil level should reach the bottom of the oil fill
level plug. Oil level should reach the bottom of the oil fill
level plug.
7. Re-plug the fill level hole.
12. Re-plug the fill level hole.
8. Proceed to Step 14.
NOTE 630C
SHOWN SOME
HOSES SHOWN
ARE NOT USED
ON 635C
MODEL

•
630C-152 FILL SUCTION LINE

13. Fill the suction line with as much oil as possible.

COMPLETING THE PROCEDURE
14. Reconnect all hoses disconnected during this
procedure. Care should be taken to ensure all
hoses and fittings are kept clean to avoid
contamination of the hydraulic circuit.
15. Replace all pans and panels.

3.55
Tigercat 635C Skidder Lubrication and Maintenance
STARTUP PROCEDURE AFTER MAJOR • Watch for oil leaking from tee connection and
MACHINE MAINTENANCE reconnect case drain line when oil leaks out.
(6350501 TO 6350530)
• Prepare the hand fill pump on the machine to
This procedure should be followed: add hydraulic oil. Clean the fill line pipe,
• after major service or a rebuild. remove cap on end of pipe and insert pipe into
oil supply drum.
• whenever the machine has been drained of
hydraulic oil. LOOSEN
FITTING
• 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, front axle (axle circuit
reservoir ), winch (if equipped) and cab/hood
tilt system.
3. Check coolant level in the radiator. LOOSEN FITTING
4. Do a final inspection of all fittings and clamps 635C-21
LEFT HAND DRIVE MOTOR
to make sure they are tight and will not leak.
• Loosen the fitting on the top of the left hand
5. Install the articulation lock bar and engage the
drive motor.
parking brake.
6. Turn differential lock switch to OFF. LOOSEN
FITTING DRIVE
7. Do not start engine. Purge air from hydraulic PUMP
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 TEE

MAKE-UP LINE CONNECTOR
LOOSEN FITTING ON DRIVE PUMP
635C-11 (EARLIER DRIVE PUMP)

•• • LOOSEN
• FITTING
DRIVE
PUMP

OIL FILL LINE

•
RIGHT HAND DRIVE MOTOR
620C-46 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.
630C-238 LOOSEN FITTING ON DRIVE PUMP

• Loosen fitting on drive pump.

3.56
Tigercat 635C Skidder Lubrication and Maintenance
• Operate the hand fill pump at medium speed, MACHINE STARTUP
using a steady motion.
Before beginning this procedure, perform the
• Watch for oil leaking from each plug/fitting PRE-STARTUP AND FILLING steps.
previously loosened and tighten each plug/
fitting when oil leaks out. CAUTION
• Continue pumping slowly and watch the oil Machine operator must ONLY take directions
sight gauge on the reservoir. Continue from the person doing the set-up.
pumping slowly until the hydraulic tank is full.
1. Ensure the articulation lock bar is installed.
NOTE: If the axles were drained of oil, refer to
AXLE OIL FILL AND BLEED in SECTION 15 of
THE SERVICE MANUAL.
12-PIN CONNECTOR

ENGINE 12 PIN CONNECTOR

635C-16 (GROUND BUSBAR)

2. Disconnect 12 pin connector (ground

busbar) on engine (prevents engine starting).
3. Crank engine for 10 seconds, wait for 10
seconds. Repeat 6 times to pump oil into
pumps.

IMPORTANT
Note that the 635C skidder has two separate
hydraulic systems (the main hydraulic system
and the axle circuit). These two hydraulic
systems require two different types of
hydraulic oil that MUST NOT BE
INTERCHANGED under any circumstances.
Always use the correct type of hydraulic oil
for the circuit you are filling. Refer to
APPROVED HYDRAULIC OILS in THIS
SECTION.

4a. Check hydraulic oil levels in the main hydraulic

tank and add hydraulic oil as required.
4b. Check axle circuit reservoir oil level (in front
axle) and add hydraulic oil as required. Refer
to AXLE OIL LEVEL CHECK AND AXLE
CIRCUIT FILL in THIS SECTION.
5. Reconnect 12 pin connector (ground
busbar) on engine.

Continued on page next page

3.57
Tigercat 635C Skidder Lubrication and Maintenance
Continued from previous page 11. Top up the radiator with clean coolant.
6. Start engine. 12. With cylinders fully retracted, top up the main
hydraulic oil reservoir with clean hydraulic
7. Check for leaks.
oil.
13. Top up the front axle with clean oil.
DRIVE NOTE: If the machine was on wheels, the steer
PUMP
and drive functions were not properly purged or
flushed. Remove the articulation lock bar and at
LOW IDLE, slowly operate the steer function right
CONNECTORS • 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.

DISCONNECT TWO CONNECTORS

ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
635C-11
(EARLIER DRIVE PUMP)

CONNECTORS ARE
LOCATED ON THE
BOTTOM OF PUMP.
PUMP SHOWN WITH
HOSES REMOVED
FOR CLARITY CONNECTORS
(2 PLACES)

•
DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
(LATER DRIVE PUMP)

8. Bleed brakes (front 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, parking brake ON, hold
foot brake down, bleed brakes in front axle
(both sides). Refer also to AXLE ~ SERVICE
BRAKES ~ BRAKE BLEEDING in SECTION
15 of the SERVICE MANUAL.
Reconnect two connectors on drive pump.
9. Set throttle to IDLE and run each function for 2
minutes to purge air from circuit.
10. Set throttle to FULL and run each function
again for 2 minutes to flush circuit.

3.58
Tigercat 635C Skidder Lubrication and Maintenance
STARTUP PROCEDURE AFTER MAJOR • Watch for oil leaking from tee connection and
MACHINE MAINTENANCE reconnect case drain line when oil leaks out.
(6350531 AND UP)
• Prepare the hand fill pump on the machine to
This procedure should be followed: add hydraulic oil. Clean the fill line pipe,
• after major service or a rebuild. remove cap on end of pipe and insert pipe into
oil supply drum.
• whenever the machine has been drained of
hydraulic oil. LOOSEN
FITTING
• 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, front axle (axle circuit
reservoir ), winch (if equipped) and cab/hood
tilt system.
3. Check coolant level in the radiator. LOOSEN FITTING
4. Do a final inspection of all fittings and clamps 635C-21
LEFT HAND DRIVE MOTOR
to make sure they are tight and will not leak.
• Loosen the fitting on the top of the left hand
5. Install the articulation lock bar and engage the
drive motor.
parking brake.
• Loosen fitting on drive pump.
6. Turn differential lock switch to OFF.
• Operate the hand fill pump at medium speed,
7. Do not start engine. Purge air from hydraulic
using a steady motion.
system by adding oil as follows:
• Watch for oil leaking from each plug/fitting
• Pre-fill the cases of the hydrostatic drive pump,
previously loosened and tighten each plug/
main pump and any other components that
fitting when oil leaks out.
have been drained of oil with clean, filtered
hydraulic oil. • Continue pumping slowly and watch the oil
sight gauge on the reservoir. Continue
pumping slowly until the hydraulic tank is full.
NOTE: If the axles were drained of oil, refer to
CASE DRAIN TEE
MAKE-UP LINE CONNECTOR AXLE OIL FILL AND BLEED in SECTION 15 of
THE SERVICE MANUAL.

•• •
• LOOSEN
FITTING
DRIVE
PUMP

OIL FILL LINE

•
RIGHT HAND DRIVE MOTOR
DISCONNECT CASE DRAIN LINE
620C-46
••
• 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.
630C-238 LOOSEN FITTING ON DRIVE PUMP

3.59
Tigercat 635C Skidder Lubrication and Maintenance
MACHINE STARTUP 5. Reconnect 4 pin engine power connector
on engine.
Before beginning this procedure, perform the
PRE-STARTUP AND FILLING steps. 6. Start engine.
7. Check for leaks.
CAUTION
Machine operator must ONLY take directions CONNECTORS ARE
from the person doing the set-up. LOCATED ON THE
BOTTOM OF PUMP.
PUMP SHOWN WITH
HOSES REMOVED
1. Ensure the articulation lock bar is installed. FOR CLARITY CONNECTORS
(2 PLACES)

•• ••
DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO
630C-11 PERFORMING PROCEDURE
4 PIN ENGINE 8. Bleed brakes (front axle) if required.
POWER
CONNECTOR
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.
630C-242 ENGINE 4 PIN POWER CONNECTOR
With engine at IDLE, engage parking brake,
2. Disconnect 4 pin engine power connector on hold foot brake down, bleed brakes in front
engine (prevents engine starting). axle (both sides). Refer also to AXLE ~
SERVICE BRAKES ~ BRAKE BLEEDING in
3. Crank engine for 10 seconds, wait for 10
SECTION 15 of the SERVICE MANUAL.
seconds. Repeat 6 times to pump oil into
pumps. Reconnect two connectors on drive pump.
9. Set throttle to IDLE and run each function for 2
IMPORTANT minutes to purge air from circuit.
Note that the 635C skidder has two separate 10. Set throttle to FULL and run each function
hydraulic systems (the main hydraulic system again for 2 minutes to flush circuit.
and the axle circuit). These two hydraulic 11. Top up the radiator with clean coolant.
systems require two different types of
hydraulic oil that MUST NOT BE 12. With cylinders fully retracted, top up the main
INTERCHANGED under any circumstances. hydraulic oil reservoir with clean hydraulic
oil.
Always use the correct type of hydraulic oil
for the circuit you are filling. Refer to 13. Top up the front axle with clean oil.
APPROVED HYDRAULIC OILS in THIS NOTE: If the machine was on wheels, the steer
SECTION. and drive functions were not properly purged or
flushed. Remove the articulation lock bar and at
4a. Check hydraulic oil levels in the main hydraulic LOW IDLE, slowly operate the steer function right
tank and add hydraulic oil as required. and left a few times. With the parking brake
4b. Check axle circuit reservoir oil level (in front released and at LOW IDLE, slowly operate the
axle) and add hydraulic oil as required. Refer drive function forward and reverse a few times.
to AXLE OIL LEVEL CHECK AND AXLE NOTE: If possible, allow the machine to stand for
CIRCUIT FILL in THIS SECTION. 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.

3.60
Tigercat 635C Skidder Lubrication and Maintenance
TORQUE CHART
LOCATION DIAMETER TORQUE (LUBRICATED)
lbf-ft Nm
Cylinders
Pin bolts 3/4" UNC 282-310 393-420
Piston nut, steer cylinder 1 3/4" UNF 1750 2372
Piston nut, arc/boom cylinder 1 3/4" UNF 1750 2372
Piston nut, dozer cylinder 1 3/8" UNF 1260 1708
Gland, steer cylinder - 550 745
Keeper plate bolts 3/4" UNC 282-310 393-420
Keeper plate bolts 5/8" UNC 159-175 216-237

Cab pin keeper plate bolts 3/4" UNC 282-310 393-420

Center joint bearing

Bearing retaining bolts 1/2" UNC 80-88 109-119
Pin retaining bolts 3/4" UNC 282-310 393-420

Engine mounting
Front 7/16" UNC 52 70
Rear 7/8" UNC 364 493
Pump Mounting
(Earlier Drive Pump~6350501 to 6350510)
Drive pump to mounting bracket 3/4" 282-310 393-420
Adapter plate to drive pump M14 130 176
Main pump to adapter plate M16 200 271
Rear mount to main pump M10 49-57 66-77
Multisection pump to main pump M12 80 109
Pump Mounting
(Later Drive Pump ~ 6350511 and up)
Drive pump to mounting bracket 3/4" 282-310 393-420
Main pump to drive pump 5/8" 159-175 216-237
Rear mount to main pump M10 49-57 66-77
Multisection pump to main pump M12 80 109
Torsional Drive Shaft Coupling (Later Design)
Coupling hub to flywheel 3/8" 33-36 44-49
Yolk flanges M10 49-57 66-77
Pump stack set screws M20 DOG PT 150-160 203-217
Torsional Drive Shaft Coupling (Earlier Design)
Coupling hub to flywheel 3/8" 33-36 44-49
Engine flywheel coupler M20 SOCKET 330-370 447-502
Pump stack coupler M20 SOCKET 330-370 447-502
Pump stack set screws M20 DOG PT 150-160 203-217
Cross-Flow Fan
Fan mounting bolts 1/2" UNC 80-88 109-119
Taperlock bushing to fan hub M6 16 21
Drive shafts
Yoke retaining nut, rear shaft 1 1/4" x 18 UNEF 475-525 640-711
Pillow block retaining bolts 3/4" UNC 282-310 393-420
Rear drive shaft
universal joint bolts 1/2" UNF 120-132 163-179
Mid. drive shaft
universal joint bolts 1/2" UNF 120-132 163-179
Front drive shaft
universal joint bolts 1/2" UNF 120-132 163-179
Axle mounting bolts
Front 3/4" UNC 300 406
Rear (Bogie) Axle M18 310 420
M20 413 560
5/8" 225 306
Wheel bolts 7/8" UNF 501-550 679-745
Transmission
Housing to Mounting Bracket 5/8"UNC 159-175 216-237
Mounting Bracket to Frame 7/8" UNC 364 493
Torque values pertaining to the engine and attachment are provided in the appropriate manuals.
635CTORQUECHARTR2.XLS 03/08
3.61
Tigercat 635C Skidder Lubrication and Maintenance
GENERAL TORQUE SPECIFICATIONS
The torque values listed below are for general use only.
IMPERIAL DO NOT use these values if a different torque value or
tightening procedure is shown for a specific application.

GRADE 8 BOLTS GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS

GRADE 8 BOLTS GRADE 5 BOLTS
COARSE DRY LUBRICATED COARSE DRY LUBRICATED
THREAD lbf-ft Nm lbf-ft Nm THREAD lbf-ft Nm lbf-ft Nm
1/4" - 20 11 - 12 15 - 16 8 - 10 11 - 13 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13
5/16" - 18 26 - 30 35 - 40 20 - 28 27 - 38 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20
3/8" - 16 44 -48 60 - 65 33 - 36 45 - 49 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34
7/16" - 14 70 - 77 95 - 104 52 - 57 71 - 77 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55
1/2" - 13 106 - 117 144 - 158 80 - 88 109 - 119 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85
9/16" - 12 153 - 168 208 - 228 115 - 127 156 - 172 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122
5/8" - 11 212 - 233 288 - 316 159 - 175 216 - 237 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168
3/4" - 10 376 - 414 510 - 561 282 - 310 393 - 420 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298
7/8" - 9 606 - 667 822 - 904 455 - 501 617 - 679 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441
1" - 8 909 - 1000 1233 - 1355 682 - 750 925 - 1016 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663
1 1/8" - 7 1288 - 1417 1746 - 1921 966 - 1062 1310 - 1441 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889
1 1/4" - 7 1817 - 1999 2464 - 2710 1360 - 1496 1844 - 2027 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252
FINE DRY LUBRICATED FINE DRY LUBRICATED
THREAD lbf-ft Nm lbf-ft Nm THREAD lbf-ft Nm lbf-ft Nm
1/4" - 28 13 - 14 18 - 19 10 - 13 14 - 17 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13
5/16" - 24 23 - 28 31 - 38 18 - 25 25 - 33 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27
3/8" - 24 49 - 54 67 - 73 37 - 41 50 - 55 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39
7/16" - 20 78 - 86 106 - 116 58 - 64 79 - 86 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61
1/2" - 20 120 - 132 163 - 179 90 - 99 122 - 134 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95
9/16" - 18 171 - 188 232 - 255 128 - 141 174 - 191 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135
5/8" - 18 240 - 264 326 - 358 180 - 198 244 - 268 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191
3/4" - 16 420 - 462 570 - 626 315 - 347 427 - 470 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332
7/8" - 14 668 - 735 906 - 996 501 - 550 679 - 745 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486
1" - 14 995 - 1096 1359 - 1486 746 - 821 1012 - 1113 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724
1 1/8" - 12 1445 - 1590 1960 - 2155 1083 - 1191 1469 - 1613 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996
1 1/4" - 12 2012 - 2213 2728 - 2997 1509 - 1660 2046 - 2250 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387

METRIC

METRIC BOLT TORQUE SPECIFICATIONS

CLASS 4.8 CLASS 8.8 OR 9.9 CLASS 10.9 CLASS 12.9
SIZE LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED DRY
Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft Nm lbf-ft
M6 4.8 3.5 6.0 4.5 9.0 6.5 11.0 8.5 13.0 9.5 17.0 12.0 15.0 11.5 19.0 14.5
M8 12.0 8.5 15.0 11.0 22.0 16.0 28.0 20.0 32.0 24.0 40.0 30.0 37.0 28.0 47.0 35.0
M10 23.0 17.0 29.0 21.0 43.0 32.0 55.0 40.0 63.0 47.0 80.0 60.0 75.0 55.0 95.0 70.0
M12 40.0 29.0 50.0 37.0 75.0 55.0 95.0 70.0 110.0 80.0 140.0 105.0 130.0 95.0 165.0 120.0
M14 63.0 47.0 80.0 60.0 120.0 88.0 150.0 110.0 175.0 130.0 225.0 165.0 205.0 150.0 260.0 190.0
M16 100.0 73.0 125.0 92.0 190.0 140.0 240.0 175.0 275.0 200.0 350.0 225.0 320.0 240.0 400.0 300.0
M18 135.0 100.0 175.0 125.0 260.0 195.0 330.0 250.0 375.0 275.0 475.0 350.0 440.0 325.0 560.0 410.0
M20 190.0 140.0 240.0 180.0 375.0 275.0 475.0 350.0 530.0 400.0 675.0 500.0 625.0 460.0 800.0 580.0
M22 260.0 190.0 330.0 250.0 510.0 375.0 650.0 475.0 725.0 540.0 925.0 675.0 850.0 625.0 1,075.0 800.0
M24 330.0 250.0 425.0 310.0 650.0 475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0
M27 490.0 360.0 625.0 450.0 950.0 700.0 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
M30 675.0 490.0 850.0 625.0 1,300.0 950.0 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
M33 900.0 675.0 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
M36 1,150.0 850.0 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
3.62
Tigercat 635C Skidder Lubrication and Maintenance

Par
arkker Assemb
Assemblly Tor que
orque

3.63
 Tigercat 635C Skidder Lubrication and Maintenance

Par
arkker Assemb
Assemblly Tor que
orque
JIC 37 Degree Flare NPTF
Tube Connection Swivel or Hose Tube Connection Swivel or Hose
SAE Dash Size Thread Size FFWR Connection FFWR SAE Dash Size Thread Size TFFT Connection TFFT
-2 5/16-24 NA NA -2 1/8-27 2-3 2-3
-3 3/8-24 NA NA -3 NA NA NA
-4 7/16-20 2 2 -4 1/4-18 2-3 2-3
-5 1/2-20 2 2 -5 NA NA NA
-6 9/16-18 1 1/2 1 1/4 -6 3/8-18 2-3 2-3
-8 3/4-16 1 1/2 1 -8 1/2-14 2-3 2-3
-10 7/8-14 1 1/2 1 -10 7/8-14 NA NA
-12 1 1/16-12 1 1/4 1 -12 3/4-14 2-3 2-3
-14 1 3/16-12 1 1 -14 NA NA NA
-16 1 5/16-12 1 1 -16 1-11 1/2 1.5-2.5 1.5-2.5
-20 1 5/8-12 1 1 -20 1 1/4-11 1/2 1.5-2.5 1.5-2.5
-24 1 7/8-12 1 1 -24 1 1/2-11 1/2 1.5-2.5 1.5-2.5
-32 2 1/2-12 1 1 -32 2-11 1/2 1.5-2.5 1.5-2.5
-40 3-12 1 1 -40 NA NA NA

F.F.W.R : Flats From Wrench Resistance T.F.F.T. : Turns from finger tight
All values are for Steel, Stainless Steel and Brass All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok BSPT

Tube Connection Swivel or Hose Tube Connection Swivel or Hose
SAE Dash Size Thread Size FFWR Connection FFWR SAE Dash Size Thread Size TFFT Connection TFFT
-2 NA NA NA -2 1/8-28 2-3 2-3
-3 NA NA NA -3 NA NA NA
-4 9/16-18 1/4 TO 1/2 1/2 TO 3/4 -4 1/4-19 2-3 2-3
-5 NA NA NA -5 NA NA NA
-6 11/16-16 1/4 TO 1/2 1/2 TO 3/4 -6 3/8-19 2-3 2-3
-8 13/16-16 1/4 TO 1/2 1/2 TO 3/4 -8 1/2-14 2-3 2-3
-10 1-14 1/4 TO 1/2 1/2 TO 3/4 -10 NA NA NA
-12 1 3/16-12 1/4 TO 1/2 1/3 TO 1/2 -12 3/4-14 2-3 2-3
-14 NA NA NA -14 NA NA NA
-16 1 7/16-12 1/4 TO 1/2 1/3 TO 1/2 -16 1-11 1.5-2.5 1.5-2.5
-20 1 11/16-12 1/4 TO 1/2 1/3 TO 1/2 -20 1 1/4-11 1.5-2.5 1.5-2.5
-24 2-12 1/4 TO 1/2 1/3 TO 1/2 -24 1 1/2-11 1.5-2.5 1.5-2.5
-32 NA NA NA -32 2-11 1.5-2.5 1.5-2.5
-40 NA NA NA -40 NA NA NA

F.F.W.R : Flats From Wrench Resistance T.F.F.T. : Turns from finger tight
All values are for Steel, Stainless Steel and Brass All pipe values are for Steel, Stainless Steel and Brass

3.64
 Tigercat 635C Skidder Lubrication and Maintenance
EATON Aeroquip Assemb
Assemblly Tor que
orque
Recommended Eaton recommends that a The values listed are for
Parallel Torque wrench be used to steel connections. Contact
Connection assure proper fitting Eaton Aeroquip for torques values for
Assembly torque assembly of these other materials
connections.

Straight Thread O-Ring Straight Thread O-Ring

Boss Low Pressure with Boss High Pressure
37º (SAEJ514) with ORS (J1453)
Jam Nut or Jam Nut or Jam Nut or Jam Nut or
Thread Straight Straight Thread Straight Straight
Dash Size Fitting Torque Fitting Torque Dash Size Fitting Torque Fitting Torque
Size (inches) lb.-ft. Newton Meters Size (inches) lb.-ft. Newton Meters
-03 3/8-24 8-9 12-13 -03 3/8-24 8-10 11-16
-04 7/16-20 13-15 18-20 -04 7/16-20 14-16 20-22
-05 1/2-20 14-15 19-21 -05 1/2-20 18-20 24-27
-06 9/16-18 23-24 32-33 -06 9/16-18 24-26 33-35
-08 3/4-16 40-43 55-57 -08 3/4-16 50-60 68-78
-10 7/8-14 43-48 59-64 -10 7/8-14 72-80 98-110
-12 1 1/16-12 68-75 93-101 -12 1 1/16-12 125-135 170-183
-14 1 3/16-12 83-90 113-122 -14 1 3/16-12 160-180 215-245
-16 1 5/16-12 112-123 152-166 -16 1 5/16-12 200-220 270-300
-20 1 5/8-12 146-161 198-218 -20 1 5/8-12 210-280 285-380
-24 1 7/8-12 154-170 209-230 -24 1 7/8-12 270-360 370-490
-32 2 1/2-12 218-240 296-325

ORS SAE 37º (JIC)

Swivel Swivel
Swivel Swivel Thread Nut Nut
Thread Nut Nut Dash Size Torque Torque
Dash Size Torque Torque Size (inches) lb.-ft. Newton Meters
Size (inches) lb.-ft. Newton Meters -04 7/16-20 11-12 15-16
-04 9/16-18 10-12 14-16 -05 1/2-20 15-16 20-22
-06 11/16-20 18-20 24-27 -06 9/16-18 18-20 24-28
-08 13/16-16 32-35 43-47 -08 3/4-16 38-42 52-58
-10 1-14 46-50 62-68 -10 7/8-14 57-62 77-85
-12 1 3/16-12 65-70 88-95 -12 1 1/16-12 79-87 108-119
-16 1 7/16-12 92-100 125-136 -16 1 5/16-12 108-113 148-154
-20 1 11/16-12 125-140 170-190 -20 1 5/8-12 127-133 173-182
-24 2-12 150-165 204-224 -24 1 7/8-12 158-167 216-227
-32 2 1/2-12 245-258 334-352

Metric BSPP
Thread Size Straight Adapter or Locknut Torque Nominal
mm lb.-ft. Newton Meters Thread Size Straight Adapter or Locknut Torque
M10x1 13-15 18-20 inches** lb.-ft. Newton Meters
M12x1.5 15-19 20-25 G1/8-28 13-15 18-20
M14x1.5 19-23 25-30 G1/4-19 19-23 25-30
M16x1.5 33-40 45-55 G3/8-19 33-40 45-55
M18x1.5 37-44 50-60 G1/2-14 55-70 75-95
M20x1.5 52-66 70-90 G3/4-14 103-118 140-160
M22x1.5 55-70 75-95 G1-11 162-184 220-250
M26x1.5 81-96 110-130 G1 1/4-11 170-192 230-260
M27x2 96-111 130-150 G1 1/2-11 258-347 350-470
M33x2 162-184 220-250 ** "G" denotes parallel threads, other than ISO 6149
M42x2 170-192 230-260 (Port connection only)
M48x2 258-347 350-470
Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.65
Tigercat 635C Skidder Lubrication and Maintenance

Weights of Commercial Wood

Species kg/m3 lb/ft3 Species kg/m3 lb/ft3

Alder, Red 737 46 Maple, Big Leaf 753 47

Ash, White 769 48 Maple, Black 865 54
Aspen, Quaking 689 43 Maple, Red 801 50
Bald Cypress 817 51 Maple, Silver 721 45
Basswood, American 673 42 Maple, Sugar 897 56
Beech, American 865 54 Oak, Black 1009 63
Birch, Paper 801 50 Oak, Chestnut 977 61
Birch, Yellow 929 58 Oak, Red 1009 63
Cedar, Alaska 577 36 Oak, Red, Swamp 1073 67
Cedar, Incense 721 45 Oak, Swamp Chestnut 1041 65
Cedar, Northern White 449 28 Oak, White 993 62
Cedar, Port-Orford 897 36 Oak, White, Swamp 1105 69
Cedar, Western Red 433 57 Pine, Jack 801 50
Cherry, Black 721 45 Pine, Loblolly 993 62
Cottonwood, Eastern 785 49 Pine, Lodgepole 625 39
Douglas Fir, Coast 881 55 Pine, Long Leaf 993 62
Douglas Fir, Inland North 577 36 Pine, Norway, Red 673 42
Elm, American 865 54 Pine, Short Leaf 993 62
Fir, Alpine 449 28 Pine, Slash 993 62
Fir, Balsam 721 45 Pine, Sugar 817 51
Fir, Nobel 481 30 Pine, Western Yellow 721 45
Fir, Red 769 48 Pine, White-Western 561 35
Fir, Silver 577 36 Pine, White-Eastern 577 36
Fir, White 753 47 Poplar, Yellow 609 38
Gum, Black 721 45 Redwood 801 50
Gum, Blue 1121 70 Spruce, Black 513 32
Gum, Red 801 50 Spruce, Engleman 625 39
Gum, Tupelo 897 56 Spruce, Red 545 34
Hemlock, Eastern 801 50 Spruce, Sitka 529 33
Hemlock, Western 657 41 Spruce, White 545 34
Hickory, Pecan 993 62 Sweetgum 801 50
Hickory, True 1009 63 Sycamore, American 833 52
Larch, Western 769 48 Tamarack 753 47
Locust, Black 929 58 Walnut, Black 929 58
Magnolia, Cucumber 785 49 Willow, Black 801 50

Note: The values shown here are green weights.

3.66
Tigercat 635C Skidder Lubrication and Maintenance
COMMON CONVERSIONS
To Convert Into Multiply By To Convert Into Multiply By
Bar PSI 14.5 Cu. in. cc 16.39
cc Cu. in. 0.06102 °F °C (°F - 32) /1.8
°C °F (°C x 9/5) + 32 Gallons Liters 3.785
Kg lbs. 2.205 HP KW 0.7457
KW HP 1.341 Inches mm 25.4
Liters Gallons 0.2642 lbs. Kg 0.4535
mm Inches 0.03937 lb.-ft. Nm 1.356
Nm lb.-ft. 0.7375 PSI Bar 0.06896
N lbs. 0.22481 In. of HG PSI . 4912
In. of H2O PSI . 03613
lbs. N 4.4482

3.67
Tigercat 635C Skidder Lubrication and Maintenance

3.68
Tigercat 635C Skidder
SECTION 6 - ELECTRICAL AND COMPUTERS
OCTOBER 2008
CONTENTS - SECTION 6
ALARMS AND GAUGES ............................................................................. 6.66
CHANNELS ................................................................................................. 6.26
INPUTS
DIGITAL IN (DIN) ................................................................................. 6.26
FREQUENCY IN (FIN) ......................................................................... 6.26
VOLTAGE IN (VIN) ............................................................................... 6.26
OUTPUTS
CURRENT OUT (COUT) ..................................................................... 6.26
DIGITAL OUT (DOUT) ......................................................................... 6.26
PWM OUT (PULSE WIDTH MODULATION) ....................................... 6.26
COMPUTER
CONTROL SYSTEM ................................................................................. 6.3
IQAN CONTROL SYSTEM COMPONENTS ............................................. 6.3
COMPUTER SYSTEM OVERVIEW ............................................................. 6.3
CURRENT OUT - TROUBLESHOOTING FOR OPEN CIRCUITS ............. 6.26
DOWNLOADING APPLICATIONS FROM DEALER WEBSITE ................. 6.49
ELECTRICAL KIT - SERVICE AND DIAGNOSTICS .................................. 6.46
ELECTRICAL SYSTEM SCHEMATIC DIAGRAMS .................................... 6.70
ERROR MESSAGES AND ALARMS
FAULT CODES : ERROR MESSAGES .................................................. 6.44
MAIN SYSTEM ERRORS ........................................................................ 6.37
SYSTEM WARNING MESSAGES .......................................................... 6.31
FAULT CODES : ERROR MESSAGES ...................................................... 6.44
ERROR :INPUT HIGH ............................................................................. 6.44
ERROR: INPUT LOW ............................................................................. 6.44
ERROR: OUTPUT HIGH ......................................................................... 6.44
ERROR: OUTPUT LOW ......................................................................... 6.44
INTERPRETING ERROR MESSAGES ................................................... 6.44
FAULT CODES, READING ACTIVE ENGINE CODES .............................. 6.19
FUSE AND RELAY PANELS
6350501 TO 6350530 .............................................................................. 6.60
6350531 TO 6350550 .............................................................................. 6.62
6350551 TO 6351000 .............................................................................. 6.64
GAUGES AND ALARMS ............................................................................. 6.66
GET APPLICATION .................................................................................... 6.54
GET ERROR/EVENT LOG ......................................................................... 6.58
ID-TAG ........................................................................................................ 6.17
INFORMATION CENTER -IQAN MDM COMPUTER DISPLAY ................. 6.18
SYSTEM DIAGNOSTICS MENUS .......................................................... 6.20
DIAGNOSTICS MENU DESCRIPTIONS ............................................. 6.21
DIAGNOSTICS MENU OPERATION ................................................... 6.22
SYSTEM WARNING MESSAGES .......................................................... 6.31
AIR INTAKE RESTRICTED SERVICE INTAKE TO CORRECT .......... 6.35
AXLE FILTER IN BYPASS WARNING ................................................. 6.34
BRAKE PRESSURE LOW ................................................................... 6.36
CHARGE FILTER IN BYPASS WARNING ........................................... 6.34
CHARGE PRESSURE LOW WARNING ............................................. 6.36
ENGINE TEMPERATURE WARNING ................................................. 6.33
Tigercat 635C Skidder Electrical and Computers
FAN CLEAN MODE ............................................................................. 6.36
FUEL LEVEL LOW ............................................................................... 6.36
HYDRAULIC OIL LEVEL LOW WARNING .......................................... 6.32
HYDRAULIC OIL TEMPERATURE WARNING .................................... 6.31
LOW COOLANT LEVEL WARNING .................................................... 6.32
MODULE IS OFFLINE SYSTEM WARNING ....................................... 6.37
OIL PRESSURE WARNING ................................................................ 6.31
SERVICE USE ONLY (PROGRAM MODE) ......................................... 6.35
VOLTAGE WARNING .......................................................................... 6.33
WINCH FREESPOOL ON .................................................................... 6.33
IQAN MODULES
CONTROL SYSTEM OVERVIEW ............................................................. 6.3
IQAN CONTROL SYSTEM COMPONENTS ............................................. 6.3
MDM DISPLAY MODULE .......................................................................... 6.5
XP2-A0 REAR CHASSIS MODULE ........................................................ 6.14
XS-A0 CAB MODULE ................................................................................ 6.6
XT2-A0 FRONT CHASSIS MODULE ...................................................... 6.10
IQAN SOFTWARE ...................................................................................... 6.48
DOWNLOADING APPLICATIONS FROM DEALER WEBSITE .............. 6.49
GET APPLICATION (DOWNLOAD FROM MDM)
USING A PC/LAPTOP .......................................................................... 6.55
USING A PDA ...................................................................................... 6.54
GET ERROR/EVENT LOG
USING A PC/LAPTOP .......................................................................... 6.59
USING A PDA ...................................................................................... 6.58
GRAPHING AND MEASUREMENT OF CHANNELS
USING A PC/LAPTOP .......................................................................... 6.57
USING A PDA ...................................................................................... 6.56
IQAN DEVELOP G4 SOFTWARE UPGRADE (PSB 1739) .................... 6.48
PDA REGISTRATION ............................................................................. 6.48
UPDATING THE IQAN APPLICATION
FROM A PC/LAPTOP ........................................................................ 6.52
FROM A PDA ....................................................................................... 6.50
MAIN SYSTEM ERRORS ........................................................................... 6.37
ENGINE RELATED J1939 CONNECTION ERRORS ............................. 6.41
MDM MODULE BLANK SCREEN ........................................................... 6.37
MODULE IS OFFLINE ............................................................................. 6.37
XP2-A0 MODULE OFFLINE ERRORS ................................................... 6.40
XS-A0 MODULE OFFLINE ERROR ....................................................... 6.38
XT2-A0 MODULE OFFLINE ERROR ..................................................... 6.39
MODULE IS OFFLINE ................................................................................ 6.37
PDA REGISTRATION ................................................................................. 6.48
READING ENGINE FAULT CODES ........................................................... 6.19
SWITCH AND SENSOR LOCATIONS
6350501 TO 6350530 .............................................................................. 6.67
6350531 TO 6350550 .............................................................................. 6.68
6350551 TO 6351000 .............................................................................. 6.69
UPDATE APPLICATION ............................................................................. 6.50
WIRE COLOUR CODE CHART .................................................................. 6.70

6.2
Tigercat 635C Skidder Electrical and Computers

IQAN COMPUTER CONTROL LCD DISPLAY

SCROLL
UP/DOWN

SYSTEM BUTTON

Machine operation is controlled electronically by

the IQAN computer control system. During
•• ••
operation of the electronic joystick, 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
F1 F2 F3 ESCAPE
valve functions. BUTTON BUTTON BUTTON BUTTON

IQAN SYSTEM COMPONENTS 630C-31 MDM COMPUTER MODULE

1. MDM Display/Control Module The computer also monitors and analyzes inputs
and produces outputs (as defined in its program) to
2. (XS-A0) I/O Cab Module
control the machine proportional valve functions.
3. (XT2-A0) Front Chassis Module Proportional valve functions are:
4. (XP2-A0) Rear Chassis Module • Winch
The MDM display and control module (1), located • Dozer
on the instrument panel, is connected in series to • Arch and Boom
the CAN 1 terminal on the cab module (2), located
• Grapple
below the control panel assembly. The cab module
(2) is connected via the CAN 2 terminal to front • Fan
chassis module (3) and rear chassis module (4). • Differential locks
The engine computer is connected to the front • Parking Brake (6350621 to 6351000)
chassis module via communication wire J1939.
The operator can view input and output information Inputs:
and enter function parameter settings for various The computer monitors analogue, digital, and
modules using the MDM Display Terminal. frequency inputs and CAN Bus inputs. CAN Bus is
The computer monitors and analyzes engine and a data bus system that allows several input signals
transmission inputs and produces outputs (as to be sent to the MDM through a reduced number
defined in its program) to control the engine and of wires.
drive functions. Outputs:
The computer directs a proportional output (12 Volt
electrical current) to the solenoids on the control
valve (winch, arch, dozer, grapple, boom),
differential lock and winch manifold, fan manifold,
drive pump, drive motors and controls engine RPM
by sending appropriate signals to the engine’s
control computer.

635C-02 IQAN CONTROL SYSTEM COMPONENTS

6.3
Tigercat 635C Skidder Electrical and Computers
The IQAN MDM computer display is the operator
interface with the IQAN control system. The IQAN
MDM (master display module) is the central unit in
the IQAN control system, which works as both a
master and a display unit. It has a backlit graphic
LCD display. Three function buttons (F1, F2 and
F3), a scrolling up/down button and an escape
button are used by the operator to move through
menus and adjust the settings of the IQAN control
system.

GAUGES INFORMATION CENTER -

SWITCH IQAN MDM COMPUTER DISPLAY

•• •
635C-28 XS-A0 CAB MODULE

635C-05 INSTRUMENT PANEL

The GAUGES switch to the left of the IQAN-MDM

display is used to select between the gauge menus
and the diagnostic and function adjustment menus.
Press the top of the GAUGES switch to display the
gauge menus.
XT2-A0 FRONT CHASSIS MODULE
Press the bottom of the GAUGES switch to display 630C-153 FRONT CHASSIS (RIGHT SIDE)
the IQAN-MDM diagnostic and function adjustment
menus. In addition when the system is in
diagnostic mode any active engine codes will be
transmitted to the engine warning lights. Refer to
READING ENGINE FAULT CODES in THIS
SECTION.
Note: Whenever an alarm is activated, the gauge
display menus are replaced with the alarm warning
message. When the alarm function is cleared,
diagnostic and function adjustment menus appear.
Press the top of the GAUGES switch to display the
gauge menus.
Refer to IQAN MDM COMPUTER DISPLAY in 635C-33 XP2-A0 REAR CHASSIS MODULE
SECTION 2 of the OPERATOR’S MANUAL for
more information.

6.4
Tigercat 635C Skidder Electrical and Computers
MDM DISPLAY MODULE
6 5 2 5 3

•• ••
•• • •

•
•
•• ••
1 5 4 5
1014-032

REAR OF MDM MODULE

The back of the MDM Module consists of the
following.
1. Tag with serial number and part number. MDM MDM
BATTERY CLOCK
2. RS-232 serial port, 8 pin for PC connection. FROM
BATTERY
3. Voltage supply indicator. LED with green light
ON indicates supply voltage is activated. LED
FROM
light OUT indicates supply voltage is OFF. ACCESSORY
RELAY
4. Main connector for voltage supply, CAN 630C-02T
communication and alarm output.
5. Snap on attachment for mounting in panel.
6. Membrane valve for condensation prevention
inside unit.
MDM MODULE WIRING PIN ASSIGNMENT
1. CAN LOW
2. ALARM OUT
3. BATTERY GROUND
4. CAN HIGH
5. POWER SUPPLY - Real Time Clock
6. POWER SUPPLY 1014-035 MDM MODULE REPLACEMENT
NOTE: Refer to the MDM DISPLAY AND XS-A0 MDM MODULE REPLACEMENT
CAB MODULE SCHEMATIC and ELECTRICAL
SCHEMATIC in THIS SECTION for detailed pin 1. Turn battery disconnect switch OFF.
and wiring assignment. 2. Remove 4 screws holding MDM frame plate.
3. Lift the module out of the instrument panel
carefully.
4. Disconnect the wiring harness at the module.
5. Remove module from frame plate (4 screws).
6. Install module in reverse order as removed.
NOTE: Refer to IQAN SOFTWARE - UPDATE
APPLICATION in THIS SECTION for procedure to
update the application in an MDM module.

6.5
Tigercat 635C Skidder Electrical and Computers
XS-A0 CAB MODULE XS-A0 CAB MODULE REPLACEMENT

1014-038

A. Supply Voltage LED.

LED ON solid green light indicates supply 635C-28 XS-AO CAB MODULE
voltage is ON.
1. Turn battery disconnect switch OFF.
LED OFF indicates supply voltage is OFF.
2. Remove the 8 screws holding the instrument
B. Arrow and Heart Status Indicator LEDs. panel in place and carefully tilt the panel out to
LED for Heart and Arrow flash alternately access the back side.
(solid green) indicates Status is Correct.
When LED for Heart is off and LED for arrow
flashes (green), this indicates the following
errors:
• One flash indicates fault on inputs/outputs
or that supply voltage is to low or to high.
• Two flashes in a row indicates that the
internal temperature of the unit is to high or
to low.
• Three flashes in a row indicates that the 1014-037
fault is related to the CAN-bus.
• Four flashes in a row indicates an internal 3. Disconnect the wiring harness connectors on
fault on the hardware of the unit. the module.
XS Module 4. Remove the two hex nuts and lift the module
Error code Blink (Arrow only green light) out.
I/O and voltage errors
Low/High temperature
CAN error
VREF error

C. Connectors CAN1 and CAN2 for CAN-bus.

D. C1 connector for inputs and outputs.
E. Module assembly.
F. Mounting hole.
NOTE: Refer to the MDM DISPLAY AND XS CAB 1014-036
MODULE WIRING SCHEMATIC and
ELECTRICAL SCHEMATICS in THIS SECTION
5. Reverse procedure to install module.
for detailed pin and wiring assignment.

6.6
Tigercat 635C Skidder Electrical and Computers

MDM DISPLAY AND XS-A0 CAB MODULE SCHEMATIC

635C-13 (6350501 TO 6350550)

6.7
Tigercat 635C Skidder Electrical and Computers

6.8
Tigercat 635C Skidder Electrical and Computers

MDM DISPLAY AND XS-A0 CAB MODULE SCHEMATIC

630C-104 (6350551 TO 6351000)

6.9
Tigercat 635C Skidder Electrical and Computers
XT2-A0 FRONT CHASSIS MODULE • Five flashes in a row indicates that the fault
is related to the address.
• Continuous flashing indicates the fault is
related to software.

XT2-A0 FRONT CHASSIS MODULE

630C-153 FRONT CHASSIS (RIGHT SIDE)
1014-041
XT2-A0 MODULE LED INDICATORS
XT2-A0 MODULE WIRING PIN ASSIGNMENT
B

• ••
1014-042XT2-A0 MODULE LED INDICATORS
A. Supply Voltage LED (green).
LED with green light ON indicates supply
voltage is ON. 1014-043

LED OFF indicates supply voltage is OFF. NOTE: Refer to the XT2-A0 FRONT CHASSIS
B. Status indicator LED (yellow/red). MODULE SCHEMATIC and ELECTRICAL
SCHEMATIC in THIS SECTION for detailed pin
LED yellow flashing light indicates status is and wiring assignment.
correct.
LED flashing red light indicates error status as
follows:
• One flash indicates fault on inputs/outputs
or that supply voltage is to low or to high.
• Two flashes in a row indicates that the
internal temperature of the unit is to high or
to low.
• Three flashes in a row indicates that the
fault is related to the CAN-bus.
• Four flashes in a row indicates an internal
fault on the hardware of the unit.

LX-, XP2- and XT2- module

Error code Blink (red light)

I/O and voltage errors

Low/High temperature
CAN error
Hardware error
Address error
Software error

6.10
Tigercat 635C Skidder Electrical and Computers

XT2-A0 FRONT CHASSIS MODULE SCHEMATIC

635C-14 (6350501 TO 6350530)

6.11
Tigercat 635C Skidder Electrical and Computers

XT2-A0 FRONT CHASSIS MODULE SCHEMATIC

630C-102 (6350531 TO 6350620)

6.12
Tigercat 635C Skidder Electrical and Computers

XT2-A0 FRONT CHASSIS MODULE SCHEMATIC

635C-39 (6350621 TO 6351000)

6.13
Tigercat 635C Skidder Electrical and Computers
XP2-A0 REAR CHASSIS MODULE • Five flashes in a row indicates that the fault
is related to the address.
• Continuous flashing indicates the fault is
related to software.

635C-33 XP2-A0 REAR CHASSIS MODULE

1014-041
2

1 XP2-A0 MODULE WIRING PIN ASSIGNMENT

•• ••
1014-042 XP2-A0 MODULE LED INDICATORS
XP2-A0 MODULE LED INDICATORS
1. Supply Voltage LED (green)
LED with green light ON indicates supply
voltage is ON. LED OFF indicates supply 1014-043
voltage is OFF.
NOTE: Refer to the XP2-A0 REAR CHASSIS
2. Status indicator LED (yellow/red)
MODULE SCHEMATIC and ELECTRICAL
LED yellow flashing light indicates status is SCHEMATIC in THIS SECTION for detailed pin
correct. and wiring assignment.
LED red flashing light indicates error status as
follows:
• One flash indicates fault on inputs/outputs
or that supply voltage is to low or to high.
• Two flashes in a row indicates that the
internal temperature of the unit is to high or
to low.
• Three flashes in a row indicates that the
fault is related to the CAN-bus.
• Four flashes in a row indicates an internal
fault on the hardware of the unit.

LX-, XP2- and XT2- module

Error code Blink (red light)

I/O and voltage errors

Low/High temperature
CAN error
Hardware error
Address error
Software error

6.14
Tigercat 635C Skidder Electrical and Computers

XP2-A0 REAR CHASSIS MODULE SCHEMATIC

635C-15 (6350501 TO 6350530)

6.15
Tigercat 635C Skidder Electrical and Computers

XP2-A0 REAR CHASSIS MODULE SCHEMATIC

630C-101 (6350531 TO 6351000)

6.16
Tigercat 635C Skidder 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
42 29
the module type and then, secondly, through the
modules having a unique addresses. 28 15
14 1
EXAMPLE
If a system has an XP2 module with address 0, the ADDR-L, pos. 14 ADDR-H, pos. 1
system will denote this one as XP2-A0, The letter
“A” refers to CAN-bus A.
In order to assign any XP2 module a unique CAN- Id-Tag
address, an Id-Tag will have to be connected to the CONNECTING ID-TAG (XT2 OR XP2)
positions ADDR-H and ADDR-L.
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 IQAN-
XP2 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; ASSEMBLING ID-TAG (XT2 OR XP2)
0T, 1T, 2T...
Selecting appropriate Id-Tag
• Check the address number of the module.
• If the module is located at the end of the CAN-
bus then select the appropriate Id-Tag denoted
with a “T”.
MODULE ID-TAG RESISTANCE
MDM NO TAG -
XS-A0 NO TAG -
XT2-A0 0 287 Ω
XP2-A0 0T 432 Ω

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 Id-
Tag’s cables towards the opposite side, where the
other cables enter the connector.

6.17
Tigercat 635C Skidder Electrical and Computers
INFORMATION CENTER - The GAUGES SWITCH to the left of the IQAN-
MDM display is used to select between the
IQAN MDM COMPUTER DISPLAY GAUGE MENUS and the SYSTEM
DIAGNOSTICS MENUS.
GAUGES INFORMATION CENTER -
Press the top of the GAUGES switch to display the
SWITCH IQAN MDM COMPUTER DISPLAY GAUGE MENUS. Refer to INFORMATION

•• • CENTER ~ GAUGE MENUS in SECTION 2 of the

OPERATOR’S MANUAL.
Press the bottom of the GAUGES switch to display
the SYSTEM DIAGNOSTICS MENUS. Refer to
INFORMATION CENTER ~ SYSTEM
DIAGNOSTICS MENUS in THIS SECTION. In
addition when the system is in diagnostic mode
any active engine codes will be transmitted to the
625C-08 INSTRUMENT PANEL engine warning lights. Refer to READING
ENGINE FAULT CODES in THIS SECTION.
The INFORMATION CENTER display (IQAN-
In addition, SYSTEM WARNING MESSAGES
MDM computer display) is the operator interface
displayed on the IQAN-MDM screen when an
with the IQAN control system. The IQAN MDM
alarm condition is detected, regardless of the
(master display module) is the central unit in the
position of the GAUGES SWITCH. The alarm
IQAN control system, which works as both a
warning light on the instrument panel will flash and
master and a display unit.
horn will sound whenever a warning message is
SCROLL shown on the screen. Refer to INFORMATION
LCD DISPLAY UP/DOWN CENTER ~ SYSTEM WARNING MESSAGES in
BUTTON
SECTION 2 of THE OPERATOR’S MANUAL.
NOTE: The IQAN control system is software-
•• •• based. 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
F1 F2 F3 ESCAPE the machine and/or software are on-going and may
BUTTON BUTTON BUTTON BUTTON
not be covered. In these cases contact your
630C-31 MDM COMPUTER MODULE Tigercat dealer for appropriate information.
The IQAN MDM has a backlit graphic LCD display.
Three function buttons (F1, F2 and F3), a SCROLL
UP/DOWN button and an ESCAPE button are
used by the operator to move through the menu
displays and adjust the settings of the IQAN
control system.

6.18
Tigercat 635C Skidder Electrical and Computers
READING ENGINE FAULT CODES
GAUGES ENGINE: STOP ENGINE: WARNING
(RED) LIGHT (AMBER) LIGHT
When the system is in diagnostic mode any active SWITCH
engine codes will be transmitted to the engine
warning lights. • • ••
PROCEDURE:
1. Turn ignition switch to the ON position.
2. Press the bottom of the gauges switch to place
the IQAN-MDM display in system diagnostics
mode.
3. When an active engine code is being INSTRUMENT PANEL
transmitted the ENGINE: STOP(red) and 635C-05 (6350501 TO 6350530)
ENGINE: WARNING (amber) lights will both
be lit and then begin to flash to indicate the ENGINE: STOP ENGINE: WARNING
GAUGES (AMBER) LIGHT
active engine code(s) being transmitted. SWITCH (RED) LIGHT

4. Codes transmitted are expressed by the •• •

number of light flashes separated by pauses. •
EXAMPLE: CODE 132
Lights will flash as follows:
Amber (indicates begin of code transmission)
Pause
Red INSTRUMENT PANEL
Pause 625C-08 (6350531 TO 6350620)

Red ENGINE: WARNING

GAUGES ENGINE: STOP
Red SWITCH (RED) LIGHT (AMBER) LIGHT
Red
•• ••
Pause ••
Red
Red
Pause
Amber (indicates code transmission complete)
Note each active engine code will be
INSTRUMENT PANEL
transmitted twice in a row. If more than one (6350621 TO 6351000)
630C-241X
active engine code is being transmitted the
first will flash twice, then the second will flash
twice and so on.
Refer to engine manufacturer’s manuals and
fault code information publications for accurate
information regarding cross referencing engine
code information.

6.19
Tigercat 635C Skidder Electrical and Computers
SYSTEM DIAGNOSTICS MENUS

GAUGES INFORMATION CENTER -

SWITCH IQAN MDM COMPUTER DISPLAY

•• •

625C-08 INSTRUMENT PANEL 1014-D001B

Press the bottom of the GAUGES switch to place Press the ESCAPE button to display one of 5
the IQAN-MDM display in system diagnostics menus (MODE, INFORMATION, SETTINGS,
mode. MEASURE and PROPERTIES) that access
system diagnostics and function adjustment
The display will appear as shown. menus.
The display should show the current date and Use the SCROLL UP/DOWN buttons to scroll
time, software program and version identification. through the menus.
TIME DATE SCROLL Use the F1, F2, and F3 buttons to select the
UP/DOWN
BUTTON
highlighted menu options located above each
button in the LCD menu display.
SOFTWARE
PROGRAM
AND •• • •
•
Use the ESCAPE button to move back to the
previous menu display.
VERSION
••
•• • • ••
F1 F2 F3 ESCAPE
BUTTON BUTTON BUTTON BUTTON
630C-65 MDM COMPUTER MODULE

6.20
Tigercat 635C Skidder Electrical and Computers
DIAGNOSTICS MENU DESCRIPTIONS

4. MEASURE MENU DESCRIPTION

1. MODE MENU DESCRIPTION A. Input channel measurement can be

viewed.
This menu is not used by machine operators
for the 635C application at this time. B. Output channel measurement can be
viewed.
C. EVENT COUNTER and HOUR
COUNTER can be viewed.

2. INFORMATION MENU DESCRIPTION

A. Software application information can be
displayed, including comments.
5. PROPERTIES MENU DESCRIPTION
B. Module information can be displayed
including status, software information and A. Function parameters can be adjusted.
hardware information.
Refer also to INFORMATION CENTER~SYSTEM
DIAGNOSTICS MENU~DIAGNOSTICS MENU
OPERATION in THIS SECTION and SECTION 2
of THE OPERATOR’S MANUAL.

3. SETTINGS MENU DESCRIPTION

A. Display CONTRAST can be adjusted.
B. Display BRIGHTNESS can be adjusted.
C. Computer SOUND volumes can be
adjusted.
D. Computer DATE and TIME can be
adjusted.

6.21
Tigercat 635C Skidder Electrical and Computers
DIAGNOSTICS MENU OPERATION B. VIEW MODULE INFORMATION
1. MODE MENU OPERATION
This menu is not used by machine operators
for the 635C application at this time.
2. INFORMATION MENU OPERATION
Machine software application and module
status information can be viewed in this menu.
A. VIEW APPLICATION INFORMATION

Press MODULES (F2) to select MODULES.

Press APPLIC (F1) to select APPLICATION

INFORMATION.
Choose an IQAN module using UP/DN (MDM
shown as an example).
Press STATUS (F1) to select STATUS.
Note: Status (enabled/disabled) refers to the
enabling or disabling of the MODULE IS
OFFLINE warning function for a module. For
some modules it is possible for an operator or
technician to disable this warning message. It
is recommended that all available modules
Press MORE (F1) and COMMENT (F2) to ALWAYS be set to ENABLED. Refer to
select MORE...(screen shown below) or MODULE IS OFFLINE in THIS SECTION for
COMMENT. more more information.

Press INTERNAL (F2) to select INTERNAL.

6.22
Tigercat 635C Skidder Electrical and Computers
3. SETTINGS MENU OPERATION
The computer sound volume, display contrast,
light, date, time and language can be adjusted
in this menu.
Refer also to INFORMATION
CENTER~SYSTEM DIAGNOSTICS
MENU~DIAGNOSTICS MENU OPERATION in
SECTION 2 of THE OPERATOR’S MANUAL
for complete information.
Press INFO SW (F2) to select INFO SW
(software information).

Press INFO HW (F3) to select INFO HW

(hardware information).

6.23
 Tigercat 635C Skidder Electrical and Computers
4. MEASURE MENU OPERATION
Measurements can be viewed for the following
channels:

CHANNELS FOR 635C SKIDDERS

6350501-6350510

6350511-6350513
6350515-6350530

6350531-6350550

6350551-6350620

6350621-6351000

INPUTS
6350514

TYPE SCREEN MESSAGE ACTIVATING CONTROL/SENSOR/SWITC LOCATION

* * * * * VOLTAGE IN Travel Speed Maximum speed control dial Control panel
* * * * * VOLTAGE IN Drive Pedal Fwd Forward drive pedal potentiometer Cab
* * * * * VOLTAGE IN Dozer Dozer lever Control panel
* * * * * VOLTAGE IN Drive Pedal Rev Reverse drive pedal potentiometer Cab
* * * * * VOLTAGE IN Winch In Winch lever Control panel
* * * * * VOLTAGE IN Front Diff Only Differential Lock Selector Switch Instrument panel
* * * * * VOLTAGE IN Joystick X Arch Joystick movement left/right Joystick
* * * * * VOLTAGE IN Joystick Y Boom Joystick movement forward/back Joystick
* * * * * VOLTAGE IN Engine Spd Trigg Engine speed control trigger Joystick trigger
* * VOLTAGE IN Brake Press Low Brake pressure switch Brake Accumulator - Under Cab
* * * VOLTAGE IN Air Filter Restricted Air Filter Restrictor Sensor Front Chassis
* * * * * VOLTAGE IN Hyd Oil Temp Hydraulic oil temperature sensor Hydraulic tank
* * * * * VOLTAGE IN Hyd Level Low Hydraulic oil level switch Hydraulic tank
* * * * * VOLTAGE IN Axle Filter Bypass Axle filter bypass switch Axle filter head
* VOLTAGE IN Park Brake PSI On Parking Brake Sensor Switch Parking Brake
* VOLTAGE IN Low Coolant Low coolant switch Surge tank
* * * * * VOLTAGE IN Drive PSI REV Drive pump reverse pressure sensor Drive pump
* * * * * VOLTAGE IN Drive PSI FWD Drive pump forward pressure sensor Drive pump
* * * * * VOLTAGE IN Charge Filter Bypass Charge filter bypass switch Charge filter head
* * * * * VOLTAGE IN Fuel Level Fuel level sender Rear chassis
* * * * * VOLTAGE IN Curvic Coupling Rear differential lock sensor switch Rear (bogie) axle

* * * * * DIGITAL IN Park Brake Sensor Parking brake proximity switch Parking brake lever - cab
* * * * * DIGITAL IN A/C Comp Clutch A/C Heater control (HVAC) Control panel
* * * * * DIGITAL IN Min Engine Spd Up Engine idle speed switch Control panel
* * * * * DIGITAL IN Min Engine Spd Dn Engine idle speed switch Control panel
* * * * * DIGITAL IN Fan Purge Fan Control switch Control panel
* * * * * DIGITAL IN Diff Lock Differential lock on/off Joystick button
* * * * * DIGITAL IN Constant Pressure Constant Pressure (Grapple) button Joystick button
* * * * * DIGITAL IN Fan Full Speed Fan Control switch Control panel
* * * * * DIGITAL IN Winch Free Spool Winch control switch Control panel
* * * * * DIGITAL IN Grapple Close Grapple Close button Joystick button
* * * * * DIGITAL IN Winch Lever Switch Winch lever switch Control panel
* * * * * DIGITAL IN Dozer Lever Switch Dozer lever switch Control panel
* * * * * DIGITAL IN Home Screen Gauges switch Instrument panel
* * * * * DIGITAL IN Grapple Open Grapple Open button Joystick button
* * * * * DIGITAL IN Grapple Rotate CW Grapple Rotate CW button Joystick button
* * * * * DIGITAL IN Grapple Rotate CCW Grapple Rotate CCW button Joystick button

* * * * * FREQUENCY IN Drive Motor rpm Drive motor speed sensor RH Drive motor

6.24
 Tigercat 635C Skidder
6350501-6350510 Electrical and Computers
6350511-6350513
6350515-6350530

6350531-6350550

6350551-6350620

6350621-6351000

OUTPUTS
6350514

TYPE SCREEN MESSAGE CONTROL ACTIVATED LOCATION

* * * CURRENT OUT Dozer Up-/Dn+ Control valve Dozer section Front chassis
* * CURRENT OUT Drive Pump Drive Pump Directional Solenoids Drive pump - front chassis
* * * * * CURRENT OUT Arch In-/Out+ Control valve arch section Rear chassis
* * * * * CURRENT OUT Winch In Control valve winch section Rear chassis
* * * * * CURRENT OUT Boom Up+/Dn- Control valve boom section Rear chassis
* * CURRENT OUT Motor Drive LH Proportional solenoid control LH Drive Motor
* * CURRENT OUT Motor Drive RH Proportional solenoid control RH Drive Motor
* * * CURRENT OUT Motor Drive Proportional solenoid control Front chassis
* * * CURRENT OUT Pump Drive Drive Pump Directional Solenoids Drive pump - front chassis

* * * * * DIGITAL OUT Front Diff Lock Differential lock relay & Selector Switch Instrument panel
* * * * * DIGITAL OUT Axle Pressure Valve Manifold Differential Lock & Winch Front chassis below hydraulic tank
* * * * * DIGITAL OUT Back-up Alarm Back-up alarm signal Cab
* * * * * DIGITAL OUT Constant Pres Light Constant pressure warning light Instrument panel
* * * * * DIGITAL OUT Fan Purge Fan manifold directional solenoid Front chassis
* * * * * DIGITAL OUT Rear Diff Lock Rear differential lock solenoid Rear chassis
* * * * * DIGITAL OUT Grapple Close Control valve grapple open/close section Rear chassis
* * * * * DIGITAL OUT Grapple Open Control valve grapple open/close section Rear chassis
* * * DIGITAL OUT Grapple Rotate CW Grapple Rotate CW button Joystick button
* * * DIGITAL OUT Grapple Rotate CCW Grapple Rotate CCW button Joystick button

* * PWM OUT Grapple Rotate Control valve grapple cw/ccw section

* * * * * PWM OUT Fan Speed(-) Fan manifold proportional solenoid Front chassis
* * PWM OUT Dozer Up-/Dn+ Dozer control valve Front chassis

6.25
Tigercat 635C Skidder Electrical and Computers
CHANNELS CURRENT OUT - TROUBLESHOOTING
The definition ‘channels’ is a collective name for FOR OPEN CIRCUITS
the inputs and outputs found on the different IQAN The COUT channel maintains a constant output
modules. There are also channels internally in the current to control proportional solenoids. The
system, to handle for example, MDM messages voltage is regulated to maintain the constant
and mathematical calculations. The channels are current based on the resistance of the circuit.
used to collect and/or send data. Input and output
It is important to note that currrent out readings
channels are described below.
displayed on the MDM display screen are
INPUTS measured at the current out (COUT) side of the
VOLTAGE IN (VIN) connection to the IQAN module (rather than the
current return (CRET) side).
The input signal at these inputs comes primarily
from analog sensors, levers, and switches. These When troubleshooting for problems with a function
devices use a power/signal/ground system to controlled by a CURRENT OUT signal the correct
provide an input value (VIN) between the high reading may appear on the screen even if there is
(+5V) and low (0 V) signals generated in the no CURRENT RETURN signal (an open circuit).
modules. In the case of an open circuit it will be necessary to
use a diagnostic breakout harness to identify an
DIGITAL IN (DIN) open circuit locate it. Refer to ELECTRICAL KIT -
An input that is typically on or off, such as a switch. SERVICE AND DIAGNOSTICS in this section for
This input is often used to determine if an event more information about diagnostic breakout
has occurred, such as pushing a button or harnesses.
engaging a relay.
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. CURRENT OUT VALUE
MEASURED AT COUT
OUTPUTS
CURRENT OUT (COUT) 620C-34 CURRENT OUT CONNECTIONS

The COUT channel maintains a constant output

current to control proportional solenoids. The
voltage is regulated to maintain the constant
current based on the resistance of the circuit.
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 the resistance in the circuit.
630C-211 DIAGNOSTIC BREAKOUT HARNESS
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.

6.26
Tigercat 635C Skidder Electrical and Computers
EXAMPLE ~ VIEW INPUT CHANNELS

Press SELECT (F1) to select VOLTAGE IN.

Press INPUTS (F1) to select INPUTS. Use UP/DOWN scroll buttons to select the
input channel you wish to view

Press MV (F1) to select show the voltage

value of the measurement.

Press UP/DOWN scroll button to move

through the INPUTS display screens
(VOLTAGE IN and DIGITAL IN).

Press SCALED (F1) to show the scaled value

of the measurement.

Press scope (F3) to view a graph of the

measurement over time.
Press ESCAPE button to return to previous
screen.

6.27
Tigercat 635C Skidder Electrical and Computers
EXAMPLE ~ VIEW OUTPUT CHANNELS

Press SELECT (F1) to select CURRENT OUT.

Press OUTPUTS (F2) to select OUTPUTS.
Press scope (F3) to view a graph of the

measurement over time.

Press ESCAPE button to return to previous

screen.

Press UP/DOWN scroll button to move

through the OUTPUTS display screens
(CURRENT OUT, PWM OUT and DIGITAL
OUT).

6.28
Tigercat 635C Skidder Electrical and Computers
5. PROPERTIES MENU OPERATION EXAMPLE:
A. ADJUST FUNCTION PARAMETERS
Adjusting function parameters is normally used
only by qualified Tigercat service technicians. Do
NOT attempt to adjust the function parameter
without proper training or specific instructions
from a service technician.
Auto RPM:
1.0 (function enabled) *
0.0 (function disabled) 620C-72

Pump Max Current: Press OTHER(F3) to select other

625 mA* (1250 mA earlier machines) properties for adjustment.
Motor Max Current: Use UP/DOWN scroll buttons to select
980 mA* type of output you wish to adjust.
Program Mode:
1 Normal mode*
2 HP Test mode**
3 Motor setup mode**
4 POR setup mode**
Clean Frequency (later machine programs):
30 minutes*
Fan Auto Clean (later machine programs):
1* (ON for normal operation)
620C-73
0 (OFF for service procedures)
* NOTE: Factory default settings are marked. Press SELECT (F1) to select.
Pump max current and motor max current Use UP/DOWN scroll buttons to select the
values may vary slightly from the factory default output you wish to adjust.
value given as these settings are factory
adjusted for optimum calibration of the drive
pump and motor.
**NOTE: When program modes 2,3 and 4 are
used a "For Service Use Only" warning
message is shown on the electronic display, an
alarm will sound and the alarm warning light will
flash. In addition the arch and boom are
deactivated in program modes 2,3 and 4.
620C-74

IMPORTANT Press SELECT(F1) to select a function

Machine must be in Program Mode 1 parameter for adjustment.
(Normal mode) to operate normally. Continued on next page

Program modes 2,3 and 4 are used for

service/setup procedures only.
When program modes 2,3 and 4 are used a
"For Service Use Only" warning message is
shown on the electronic display, an alarm
will sound and the alarm warning light will
flash. In addition the arch and boom are
deactivated in program modes 2,3 and 4.

6.29
Tigercat 635C Skidder Electrical and Computers

620C-75

Use UP/DOWN scroll buttons adjust

parameter setting.

620C-76

Select OK (F1) to confirm new setting.

6.30
Tigercat 635C Skidder Electrical and Computers
SYSTEM WARNING MESSAGES
When system warning messages are displayed the
alarm warning light will flash and horn will sound.
All system warning messages are logged and
recorded by the IQAN system for use by Tigercat
service technicians. Operators should respond to
all warning messages immediately by bringing the
machine to a safe stop and investigating the cause
630C-117
of the alarm.
The alarm can be acknowledged by pressing OK 1. OIL PRESSURE WARNING
(F1), if applicable. Note that acknowledging the
warning message does not address the cause of This warning will be displayed, alarm warning
the alarm. Ignoring system warning messages light will flash and horn will sound when engine
may result in component damage and/or oil pressure falls below 10psi(0.7 Bar). Stop
subsequent malfunction. In addition ignoring the engine when this alarm is activated.
system warning messages may also affect Check engine oil levels. See OPERATING
warranty claims. All warning messages should be MACHINE in SECTION 2 of the OPERATOR’S
addressed immediately to help ensure the efficient MANUAL for more information.
long term operation of the machine and avoid
costly repairs.

630C-121

2. HYDRAULIC OIL TEMPERATURE WARNING

This warning will be displayed, alarm warning
light will flash and horn will sound when the oil
temperature exceeds normal operating
temperatures.
If the temperature goes above 200°F (93°C)
check the following:
• Plugged oil cooler
• Malfunction in a hydraulic system
• High loads on the hydraulic system
• Low hydraulic oil level
Operation above 200°F (93°C) will shorten
hydraulic component life.
If the temperature reaches 200°F (93°C) DO
NOT continue to operate the machine. Refer
to FAN CONTROL in SECTION 2 of the
OPERATOR’S MANUAL.

6.31
Tigercat 635C Skidder Electrical and Computers

630C-120 630C-119

3. HYDRAULIC OIL LEVEL LOW WARNING 4. LOW COOLANT LEVEL WARNING

This warning will be displayed, alarm warning This warning will be displayed, alarm warning
light will flash and horn will sound when the light will flash and horn will sound when the
main hydraulic tank oil level is low. coolant level drops below a safe operating
level. The sensor is located in the surge tank.
Stop the engine immediately when this alarm is
If this light comes on when the engine is
activated. Operating machine with a low
running, stop the engine immediately and
hydraulic oil level can cause hydraulic pumps
correct the fault. With engine running, top up
to fail.
radiator using correct solution of coolant
When this alarm is activated stop the engine antifreeze. Refer to SERVICE AND
and look for signs of broken hoses or other LUBRICATION POINTS CHART in SECTION
leaks. Repair leaks and refill the main 3 of THIS MANUAL.
hydraulic tank to FULL mark on the sight
gauge. Restart engine and inspect for leaks. WARNING

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.

6.32
Tigercat 635C Skidder Electrical and Computers

630C-123 630C-122

5. WINCH FREESPOOL ON WARNING 7A. VOLTAGE WARNING

EARLIER MACHINES 6350501 TO 6350530
This warning will be displayed, alarm warning
light will flash and horn will sound whenever This warning will be displayed, alarm warning
the winch control switch is in the FREE light will flash and horn will sound when
SPOOL position. Refer also to WINCH voltage readings of less than 9 volts or greater
CONTROL SWITCH in SECTION 2 of THE than 15 volts are detected.
OPERATOR’S MANUAL.
When this alarm is activated investigate the
cause immediately.

IMPORTANT
12 VOLT ELECTRICAL SYSTEM

630C-118

6. ENGINE TEMPERATURE WARNING

This warning will be displayed, alarm warning
light will flash and horn will sound when engine
temperature exceeds 220°F (104°C). 630C-122X

When this alarm is activated check for low fan

7B. VOLTAGE WARNING
speed setting, plugged air intake access panel
LATER MACHINES 6350531 TO 6351000
screens or plugged radiator. DO NOT continue
to operate machine. Refer to CLEANING A/C This warning will be displayed, alarm warning
CONDENSER AND COOLING ASSEMBLY light will flash and horn will sound when
and FAN CONTROL in SECTION 2 of THE voltage readings of less than 20 volts or
OPERATOR’S MANUAL. greater than 30 volts are detected.
When this alarm is activated investigate the
cause immediately.
IMPORTANT
24 VOLT ELECTRICAL SYSTEM

6.33
Tigercat 635C Skidder Electrical and Computers

8. AXLE FILTER IN BYPASS WARNING 9. CHARGE FILTER IN BYPASS WARNING

This warning will be displayed when an oil flow This warning will be displayed when an oil flow
restriction in excess of 50 psi (3.5 Bar) is restriction in excess of 50 psi (3.5 Bar) is
encountered at the axle filter. This pressure encountered at the hydrostatic oil charge filter.
build up also opens the filter bypass valve in This pressure build up also opens the filter
the filter head allowing oil to bypass the filter bypass valve in the filter head allowing oil to
element. bypass the filter element.
When this happens the filter requires When this happens the filter requires
immediate service. When axle filter is in immediate service. If alarm sounds during cold
bypass differential locks function is not start-ups, the engine speed should be reduced
available. If alarm sounds during cold start- and the warm-up procedure continued. Note
ups, the engine speed should be reduced and that the bypass warning will only be displayed
the warm-up procedure continued. Note that when hydraulic oil temperature is above 75°F
the bypass warning will only be displayed when (24°C) and the filter is in bypass mode.
hydraulic oil temperature is above 75°F (24°C)
and the filter is in bypass mode.

6.34
Tigercat 635C Skidder Electrical and Computers

IMPORTANT
Machine must be in Program Mode 1
(Normal mode) to operate normally.

Program modes 2,3 and 4 are used for

service/setup procedures only.
610-20-2 When program modes 2,3 and 4 are used a
"For Service Use Only" warning message is
shown on the electronic display, an alarm
will sound and the alarm warning light will
flash. In addition the arch and boom are
deactivated in program modes 2,3 and 4.

610-20-3

630C-250

11. AIR INTAKE RESTRICTED

SERVICE INTAKE TO CORRECT
610-20-4 This warning will be displayed when a signal is
received from the restriction indicator switch (if
equipped) on the engine air cleaner. Later
10. FOR SERVICE USE ONLY WARNING machines (6350531 to 6351000) are factory
One of these warnings will be displayed when equipped with a restriction indicator switch.
the machine is placed in a service program When this happens the engine air cleaner
mode: requires immediate service. Refer to AIR
HP Test mode (Program Mode 2) CLEANER MAINTENANCE in SECTION 3 of
Motor Setup mode (Program Mode 3) THIS MANUAL.
POR setup mode (Program Mode 4)
Program modes 2, 3 and 4 are intended for
setup and testing and should only be used by
qualified Tigercat service technicians or on
specific instructions from a service technician.
Note also that the arch and boom are
deactivated in program modes 2, 3 and 4.
For more information on the Program Mode
function parameter refer to INFORMATION
CENTER -IQAN MDM COMPUTER
DISPLAY~SYSTEM DIAGNOSTICS
MENUS~DIAGNOSTICS MENU
OPERATION~PROPERTIES MENU
OPERATION in THIS SECTION.

6.35
Tigercat 635C Skidder Electrical and Computers

12. BRAKE PRESSURE LOW 14. CHARGE PRESSURE LOW WARNING

(LATER PROGRAMS) (LATER PROGRAMS)
This warning will be displayed when service This warning will be displayed when charge
brake pressure falls below 800 psi (55 Bar). pressure falls below 250 psi (17 Bar). The
When this warning is activated first check for charge pressure is monitored at the forward
leaks in the brake circuit. If no leaks are found and reverse pressure sensors on the drive
check for proper operation of the brake pump.
pressure section of the control valve and When this warning is activated check the
check the brake pressure sensor for proper charge filter for proper operation then, if
operation. For more information about the necessary, check the charge pressure using a
service brake circuit refer to SECTION 9 in gauge. Refer to DRIVE PUMP PRESSURE
THIS MANUAL. CHECKS in SECTION 8 of THIS MANUAL.
Refer also to CHARGE FILTER BYPASS
WARNING in THIS SECTION.

13. FUEL LEVEL LOW (LATER PROGRAMS) 822C-48

This warning will be displayed when the fuel

level falls below 2% of full. Refer to FUEL 15. FAN CLEAN MODE
TANK in SECTION 2 of the OPERATOR’S This message will be displayed while the
MANUAL for tank capacities. cooling fan control is performing an automatic
CLEAN cycle. The graphical display indicates
to the operator the percentage of the cycle
completed.
The CLEAN cycle is either operated manually
from the COOLING FAN SWITCH or
automatically by the timed purge function of
the computer control system. Refer also to
CAB CONTROLS ~ FAN CONTROL SWITCH
and COMPUTER ~ DIAGNOSTICS ~ ADJUST
FUNCTION PARAMETERS (Clean Frequency,
Fan Auto Clean) in THIS SECTION.

6.36
Tigercat 635C Skidder Electrical and Computers
MAIN SYSTEM ERRORS MODULE IS OFFLINE

MDM MODULE BLANK SCREEN The MODULE IS OFFLINE warning message

indicates a loss of communication with or power to
The MDM module is the central unit in the IQAN
an IQAN module. The offline module is identified
control system, which works as both a master and
on the display screen.
a display unit. Faults or failure in this unit will
affect all other IQAN components. When a module goes offline all machine functions
controlled by that module cease and all alarms and
Likely causes are:
warnings associated with that module are
• Power - Fuse (MDM BATTERY or MDM CLOCK) triggered. If the problem is with the CAN wires all
• Ground modules beyond the problem module will also be
affected.
• LCD display settings too light to read
NOTE: It is possible for an operator or service
• Faulty MDM module technician to disable this warning message. If the
MODULE IS OFFLINE warning function is disabled
for a module the first indication of a loss of
communication or power to a module will be the
loss of all machine functions controlled by the
module and the triggering of all alarms and
warnings associated with that module. This may
cause problems in identifying the source of a
control problem, as it will not be immediately
obvious that a loss of communication or power to
the module is the source of the problem.

To greatly reduce the time required to diagnose a

MODULE IS OFFLINE warning, it is recommended
that all available modules ALWAYS be set to
ENABLED as shown. This screen is accessed
through the INFORMATION MENU, which should
normally be accessed by Tigercat service
technicians only. Refer to INFORMATION
CENTER~SYSTEM DIAGNOSTICS
MENUS~DIAGNOSTICS MENU OPERATION
inTHIS SECTION.

6.37
Tigercat 635C Skidder Electrical and Computers

SUPPLY
VOLTAGE LED
XS-A0 MODULE OFFLINE ERROR
Expect all machine functions controlled by this HEART LED
module to cease and all alarms and warnings
associated with this module to be triggered. ••••• ARROW LED

1. CHECK FOR OTHER ERROR/ALARM

MESSAGES ON SCREEN
635C-28 XS-A0 CAB MODULE
Press OK to acknowledge each error
2. CHECK MODULE STATUS INDICATORS
message. Note that module offline errors will
be followed by other alarm messages Status lights can also give an immediate
associated with the module(s) which is(are) indication of the nature of the error.
offline.
Supply Voltage LED.
If XS-A0 MODULE IS OFFLINE is the only
LED ON solid green light indicates supply
module is offline error message the likely
voltage is ON.
causes are:
LED OFF indicates supply voltage is OFF.
• Power - Fuse (XS MODULE)
Arrow and Heart Status Indicator LEDs.
• Ground
LED for Heart and Arrow flash alternately
• Address (ID-Tag)
(solid green) indicates Status is Correct.
If the XS-A0 MODULE IS OFFLINE is
When Heart LED is off and LED for arrow
followed by XT2-A0 and XP2-A0 MODULE IS
flashes (green), this indicates the following
OFFLINE errors the likely cause is:
errors:
• CAN wire connection
• One flash indicates fault on inputs/outputs
or that supply voltage is to low or to high.
• Two flashes in a row indicates that the
internal temperature of the unit is to high or
to low.
• Three flashes in a row indicates that the
fault is related to the CAN-bus.
• Four flashes in a row indicates an internal
fault on the hardware of the unit.
XS Module

Error code Blink (Arrow only green light)

I/O and voltage errors

Low/High temperature
CAN error
VREF error

6.38
Tigercat 635C Skidder Electrical and Computers

•• ••
1014-042 XT2-A0 MODULE LED INDICATORS
2. CHECK MODULE STATUS INDICATORS
XT2 MODULE OFFLINE ERROR
Status lights can also give an immediate
Expect all machine functions controlled by this indication of the nature of the error.
module to cease and all alarms and warnings
associated with this module to be triggered. (1) Supply Voltage LED.

1. CHECK FOR OTHER ERROR/ALARM LED ON solid green light indicates supply
MESSAGES ON SCREEN voltage is ON.

Press OK to acknowledge each error LED OFF indicates supply voltage is OFF.
message. Note that module offline errors will (2) Status indicator LED (yellow/red).
be followed by other alarm messages
LED yellow flashing light indicates status is
associated with the module(s) which is(are)
correct.
offline.
LED flashing red light indicates error status as
If XT2-A0 MODULE IS OFFLINE is the only
follows:
module is offline error message the likely
causes are: • One flash indicates fault on inputs/outputs
or that supply voltage is to low or to high.
• Power - Fuse (XT2 MODULE)
• Two flashes in a row indicates that the
• Ground internal temperature of the unit is to high or
• Address (ID-Tag) to low.
• Three flashes in a row indicates that the
If the XT2-A0 MODULE IS OFFLINE is
fault is related to the CAN-bus.
followed by the XP2-A0 MODULE IS
OFFLINE error the likely cause is: • Four flashes in a row indicates an internal
fault on the hardware of the unit.
• CAN wire connection
• Five flashes in a row indicates that the fault
is related to the address.
• Continuous flashing indicates the fault is
related to software.
LX-, XP2- and XT2- module

Error code Blink (red light)

I/O and voltage errors

Low/High temperature
CAN error
Hardware error
Address error
Software error

6.39
Tigercat 635C Skidder Electrical and Computers

•• ••
1014-042 XP2-A0 MODULE LED INDICATORS
2. CHECK MODULE STATUS INDICATORS
XP2 MODULE OFFLINE ERRORS Status lights can also give an immediate
Expect all machine functions controlled by this indication of the nature of the error.
module to cease and all alarms and warnings (1) Supply Voltage LED.
associated with this module to be triggered.
LED ON solid green light indicates supply
1. CHECK FOR OTHER ERROR/ALARM voltage is ON.
MESSAGES ON SCREEN
LED OFF indicates supply voltage is OFF.
Press OK to acknowledge each error
message. Note that module offline errors will (2) Status indicator LED (yellow/red).
be followed by other alarm messages LED yellow flashing light indicates status is
associated with the module(s) which is(are) correct.
offline.
LED flashing red light indicates error status as
Note also that the XP2-A0 module is the follows:
terminal module in the series connection.
• One flash indicates fault on inputs/outputs
Therefore failure of this module alone will not
or that supply voltage is to low or to high.
affect any other modules in the series.
• Two flashes in a row indicates that the
If the XP2-A0 MODULE IS OFFLINE is internal temperature of the unit is to high or
the only module is offline error message the to low.
likely causes are: • Three flashes in a row indicates that the
• Power - Fuse (XP2 MODULE) fault is related to the CAN-bus.
• Ground • Four flashes in a row indicates an internal
fault on the hardware of the unit.
• Address (ID-Tag)
• Five flashes in a row indicates that the fault
• CAN wire connection is related to the address.
If the XP2-A0 MODULE IS OFFLINE error is • Continuous flashing indicates the fault is
not the only module is offline error message related to software.
check other affected modules in order from the
LX-, XP2- and XT2- module
MDM connection (XS-A0, XT2-A0). Refer to
MODULE IS OFFLINE ERROR for each Error code Blink (red light)

module for more detailed information. I/O and voltage errors

Low/High temperature
CAN error
Hardware error
Address error
Software error

6.40
Tigercat 635C Skidder Electrical and Computers
ENGINE RELATED
J1939 CONNECTION ERRORS
The J1939 connection to the engine computer is
connected to the XT2-A0 (front chassis) module.
If this connection is damaged or severed the
following error messages will appear on screen in
order (immediately after the key is turned OFF
then back to RUN).

5. 0.0 ! (Oil Pressure Default value)

6. 0.0 ! (Voltage Default value)

630C-117

1. Low Engine Oil Pressure Alarm

7. 410 ! (Engine Temp Default value)

8. 410 ! (CAC Temp Default value)

630C-118

2. High Engine Temp Alarm

9. 0.0 ! (Eng % Torque Default value)

10. 0.0 ! (Eng%Load Default value)
11. 0.0 ! (Boost - Default value)
630C-122
12. 0.0 ! (Fuel Temp - Default value)
3. Voltage Alarm 13. 0.0! (Fuel Rate - Default value)
14. 0.0! (Fuel Used - Default value)

4. 1000 ! (Engine Speed Default value)

6.41
Tigercat 635C Skidder Electrical and Computers
The two most likely causes of this type of error are:
• J1939 wire connections to XT2-A0
• Loss of power to XT2-A0.
LOSS OF POWER TO XT2-A0
The loss of power to XT2-A0 may cause problems
with the J1939 connection. In particular loss of
power during engine starts may cause this type of
problem.
When power to the XT2-A0 is lost and then
restored the XT2-A0 may not reconfigure the
J1939 connection on its own.
Temporary Fix:
• To force the XT2-A0 to reconfigure the J1939
connection, disconnect the CAN connector
from the back of the MDM module and then
reconnect it. Refer to MDM DISPLAY
MODULE in THIS SECTION.
Permanent Fixes:
• Troubleshoot XT2 power connections and
correct any problems found.
• Replace the XT2 module.

6.42
Tigercat 635C Skidder Electrical and Computers
TEMPORARY FIX FOR ENGINE RPM
PLACE ANY FUSE TO
CONTROL PROBLEMS CAUSED BY DEFAULT ENGINE
J1939 CONNECTION ERRORS RPM TO HIGH IDLE

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. ELECTRICAL BOX
(LEFT SIDE FRONT CHASSIS)
625C-90 (6350531 TO 6350550)

PLACE ANY FUSE TO

DEFAULT ENGINE
RPM TO HIGH IDLE

••
PLACE ANY FUSE TO
DEFAULT ENGINE
RPM TO HIGH IDLE
ELECTRICAL BOX 625C-95
(LEFT SIDE FRONT CHASSIS)
635C-29 (6350501 TO 6350530)

••
2A

ELECTRICAL BOX
(LEFT SIDE FRONT CHASSIS)
(6350551 TO 6351000)

6.43
Tigercat 635C Skidder Electrical and Computers
FAULT CODES : ERROR MESSAGES COMMON ERROR MESSAGES
A typical fault code error message is described ERROR: INPUT LOW
below.
Applies to : Voltage In if fault detection is in use.
Note: When contacting Tigercat Customer service
Probable cause: Short circuit to ground.
about any error message it is very important to
write down and communicate the whole message ERROR :INPUT HIGH
(all text shown on the screen). This will greatly Applies to : Voltage In if fault detection is in use.
reduce troubleshooting time.
Probable cause: Short circuit to VBAT (battery
1 3 5 side).
ERROR: OUTPUT LOW
2
•••• •• •• Applies to : Current Out if fault detection is in use.

4
• Probable cause: Return current is lower than the
set value.
ERROR: OUTPUT HIGH
Applies to : Current Out if fault detection is in use.
630C-187 TYPICAL ERROR MESSAGE
Probable cause: Return current is higher than the
1. TYPE OF ERROR set value.
Refers to the type of error being shown. There
are several common error types including:
• ERROR: INPUT LOW
• ERROR :INPUT HIGH
• ERROR: OUTPUT LOW
• ERROR: OUTPUT HIGH
2. MODULE ADDRESS
The module address identifies the module Example 1:
from which an error signal is being received.
In this case XS-A0. Refer also to ID-TAG in 1. ERROR: INPUT LOW
THIS SECTION for additional information 2. XS-A0 IQAN module (cab)
about module addresses. 3. Connector 1 : Pin 3 (on XS module)
4. Drive Pedal Fwd (Forward Drive Pedal)
3. PIN NUMBER 5. Defaults to 0.0% in the event of an error
Refers to pin number for the error generating Probable cause: Short circuit to ground.
function. Pin numbers match those shown on
pin diagrams and electrical schematics.
4. FUNCTION NAME
This name is programmed by tigercat to
identify the function.
5. DEFAULT ERROR VALUE
This is a programmed default value, which the
computer control system substitutes for actual
readings in the event of a signal error. These
values are chosen for safety reasons and to
protect the machines components from
damage in the event of a signal error from the
control system.

6.44
Tigercat 635C Skidder Electrical and Computers

Example 2:
1. ERROR: INPUT LOW
2. XT2-A0 module (front chassis)
3. Connector 1 : Pin 36
4. Drive PSI (pressure sensors on drive
motors)
5. Defaults to 5000 psi in the event of an error
Probable cause: Short circuit to ground.

6.45
Tigercat 635C Skidder Electrical and Computers
ELECTRICAL KIT - SERVICE AND
DIAGNOSTICS
This kit includes a variety of electrical connectors,
tools, cable, IQAN components, diagnostic break-
out 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 DIAGNOSTIC BREAKOUT HARNESS
2. DIAGNOSTIC BREAKOUT HARNESS is tagged as “Modem” and the serial connector
DEUTSCH CONNECTOR - VOLTAGE will have female sockets. Cable DG023 can
(20037B) be used in place of DG029 for most purposes
This harness is used to check voltage (volts) to however, to install an IQAN vmAC file cable
a component with a Deutsch connector and DG029 must be used.
verify inputs. 6. IQAN DATA CABLE FOR PC/LAPTOP
3. DIAGNOSTIC BREAKOUT HARNESS (DG024 - NOT STANDARD IN THIS KIT)
AMP CONNECTOR - CURRENT (20038B) This cable is used to connect the IQAN MDM
This harness is used to check current (amps) module RS232 port directly to COM1 serial
flow to a component with an Amp connector port on the PC/Laptop. This cable is tagged as
and verify outputs. “PC”.
4. DIAGNOSTIC BREAKOUT HARNESS 7. ID-TAG ‘0’ (AN068)
AMP CONNECTOR - VOLTAGE (20039B) This is a replacement address tag. This tag is
This harness is used to check voltage (volts) to used for addressing the LX-A0 and XT2-A0
a component with an Amp connector and verify modules. Refer to ID-TAG in THIS SECTION
inputs. for more detailed information.
5. IQAN DATA CABLE FOR PDA (DG029) 8. ID-TAG ‘0T’ (AN071)
This cable is used to connect the IQAN MDM This is a replacement address/terminating tag.
module RS232 port to a PDA via a serial port This tag is used for addressing the XP2-A0
adapter cable (for the PDA being used ). The module. Refer to ID-TAG in THIS SECTION
serial port adapter cable is unique to each for more detailed information.
specific PDA model and is not available 9. DEUTSCH 2 POLE SERVICE HARNESS
through Tigercat. (24860B)
It is very important that the correct IQAN data This harness is used to bypass a wiring
cable be used for connection to a PDA. Use of harness while troubleshooting electrical
the incorrect cable may cause damage to the problems. This will identify or eliminate the
PDA. This cable is tagged as “Palm” and the wiring harness as a cause.
serial connector will have female sockets.
10. AMP 2 POLE SERVICE HARNESS (24859B)
Note: Some earlier versions of this kit supplied
IQAN data cable for PDA (DG023) This cable This harness is used to bypass a wiring
harness while troubleshooting electrical
problems. This will identify or eliminate the
IMPORTANT
wiring harness as a cause.
Damage may occur to the PDA if the wrong
data cable is used. Ensure the appropriate
cable is selected when using a PDA; DO NOT
USE AN ADAPTER TO MATCH UP SERIAL
PORTS.

6.46
Tigercat 635C Skidder Electrical and Computers

1 2
9

3 4
10

5 6

7 8 TWISTED PAIR WIRE

REPAIR HARNESS

855C-002 ELECTRICAL KIT - SERVICE AND DIAGNOSTICS - SELECTED ITEMS

6.47
Tigercat 635C Skidder Electrical and Computers
IQAN SOFTWARE PDA REGISTRATION
IQAN software can be downloaded from the In order to use a PDA (personal digital assistant)
Tigercat Dealer Website. to perform maintenance procedures the PDA must
All software required for both PC (laptop) and PDA be registered for authorized use of the software on
use is included in this download. A user’s manual Tigercat products. Each Tigercat product line has
in PDF format is also included. Some of the its own application code and must be registered
software requires a software key (available from separately for authorized use.
Tigercat). NOTE: In the event of a battery failure in a PDA
Contact Tigercat Customer Service for more registration information may be lost. If this occurs
information about specific hardware requirements it will be necessary to re-register the PDA for use.
for PC (laptop) and PDA. Contact Tigercat Customer Service or your
Tigercat District Manager for more information
about registering a PDA.
IQAN DEVELOP G4 SOFTWARE
UPGRADE (PSB 1739)
Due to a recent update, new Tigercat machines
equipped with MDM display modules will no longer
be serviceable using IQAN Develop software in the
G3 version. Instead, the new machines will require
IQAN Develop G4 to send and receive programs
and take live measurements and graphs.
Although the G3 software will still be compatible
with older machines, deleting all G3 software and
using only the G4 version is strongly
recommended to avoid confusion. Replacement
MDM modules will only be programmable with the
G4 software.
Upgraded IQAN Develop G4 can be used to
service ALL machines equipped with any MDM,
APPLICATION PROGRAM UPDATES including those that were originally programmed
FOR PRODUCT SERVICE BULLETINS with the G3 software.
Machine program updates are also available on However, when servicing a G3 programmed MDM
the Tigercat dealer website. These program (vmAC version is 3.72 or lower) the vmAC will
updates are generally associated with specific need to be updated to 4.50 or higher. The vmAC
Product Service Bulletins. Updating of programs version is briefly displayed on the screen when an
should only be undertaken as part of a PSB or MDM module is powered on.
under instruction from Tigercat Customer Service.
The latest version of the application can be run on Please refer to Tigercat PSB 1739 for complete
any machine provided that all applicable Product information and instructions to install IQAN
Service Bulletin updates have been completed. Develop G4 software and update the vmAC
(version is 3.72 or lower) to be compatible with G4
software.

6.48
Tigercat 635C Skidder Electrical and Computers
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.
DOWNLOADING APPLICATIONS AS IDT FILES

3. The correct folder location must be manually

chosen. C:\Program Files\IQANdevelop 4\
Applications.
4. Click on Save.
5. The IQAN program file has now been
downloaded to the correct folder.

1. Click on the IDT to the right of the file you wish

to download.

2. Click on Save.

6.49
Tigercat 635C Skidder Electrical and Computers
UPDATING THE IQAN APPLICATION
A. UPDATING THE IQAN APPLICATION FROM
A PDA (PERSONAL DIGITAL ASSISTANT)
The following procedure instructs how to send
a Tigercat IQAN application from a PDA
(Personal Digital Assistant) device to the MDM
module.
To perform this procedure you will require:
• PDA
• IQAN data cable for PDA
• PDA serial port adapter cable (for the PDA
being used).
1. Park machine on level ground, lower all
implements to the ground, set the park
brake ON, and turn the key switch to OFF.
2. Locate the ‘round’ RS232 port connection
on the back of the MDM. Do not
disconnect the rectangular 6-pin
connector. PDA MAIN IQAN WINDOW
Note: This will require temporary removal 5. Turn on power to the PDA, and start the
of the MDM from its mounting location (4 IQANdevelop program.
screws). 6. Turn the key switch to ‘RUN’. DO NOT
3. Remove the rubber dust seal from the START THE MACHINE.
RS232 port and connect IQAN data cable
for PDA.

IMPORTANT
Damage may occur to the PDA if the wrong
data cable is used. Ensure the appropriate
cable is selected when using a PDA; DO NOT
USE AN ADAPTER TO MATCH UP SERIAL
PORTS.

IQAN DATA CABLE PDA SERIAL PORT

FOR PDA ADAPTER CABLE

IQAN - MDM
PALM OS PDA

CONNECTING MDM TO PDA

PDA DROP DOWN MENU DISPLAY
4. Connect the other end of the cable to the
serial port adapter cable for the PDA being 7. Select the ‘IQAN’ box from the top left
used. corner of the PDA screen. This will display
a drop down menu showing ‘System /
Options / Help’.

6.50
Tigercat 635C Skidder Electrical and Computers
8. From the ‘System’ menu, select ‘Update 18. Start the machine and verify correct
application…’. Note: it will take a moment operation of the new application.
for the PDA to display available application
19. Turn the key switch to ‘OFF’.
programs.
20. Turn off power on the PDA.
9. All IQAN application programs available for
upload will be displayed. 21. Disconnect the IQAN data cable for PDA
from both the MDM and the PDA serial port
10. Highlight the appropriate application
adapter cable.
program by selecting it on the PDA screen.
22. Reinstall the rubber dust seal on the MDM
RS232 port. Reinstall the MDM into the
mounting panel (4 screws).

PDA SEND APPLICATION DIALOG BOX

11. Select the ‘SEND’ box. This will display a
dialog box titled ‘Send application’.
12. Set the ‘Factory default values’ to ‘Use
values from application file’.
13. Set the ‘Adjustable values’ to ‘Use values
from application file’.
14. Set the ‘Stored values’ to:
For an MDM previously installed:
‘Leave values in master unchanged’.
For a new MDM (field replacement):
‘Reset all values to zero’.
15. Select the ‘SEND’ box. The MDM will
display ‘! RECEIVING APPLICATION !’.
Important: The upload process should
take less than one minute to complete.
During this time, do not perform any other
functions on the PDA, or turn off power to
the MDM. DO NOT START THE
MACHINE. Should this occur, the upload
will be halted and incomplete; starting from
the beginning will be required.
16. Once the application is sent, turn off power
to the MDM.
17. Select the ‘DONE’ box on the PDA. This
will return the PDA display to the
IQANdevelop main screen.

6.51
Tigercat 635C Skidder Electrical and Computers
B. UPDATING THE IQAN APPLICATION FROM code and select the ‘OK’ box. Note:
A PC/LAPTOP contact the Tigercat Customer Service to
acquire the correct application code.
The following procedure instructs how to send
a Tigercat IQAN application from a personal
computer (PC) or laptop to complete an upload
of a Tigercat IQAN application.
To perform this procedure you will require:
• PC/Laptop
• IQAN data cable for PC/Laptop (no adapter
cable required)
• Hardware key (Parker IQAN component
available from Tigercat)
1. Park machine on level ground, lower all
implements to the ground, set the park
brake ON, and turn the key switch to OFF.
2. Locate the ‘round’ RS232 port connection
on the back of the MDM. Do not 9. Using the toolbar: select the ‘Send current
disconnect the rectangular 6-pin application to IQAN system’ icon.
connector.
OR
Note: This will require temporary removal
of the MDM from its mounting location (4 Using the drop-down menus: select
screws). ‘System’, ‘Send application…’.
3. Remove the rubber dust seal from the
RS232 port and connect IQAN data cable
for PC/Laptop.
4. Connect the other end of the cable to the
COM1 serial port on the PC/Laptop.
5. Turn on power to the computer, and start
the IQANdevelop program.
6. Turn the key switch to ‘RUN’. DO NOT
START THE MACHINE.
7. Open the new application in IQANdevelop
on the computer.

10. This will display another dialog box titled

‘Send application’.
11. Set the ‘Factory default values’ to ‘Use
values from application file’.
12. Set the ‘Adjustable values’ to ‘Use values
from application file’.
13. Set the ‘Stored values’ to:
For an MDM previously installed:
‘Leave values in master unchanged’.
For a new MDM (field replacement):
8. A dialog box titled ‘Enter application code’ ‘Reset all values to zero’.
will appear. Enter the correct application

6.52
Tigercat 635C Skidder Electrical and Computers
20. Disconnect the IQAN data cable for PC/
Laptop from both the MDM and the
computer.
21. Reinstall the rubber dust seal on the MDM
RS232 port. Reinstall the MDM into the
mounting panel if previously removed.

14. Select the ‘SEND’ box. The MDM will

display ‘! RECEIVING APPLICATION !’.
Note: In some cases a dialog box will
appear titled ‘IQANdevelop: Confirmation’.
This dialog box states that the current
application has a different description than
the application loaded in the IQAN system.
Select the ‘Yes’ box to continue.
Important: The upload process should
take less than one minute to complete.
During this time, do not perform any other
functions on the computer, or turn off
power to the MDM. DO NOT START THE
MACHINE. Should this occur, the upload
will be halted and incomplete; starting from
the beginning will be required.

15. When the upload is complete, the

computer display will return to the
IQANdevelop main screen.
16. Turn off power on the MDM.
17. Start the machine and verify correct
operation of the new IQAN application.
18. Turn the key switch to ‘OFF’.
19. Turn off power on the computer.

6.53
Tigercat 635C Skidder Electrical and Computers
GET APPLICATION 5. Turn on power to the PDA, and start the
(DOWNLOAD FROM MDM) IQANdevelop program.
A. GET APPLICATION USING A PDA
(PERSONAL DIGITAL ASSISTANT)
The following procedure instructs how to
retrieve a Tigercat IQAN application with a
PDA (Personal Digital Assistant) device from
the MDM (Master Display Module).
To perform this procedure you will require:
• PDA
• IQAN data cable for PDA
• PDA serial port adapter cable (for the PDA
being used).
1. Park machine on level ground, lower all
implements to the ground, set the park
brake ON, and turn the key switch to OFF.
2. Locate the ‘round’ RS232 port connection
on the back of the MDM. Do not
disconnect the rectangular 6-pin
connector.
Note: This will require temporary removal PDA MAIN IQAN WINDOW
of the MDM from its mounting location (4
screws). 6. Turn the key switch to ‘RUN’. DO NOT
3. Remove the rubber dust seal from the START THE MACHINE.
RS232 port and connect IQAN data cable
for PDA.

IMPORTANT
Damage may occur to the PDA if the wrong
data cable is used. Ensure the appropriate
cable is selected when using a PDA; DO NOT
USE AN ADAPTER TO MATCH UP SERIAL
PORTS.

IQAN DATA CABLE PDA SERIAL PORT

FOR PDA ADAPTER CABLE

IQAN - MDM
PALM OS PDA

CONNECTING MDM TO PDA

SELECTING AN EMPTY SLOT
4. Connect the other end of the cable to the
serial port adapter cable for the PDA being 7. Select an <empty slot> from the top right of
used. the PDA screen. This is the location the
application program will be downloaded to.

6.54
Tigercat 635C Skidder Electrical and Computers
8. In the IQANdevelop main screen, select the 7. Open the new application in IQANdevelop
on the computer.

icon.

9. This will display a new dialog box titled

‘Receiving…’, and the download process will
begin.
10. Once the download process is complete, the
PDA display will return to the main
IQANdevelop window. The downloaded
application description will replace the <empty
slot> in the top right corner of the PDA.
Important: The download process should take
less than one minute to complete. During this
time, do not perform any other functions on the 8. A dialog box titled ‘Enter application code’
PDA, or turn off power to the MDM. DO NOT will appear. Enter the correct application
START THE MACHINE. Should this occur, the code and select the ‘OK’ box. Note:
download will be halted and incomplete; contact the Tigercat Customer Service to
starting from the beginning will be required. acquire the correct application code.
B. GET APPLICATION USING A 9. Using the drop-down menus: select
A PC/LAPTOP ‘System’, ‘Get application’
The following procedure instructs how to
retrieve a Tigercat IQAN application with a
personal computer (PC), or laptop from the
MDM (Master Display Module).
To perform this procedure you will require:
• PC/Laptop
• IQAN data cable for PC/Laptop (no adapter
cable required)
• Hardware key (Parker IQAN component
available from Tigercat)
1. Park machine on level ground, lower all
implements to the ground, set the park
brake ON, and turn the key switch to OFF.
10. Choose a filename and the location you
2. Locate the ‘round’ RS232 port connection wish to save the file. Click on Save.
on the back of the MDM. Do not
disconnect the rectangular 6-pin
connector.
Note: This will require temporary removal
of the MDM from its mounting location (4
screws).
3. Remove the rubber dust seal from the
RS232 port and connect IQAN data cable
for PC/Laptop.
4. Connect the other end of the cable to the
COM1 serial port on the PC/Laptop.
5. Turn on power to the computer, and start
the IQANdevelop program.
11. A pop-up box will confirm that the file is
6. Turn the key switch to ‘RUN’. DO NOT
being downloaded.
START THE MACHINE.
6.55
Tigercat 635C Skidder Electrical and Computers
12. When the download is complete, the GRAPHING AND MEASUREMENT OF
computer display will return to the CHANNELS
IQANdevelop main screen. A. GRAPHING AND MEASUREMENT OF
13. Turn the key switch to ‘OFF’. CHANNELS USING A PDA
14. Turn off power on the computer. The following procedure instructs how to graph
and measure channels with a PDA (Personal
15. Disconnect the IQAN data cable for PC/
Digital Assistant) device from the MDM (Master
Laptop from both the MDM and the
Display Module).
computer.
1. Get application from the MDM. Refer to
16. Reinstall the rubber dust seal on the MDM
IQAN SOFTWARE ~GET APPLICATION
RS232 port. Reinstall the MDM into the
procedure in THIS SECTION.
mounting panel if previously removed.
2. Tap the channels icon.
3. Select the channel type in popup list and
then a channel.
Highlight a channel by tapping on the
channel’s name. (Used for graphing)
Notice only one channel at a time can be
graphed.
Check a channel by tapping on channel
box. (Used for measure) You can measure
more than one channel at a time.
4. To measure on channels tap the Measure
button. The channel you have selected in
channels window with checkboxes will
show up. Tap the Start button to start
measure. Tap the stop button to stop. (The
button label changes from start to stop and
vice versa). For each channel you will see
the value and the status indicator. If the
value is ok, OK will show. If not then you
see “!!!”. By tapping on the channel you will
see the channel name, channel unit,
complete status message and pin
assignment at the bottom of screen.

You can change the scale (relates to the

type of channel) by taping to top right
corner.

6.56
Tigercat 635C Skidder Electrical and Computers
The Clear button is used to deselect all master cycle time. Measurement is
selected channels and return to channels typically carried out with a 100ms sample
window. interval on Palm. That means the glitches
and spikes on the signal may not be
5. You can also graph a channel. This means
registered.
you can measure graphically one channel
B. GRAPHING AND MEASUREMENT OF
CHANNELS USING A PC/LAPTOP
The following procedure instructs how to graph
and measure channels with a PC/Laptop from
the MDM (Master Display Module).
1. Get application from the MDM. Refer to
IQAN SOFTWARE ~GET APPLICATION
procedure in THIS SECTION.

at a time. In figure 3 highlight a channel

and tap the graph button. This will take you
to Figure 5. The scaling of the Y-axis is
shown next to the axis. Tap the start button
to start measure. After having measured,
the total log time is displayed after channel
name. The SMZ buttons allow you to
manipulate the graph. With the S you can
use your stylus pent to position a cursor on
the graph and read out the corresponding
value and time of the cursor at the bottom- FIGURE 10
right corner. With the M you can move the
graph and with the Z you can zoom in the 2. Use the pointer on the laptop to reset
graph. This is done by dragging your stylus selected items for graphing.
pen on the screen. The drop down menu at
the top right corner has five graph slot that From the main menu select Measure then
are available to you for measurement. choose Reset Selected from the drop
Select an empty slot, unless you want to down menu.
overwrite your current graph. The info XT2-A0 TAB
button allows you to add a comment to LEFT CLICK ON BOX TO
•• DISPLAY DIGITAL READING

••

FIGURE 3A

graph. The comment can hold 255 3. Click on a module tab and left click on the
characters. The time is automatically desired channel(s) to be measured to
captured when measurement starts. display the digital reading required.
Notice: Due to limited power of the
processor of Palm, the measurement is not
performed at full speed with respect to the

6.57
Tigercat 635C Skidder Electrical and Computers
GET ERROR/EVENT LOG
• • •• A. GET ERROR/ EVENT LOG USING A PDA

STOP
The following procedure instructs how to get
MEASURE an error/event log with a PDA (Personal Digital
GRAPH TAB
Assistant) device from the MDM (Master
START
MEASURE Display Module).
1. Get application from the MDM. Refer to
IQAN SOFTWARE~GET APPLICATION
procedure in THIS SECTION.
2. The error log is retrieved automatically
when you get the application.
FIGURE 4A

4. Click on the graph tab. Click on the START

MEASURE button (green arrow) on the
toolbar, or hit F4.
5. Perform the procedure being measured on
the chosen channel(s). A maximum of 10
channels can be graphed at a time.
6. Click on the STOP MEASURE button (red
square) on the toolbar, or hit F4.

DRAG TIME MARKERS

TRUE
RMS

STAT
TAB PDA MAIN IQAN WINDOW
3. Tap the error log icon.
FIGURE 7 ••
4. The error and event log will be retrieved
7. Drag the time markers to select the section automatically when you get the application.
of the graph where the machine was
performing the function being measured. 5. Switch between viewing the error and
event log with the two buttons in the top-
8. Select the channel tab for the function right corner.
being measured (the graph data for the
selected channel will be highlighted or bold 6. If you tap on the Module/Name button you
when selected), and click the Stat tab. will alternate between showing
“module:module name” and “module
Note that channels are selected by clicking name” alone or “channel:channel name”
on the color coded tabs to the right of the and “channel name” alone.
channel information section of the screen.
The tabs at the bottom of this section of the 7. If you tap on the Description/Time button
screen are used to view the channel and you will alternate between showing the
statistics information for the active channel. date/time and the error/event description.
The time format depends on your PDA
9. The True RMS of the selected portion of formats settings.
the graph will be shown in the channel
information section of the screen.
Note that the measured data can be saved
as a *.idl (File~Save as) file later viewing
(File ~Open).
6.58
Tigercat 635C Skidder Electrical and Computers

3. The receiving channels pop up box will

appear.

8. If you tap on one of the errors/events you

will get the description and the time at the
bottom of the screen
B. GET ERROR/ EVENT LOG USING A
PC/LAPTOP
The following procedure instructs how to get
an error/event log using a PC/Laptop
1. Get application from the MDM. Refer to
IQAN SOFTWARE~GET APPLICATION
procedure in THIS SECTION.

4. When the transmission is complete the

Events or Errors/alarms can be viewed by
selecting one of the tabs at the top of the
display.
5. Error/event logs can be copied or saved.

2. Using the drop-down menus select System

then Get error/event log.

6.59
Tigercat 635C Skidder Electrical and Computers

FUSE AND RELAY PANELS

NOTE: Refer to the ELECTRICAL SCHEMATICS
in THIS SECTION of the Service Manual for details
about fuse and relay designations and capacities.

FUSE PANEL
630C-155A (6350501 TO 6350530)

GRID HEATER ‘A’

125A
••

GRID HEATER ‘B’

STARTER 125A
SOLENOID

•• ••

CAB POWER ‘A’

80A

••
GRID HEATER ‘A’ CAB POWER ‘B’
RELAY 80A

• ENGINE HIGH IDLE

• •• • (*TEMPORARY
SERVICE USE)

• •
•
GRID HEATER ‘B’
• •
•• •
RELAY FUEL HEATER
40A(OPTIONAL)

••
BATTERY ‘B’ BATTERY ‘C’ BATTERY ‘D’ BATTERY ‘M’ BATTERY ‘S’
7.5A 7.5A 7.5A 10A 10A

ELECTRICAL BOX FUSES AND RELAYS (LEFT SIDE FRONT CHASSIS)

635C-29 (6350501 TO 6350530)

6.60
Tigercat 635C Skidder Electrical and Computers

FUSES
RELAYS

FUSE AND RELAY PANEL

(6350501 TO 6350530)
6.61
Tigercat 635C Skidder Electrical and Computers
FUSES AND RELAYS continued
NOTE: Refer to the ELECTRICAL SCHEMATICS
in THIS SECTION of the Service Manual for details
about fuse and relay designations and capacities.

630C-155A FUSE PANEL ELECTRICAL BOX

625C-90
(6350531 TO 6350550)

ELECTRICAL BOX FUSES AND RELAYS (6350531 TO 6350550)

6.62
Tigercat 635C Skidder Electrical and Computers

FUSES
RELAYS

FUSE AND RELAY PANEL

(6350531 TO 6350550)
6.63
Tigercat 635C Skidder Electrical and Computers
FUSES AND RELAYS continued
NOTE: Refer to the ELECTRICAL SCHEMATICS
in THIS SECTION of the Service Manual for details
about fuse and relay designations and capacities.

630C-155A FUSE PANEL ELECTRICAL BOX

(LEFT SIDE FRONT CHASSIS)
625C-95 (6350551 TO 6351000)
2A

ELECTRICAL BOX FUSES AND RELAYS (6350551 TO 6351000)

6.64
Tigercat 635C Skidder Electrical and Computers

FUSES
RELAYS

FUSE AND RELAY PANEL

(6350551 TO 6351000)
6.65
Tigercat 635C Skidder Electrical and Computers
GAUGES AND ALARMS
The 635C 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 MDM display in the cab and sounds all alarms
For operation of the gauges and warning lights
related to the switches and sensors shown in the
following diagrams, 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.

6.66
Tigercat 635C Skidder Electrical and Computers

FRONT

ELECTRICAL ALTERNATOR
BOX

• HYDRAULIC OIL LEVEL

SWITCH (MAIN
•• HYDRAULIC TANK)
AXLE FILTER
BYPASS SWITCH
CHARGE FILTER
BYPASS SWITCH

HYDRAULIC OIL
TEMPERATURE SENSOR

• • • ••

ENGINE COOLANT
LEVEL SENSOR
• PRESSURE SENSOR
FORWARD DRIVE
IQAN XT2 FRONT
PRESSURE SENSOR CHASSIS MODULE
REVERSE DRIVE
•• •• FAN MANIFOLD

SPEED SENSOR
•• •
•• BATTERIES
••
TO CAB
•• ••
CAB GROUND
•• • BATTERY DISCONNECT
STRAP SWITCH

TRANSMISSION

FUEL LEVEL
SENDER IQAN XP2 REAR
CHASSIS MODULE
•
••

SWITCH AND SENSOR LOCATIONS

635C-30
(6350501 TO 6350530)

6.67
Tigercat 635C Skidder Electrical and Computers

FRONT

ELECTRICAL
BOX ALTERNATOR

• HYDRAULIC OIL LEVEL

SWITCH (MAIN
•• HYDRAULIC TANK)
AXLE FILTER
BYPASS SWITCH
CHARGE FILTER
BYPASS SWITCH
A/C BINARY HYDRAULIC OIL
SWITCH TEMPERATURE SENSOR

•• • • • ••

ENGINE COOLANT
LEVEL SENSOR
• PRESSURE SENSOR
FORWARD DRIVE
IQAN XT2 FRONT
PRESSURE SENSOR CHASSIS MODULE
REVERSE DRIVE
•• •• FAN MANIFOLD

SPEED SENSOR
•• •
••
• BATTERIES

TO CAB
•• ••
CAB GROUND
•• • BATTERY DISCONNECT
STRAP SWITCH

TRANSMISSION

FUEL LEVEL
SENDER IQAN XP2 REAR
CHASSIS MODULE
•
••

SWITCH AND SENSOR LOCATIONS

635C-40 (6350531 TO 6350550)

6.68
Tigercat 635C Skidder Electrical and Computers

BATTERY FRONT
DISCONNECT
SWITCH

ELECTRICAL ALTERNATOR
BOX
••
• HYDRAULIC OIL LEVEL
• SWITCH (MAIN
HYDRAULIC TANK)
AXLE FILTER
BYPASS SWITCH
CHARGE FILTER
BYPASS SWITCH
A/C BINARY
SWITCH HYDRAULIC OIL
TEMPERATURE SENSOR

•• •• • • •

ENGINE COOLANT
LEVEL SENSOR
•• PRESSURE SENSOR
FORWARD DRIVE
IQAN XT2 FRONT
CHASSIS MODULE
PRESSURE SENSOR
REVERSE DRIVE
•• •• FAN MANIFOLD

SPEED
•• ••
SENSOR

•• • BATTERIES
TO CAB

CAB GROUND
• • ••
STRAP

TRANSMISSION

FUEL LEVEL
SENDER

• IQAN XP2 REAR

CHASSIS MODULE

SWITCH AND SENSOR LOCATIONS

630C106
(6350551 TO 6351000)

6.69
Tigercat 635C Skidder Electrical and Computers
ELECTRICAL SYSTEM SCHEMATIC DIAGRAMS
The following pages of electrical schematic NOTE: There are some exceptions to this wire
diagrams (sheets 1 through 10) represent the numbering system. Where a wire branches off or a
complete electrical system for this machine. Use wire from a special prewired component connects
sheet 1 (shown below and also enlarged on later to a machine harness, two numbers may be used
pages) as a guide or flow chart to help trace on the same circuit wire.
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 B C D E F G H

A B C D E F G H
1 1
I J K L M N O P Q R S T U V W X
2 2
1 1 1 1 1 1
3 3
2 2 2 2

4 4
3 3 3 3

5 Tigercat Industries Inc. 5

4 4 4 4
A B C D E F G H
5 Tigercat Industries Inc. 5 5 Tigercat Industries Inc. 5
I J K L M N O P Q R S T U V W X

2 2
A B C D E F G H I J K L M N O P Q R S T U V W X
6 6 6 6 6 6

7 7 7 7 7 7

8 8 8 8 8 8

9 9 9 9 9 9

10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10

3 A B C D E F G H I J K L M N O P Q R S T U V W X 3

A B C D E F G H I J K L M N O P Q R S T U V W X
11 11 11 11 11 11

12 12 12 12 12 12

13 13 13 13 13 13

14 14 14 14 14 14
4 4
15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15
A B C D E F G H I J K L M N O P Q R S T U V W X

I J K L M N O P
16 16

17 17

18 18
5 5
19 19

20 Tigercat Industries Inc. 20

I J K L M N O P

A B C D E F G H

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)

6.70
 A B C D E F G H

A B C D E F G H
1 1
I J K L M N O P Q R S T U V W X
2 2
1 1 1 1 1 1
3 3
2 2 2 2

4 4
3 3 3 3

5 Tigercat Industries Inc. 5

4 4 4 4
A B C D E F G H
5 Tigercat Industries Inc. 5 5 Tigercat Industries Inc. 5
I J K L M N O P Q R S T U V W X

2 2
A B C D E F G H I J K L M N O P Q R S T U V W X
6 6 6 6 6 6

7 7 7 7 7 7

8 8 8 8 8 8

9 9 9 9 9 9

10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10

3 A B C D E F G H I J K L M N O P Q R S T U V W X 3

A B C D E F G H I J K L M N O P Q R S T U V W X
11 11 11 11 11 11

12 12 12 12 12 12

13 13 13 13 13 13

14 14 14 14 14 14
4 4
15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15
A B C D E F G H I J K L M N O P Q R S T U V W X

I J K L M N O P
16 16

17 17

18 18
5 5
19 19

20 Tigercat Industries Inc. 20

I J K L M N O P

A B C D E F G H
 I J K L M N O P

1 R Y G Y 1

Y Y G

R
2 2

3 3

4 4

5 5

I J K L M N O P
 Q R S T U V W X

1 1

2 2

3 3

4 4

5 5

Q R S T U V W X
 A B C D E F G H

6 6

W W

7 7

8 8
A

A
B

9 9

10 10

A B C D E F G H
 I J K L M N O P

6 6

7
7

8 8

9 9

10 10

I J K L M N O P
 Q R S T U V W X

6 6

7
7

T
8 8

9 9

10 10

Q R S T U V W X
 A B C D E F G H

11 11

12 12

13 13

14 14

15 15

A B C D E F G H
 I J K L M N O P

11 11

12 12

13 13

14 14

15 15

I J K L M N O P
 Q R S T U V W X

11 11

12 12

13 13

B+ B-
14 14

+ -

15 15

Q R S T U V W X
 I J K L M N O P

16 16

17 17

18 18

W
W

19 19

W
W

W
W
W

20 20
W
W

I J K L M N O P
 A B C D E F G H

A B C D E F G H
1 1
I J K L M N O P Q R S T U V W X
2 2
1 1 1 1 1 1
3 3
2 2 2 2

4 4
3 3 3 3

5 Tigercat Industries Inc. 5

4 4 4 4
A B C D E F G H
5 Tigercat Industries Inc. 5 5 Tigercat Industries Inc. 5
I J K L M N O P Q R S T U V W X

2 2
A B C D E F G H I J K L M N O P Q R S T U V W X
6 6 6 6 6 6

7 7 7 7 7 7

8 8 8 8 8 8

9 9 9 9 9 9

10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10

3 A B C D E F G H I J K L M N O P Q R S T U V W X 3

A B C D E F G H I J K L M N O P Q R S T U V W X
11 11 11 11 11 11

12 12 12 12 12 12

13 13 13 13 13 13

14 14 14 14 14 14
4 4
15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15
A B C D E F G H I J K L M N O P Q R S T U V W X

I J K L M N O P
16 16

17 17

18 18
5 5
19 19

20 Tigercat Industries Inc. 20

I J K L M N O P

A B C D E F G H
 I J K L M N O P

1 R Y G Y 1

Y Y G

R
2 2

3 3

4 4

5 5

I J K L M N O P
 Q R S T U V W X

1 1

2 2

3 3

4 4

5 5

Q R S T U V W X
 A B C D E F G H

6 6

W W

7 7

8 8
A

A
B

9 9

10 10

A B C D E F G H
 I J K L M N O P

6 6

7
7

8 8

9 9

10 10

I J K L M N O P
 Q R S T U V W X

6 6

7
7

T
8 8

9 9

10 10

Q R S T U V W X
 A B C D E F G H

11 11

12 12

13 13

14 14

15 15

A B C D E F G H
 I J K L M N O P

11 11

12 12

13 13

14 14

15 15

I J K L M N O P
 Q R S T U V W X

11 11

12 12

13 13

B+ B-
14 14

+ -

15 15

Q R S T U V W X
 I J K L M N O P

16 16

17 17

18 18

W
W

19 19

W
W

W
W
W

20 20
W
W

I J K L M N O P
 A B C D E F G H

A B C D E F G H
1 1
I J K L M N O P Q R S T U V W X
2 2
1 1 1 1 1 1
3 3
2 2 2 2

4 4
3 3 3 3

5 Tigercat Industries Inc. 5

4 4 4 4
A B C D E F G H
5 Tigercat Industries Inc. 5 5 Tigercat Industries Inc. 5
I J K L M N O P Q R S T U V W X

2 2
A B C D E F G H I J K L M N O P Q R S T U V W X
6 6 6 6 6 6

7 7 7 7 7 7

8 8 8 8 8 8

9 9 9 9 9 9

10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10

3 A B C D E F G H I J K L M N O P Q R S T U V W X 3

A B C D E F G H I J K L M N O P Q R S T U V W X
11 11 11 11 11 11

12 12 12 12 12 12

13 13 13 13 13 13

14 14 14 14 14 14
4 4
15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15
A B C D E F G H I J K L M N O P Q R S T U V W X

I J K L M N O P
16 16

17 17

18 18
5 5
19 19

20 Tigercat Industries Inc. 20

I J K L M N O P

A B C D E F G H
 I J K L M N O P

1 Y R Y G
1

Y R G

R
2 2

3 3

4 4

5 5

I J K L M N O P
 Q R S T U V W X

1 1

2 2

3 3

4 4

5 5

Q R S T U V W X
 A B C D E F G H

6 6

W W

7 7

8 8
A

A
B

9 9

10 10

A B C D E F G H
 I J K L M N O P

6 6

7 7

8 8

9 9

10 10

I J K L M N O P
 Q R S T U V W X

6 6

7 7

T
8 8

9 9

10 10

Q R S T U V W X
 A B C D E F G H

11 11

12 12

13 13

14 14

15 15

A B C D E F G H
 I J K L M N O P

11 11

12 12

13 13

+
M
-
14 14

15 15

I J K L M N O P
 Q R S T U V W X

11 11

12 12

13 13

14 14

15 B+ B- 15
+ -

Q R S T U V W X
 I J K L M N O P

16 16

17 W
17
W

W
W

18 W
18

W
W
W
19 19

W
W

W
W
W

20 20

I J K L M N O P
 A B C D E F G H

A B C D E F G H
1 1
I J K L M N O P Q R S T U V W X
2 2
1 1 1 1 1 1
3 3
2 2 2 2

4 4
3 3 3 3

5 Tigercat Industries Inc. 5

4 4 4 4
A B C D E F G H
5 Tigercat Industries Inc. 5 5 Tigercat Industries Inc. 5
I J K L M N O P Q R S T U V W X

2 2
A B C D E F G H I J K L M N O P Q R S T U V W X
6 6 6 6 6 6

7 7 7 7 7 7

8 8 8 8 8 8

9 9 9 9 9 9

10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10

3 A B C D E F G H I J K L M N O P Q R S T U V W X 3

A B C D E F G H I J K L M N O P Q R S T U V W X
11 11 11 11 11 11

12 12 12 12 12 12

13 13 13 13 13 13

14 14 14 14 14 14
4 4
15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15

A B C D E F G H I J K L M N O P Q R S T U V W X

I J K L M N O P
16 16

17 17

18 18
5 5
19 19

20 Tigercat Industries Inc. 20

I J K L M N O P

A B C D E F G H
 I J K L M N O P

1 Y R Y G
1

Y R G

R
2 2

3 3

4 4

5 5

I J K L M N O P
 Q R S T U V W X

1 1

2 2

3 3

4 4

5 5

Q R S T U V W X
 A B C D E F G H

6 6

W W

7 7

8 8
A

A
B

9 9

10 10

A B C D E F G H
 I J K L M N O P

6 6

7 7

8 8

9 9

10 10

I J K L M N O P
 Q R S T U V W X

6 6

7 7

T
8 8

9 9

10 10

Q R S T U V W X
 A B C D E F G H

11 11

12 12

13 13

14 14

15 15

A B C D E F G H
 I J K L M N O P

11 11

12 12

13 13

+
M
-

14 14

15 15

I J K L M N O P
 Q R S T U V W X

11 11

12 12

13 13

14 14

B+ B-

15 + - 15

Q R S T U V W X
 I J K L M N O P

16 16

17 W
17
W

W
W

18 W
18

W
W
W
19 19

W
W

W
W
W

20 20

I J K L M N O P
 A B C D E F G H

A B C D E F G H
1 1
I J K L M N O P Q R S T U V W X
2 2
1 1 1 1 1 1
3 3
2 2 2 2

4 4
3 3 3 3

5 Tigercat Industries Inc. 5

4 4 4 4
A B C D E F G H
5 Tigercat Industries Inc. 5 5 Tigercat Industries Inc. 5
I J K L M N O P Q R S T U V W X

2 2
A B C D E F G H I J K L M N O P Q R S T U V W X
6 6 6 6 6 6

7 7 7 7 7 7

8 8 8 8 8 8

9 9 9 9 9 9

10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10

3 A B C D E F G H I J K L M N O P Q R S T U V W X 3

A B C D E F G H I J K L M N O P Q R S T U V W X
11 11 11 11 11 11

12 12 12 12 12 12

13 13 13 13 13 13

14 14 14 14 14 14
4 4
15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15
A B C D E F G H I J K L M N O P Q R S T U V W X

I J K L M N O P
16 16

17 17

18 18
5 5
19 19

20 Tigercat Industries Inc. 20

I J K L M N O P

A B C D E F G H
 I J K L M N O P

1 Y R Y G

Y R G

R
2 2

3 3

4 4

5 5

I J K L M N O P
 Q R S T U V W X

1 1

2 2

3 3

4 4

5 5

Q R S T U V W X
 A B C D E F G H

6 6

W W

7 7

8 8
A

A
B

9 9

10 10

A B C D E F G H
 I J K L M N O P

6 6

7 7

8 8

9 9

10 10

I J K L M N O P
 Q R S T U V W X

6 6

7 7

T
8 8

9 9

10 10

Q R S T U V W X
 A B C D E F G H

11 11

12 12

13 13

14 14

15 15

A B C D E F G H
 I J K L M N O P

11 11

12 12

13 13

+
M
-

14 14

15 15

I J K L M N O P
 Q R S T U V W X

11 11

12 12

13 13

14 14

B+ B-

15 + - 15

Q R S T U V W X
 I J K L M N O P

16 16

17 W
17
W

W
W

18 W
18

W
W
W
19 19

W
W

W
W
W

20 20

I J K L M N O P
 A B C D E F G H

A B C D E F G H
1 1
I J K L M N O P Q R S T U V W X
2 2
1 1 1 1 1 1
3 3
2 2 2 2

4 4
3 3 3 3

5 Tigercat Industries Inc. 5

4 4 4 4
A B C D E F G H
5 Tigercat Industries Inc. 5 5 Tigercat Industries Inc. 5
I J K L M N O P Q R S T U V W X

2 2
A B C D E F G H I J K L M N O P Q R S T U V W X
6 6 6 6 6 6

7 7 7 7 7 7

8 8 8 8 8 8

9 9 9 9 9 9

10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10 10 Tigercat Industries Inc. 10

3 A B C D E F G H I J K L M N O P Q R S T U V W X 3

A B C D E F G H I J K L M N O P Q R S T U V W X
11 11 11 11 11 11

12 12 12 12 12 12

13 13 13 13 13 13

14 14 14 14 14 14
4 4
15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15 15 Tigercat Industries Inc. 15
A B C D E F G H I J K L M N O P Q R S T U V W X

I J K L M N O P
16 16

17 17

18 18
5 5
19 19

20 Tigercat Industries Inc. 20

I J K L M N O P

A B C D E F G H
 I J K L M N O P

1 Y R Y G
1

Y R G

R
2 2

3 3

4 4

5 5

I J K L M N O P
 Q R S T U V W X

1 1

2 2

3 3

4 4

5 5

Q R S T U V W X
 A B C D E F G H

6 6

W W

7 7

8 8
A

A
B

9 9

10 10

A B C D E F G H
 I J K L M N O P

6 6

7 7

8 8

9 9

10 10

I J K L M N O P
 Q R S T U V W X

6 6

7 7

T
8 8

9 9

10 10

Q R S T U V W X
 A B C D E F G H

11 11

12 12

13 13

14 14

15 15

A B C D E F G H
 I J K L M N O P

11 11

12 12

13 13

+
M
-

14 14

15 15

I J K L M N O P
 Q R S T U V W X

11 11

12 12

13 13

14 14

B+ B-

15 + - 15

Q R S T U V W X
 I J K L M N O P

16 16

17 W
17
W

W
W

18 W
18

W
W
W
19 19

W
W

W
W
W

20 20

I J K L M N O P
Tigercat 635C Skidder

SECTION 7 - ENGINE START AND STOP

OCTOBER 2008
CONTENTS - SECTION 7
MAIN PUMP UNLOADING VALVE
(6350501 TO 6350620) ............................................................................ 7.3
(6350621 TO 6351000) .......................................................................... 7.11
START CIRCUIT DESCRIPTION
(6350501 TO 6350620) ............................................................................ 7.2
(6350621 TO 6351000) .......................................................................... 7.10
START CIRCUIT DIAGRAM
(6350501 TO 6350530) .................................................................... 7.4, 7.5
(6350531 TO 6350550) .................................................................... 7.6, 7.7
(6350551 TO 6350620) .................................................................... 7.8, 7.9
(6350621 TO 6351000) ................................................................ 7.12, 7.13
START MOTOR AND SOLENOID
(6350501 TO 6350620) .......................................................................... 7.10
(6350621 TO 6351000) ............................................................................ 7.2
Tigercat 635C Skidder Engine start and stop
ENGINE START CIRCUIT Refer to simplified START CIRCUIT DIAGRAMS
(6350501 TO 6350620) in THIS SECTION. Refer also to machine
ELECTRICAL SCHEMATICS in SECTION 6.
For detailed engine information refer to the
engine manufacturer's manual. CIRCUIT DESCRIPTION
For engine starting and stopping procedures refer With the battery disconnect switch ON, current
to ENGINE STARTING AND STOPPING in is supplied to the start solenoid contact, the start
SECTION 2 of the OPERATOR’S MANUAL. relay contact, the positive connection on the
alternator and the BATTERY (BAT) contact of the
The engine starting circuit is controlled by a
key switch (ignition switch). Current is also
switch (proximity switch earlier machines, limit
supplied to the accessory fuses, the constant
switch later machines) located on the parking
power fuses and the engine ECM power supply.
brake lever which prevents the engine from being
started when the parking brake is OFF. When the battery disconnect switch is ON, the
parking brake is ON and the key switch is
The parking brake must be in the ON position to
turned to the RUN position, current is supplied
allow the engine to start. Note: Earlier machines
to the parking brake & unloading relay contact
equipped with a proximity switch may experience
(wire P159) and the engine ECM (wire 53). When
cold weather starting difficulty due to a voltage
the parking brake is ON current is supplied to the
drop across the proximity switch. Refer to PSB
park brake and unloading relay (wire 194). The
1518 for more information on correcting this
park brake and unloading relay closes and current
problem.
is supplied to the start relay contact (wire P147)
The engine is started by turning ignition switch to and to the main pump unloading valve (wire 135).
the RUN position. All engine warning lights will The main pump unloading valve energizes to
come on. The wait to start light should be the last unload the main pump (standby pressure only will
to go out. Always wait until the wait to start be available while the parking brake is ON).
warning light goes out before proceeding. Turn
When the battery disconnect switch is ON, the
ignition switch to the START position to crank
parking brake is ON and the key switch is
engine. When engine starts, release ignition key
turned to the START position, parking brake &
to RUN position.
unloading relay contact (wire P159) and the start
If the engine stalls during operation of the vehicle, relay (wire 189). When the parking brake is ON
the key must be turned to the OFF position to current is supplied to the park brake and
reset the ignition switch before the engine can be unloading relay (wire 194). The park brake and
restarted. unloading relay closes and current is supplied to
the start relay contact (wire P147) and to the main
pump unloading valve (wire 135). The main
pump unloading valve energizes to unload the
main pump (standby pressure only will be
available while the parking brake is ON).

PARKING BRAKE ~ SOLENOID

630C-44 DISENGAGED POSITION
RUN START
OFF

•• •
•• •
START
MOTOR
••

630C-55 IGNITION SWITCH 630C-224 START MOTOR AND SOLENOID

7.2
Tigercat 635C Skidder Engine start and stop
The start relay closes and supplies current to 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.
••
SOLENOID,
When the battery disconnect switch is ON, the INTEGRATED
parking brake is OFF and the key switch is MAIN PUMP
UNLOADING
turned to the RUN position, current is supplied VALVE
to the parking brake & unloading relay contact
(wire P159) and the engine ECM (wire 53). When
•
the parking brake is OFF no current is supplied to
MAIN PUMP
the park brake and unloading relay (wire 194).
The main pump unloading valve is not energized.
The main pump will be fully loaded (main pump
POR pressure available while the parking brake is
OFF).
MAIN PUMP UNLOADING VALVE
To relieve the load on the engine during start-up, MAIN PUMP
the main pump is destroked to standby pressure 635C-27 (6350501 TO 6350530)
by the main pump unloading valve. It is energized
through wire 135 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.
SOLENOID,
INTEGRATED
When the parking brake is ON and the main MAIN PUMP
pump unloading valve is energized the standby UNLOADING
VALVE
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 MAIN PUMP
pump is fully loaded the main pump POR
pressure can be read using the MAIN test port.
Refer also to MAIN PUMP in SECTION 9 of THIS
MANUAL.
MAIN PUMP
630C-252 (6350531 TO 6351000)

7.3
Tigercat 635C Skidder Engine start and stop

(6350501 TO 6350530)

630C-97A START CIRCUIT -AT REST

(6350501 TO 6350530)

START CIRCUIT
BATTERY DISCONNECT ON
PARKING BRAKE ON
630C-97B IGNITION KEY - RUN POSITION

7.4
Tigercat 635C Skidder Engine start and stop

(6350501 TO 6350530)

START CIRCUIT
BATTERY DISCONNECT - ON
PARKING BRAKE - ON
630C-97C IGNITION KEY - START POSITION

(6350501 TO 6350530)

START CIRCUIT
BATTERY DISCONNECT ON
PARKING BRAKE OFF
630C-97D IGNITION KEY -RUN POSITION

7.5
Tigercat 635C Skidder Engine start and stop
START CIRCUIT -AT REST

(6350531 TO 6350550)
625C-94

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

(6350531 TO 6350550)
625C-94A

7.6
Tigercat 635C Skidder Engine start and stop
START CIRCUIT
BATTERY DISCONNECT ON
PARKING BRAKE ON
IGNITION KEY-START POSITION

(6350531 TO 6350550)
625C-94B

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

(6350531 TO 6350550)
625C-94C

7.7
Tigercat 635C Skidder Engine start and stop
START CIRCUIT -AT REST

(6350551 TO 6350620)
620C-52

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

(6350551 TO 6350620)
620C-52A

7.8
Tigercat 635C Skidder Engine start and stop
START CIRCUIT
BATTERY DISCONNECT ON
PARKING BRAKE ON
IGNITION KEY-START POSITION

(6350551 TO 6350620)
620C-52B

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

(6350551 TO 6350620)
620C-52C

7.9
Tigercat 635C Skidder Engine start and stop
ENGINE START CIRCUIT CIRCUIT DESCRIPTION
PARKING BRAKE SWITCH With the battery disconnect switch ON, current
(DRIVELINE PARKING BRAKE) is supplied to the start solenoid contact, the start
6350621 TO 6351000 relay contact, the positive connection on the
For detailed engine information refer to the alternator and the BATTERY (BAT) contact of the
engine manufacturer's manual. key switch (ignition switch). Current is also
supplied to the accessory fuses, the constant
For engine starting and stopping procedures refer power fuses and the engine ECM power supply.
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
The parking brake must be in the ON position to turned to the RUN position, current is supplied
allow the engine to start. to the parking brake & unloading relay contact
On later machines, equipped with a drive line (wire P159) and the engine ECM (wire 53). When
parking brake (6350621 to 6351000), the engine the parking brake is ON current is supplied to the
starting circuit is controlled by the parking brake park brake and unloading relay (wire 159A). The
switch on the instrument panel which prevents the park brake and unloading relay closes and current
engine from being started when the parking brake is supplied to the start relay contact (wire P147)
is OFF. and to the main pump unloading valve (wire 135).
The main pump unloading valve energizes to
The engine is started by turning ignition switch to
unload the main pump (standby pressure only will
the RUN position. All engine warning lights will
be available while the parking brake is ON).
come on. The wait to start light should be the last
to go out. Always wait until the wait to start When the battery disconnect switch is ON, the
warning light goes out before proceeding. Turn parking brake is ON and the key switch is
ignition switch to the START position to crank turned to the START position, parking brake &
engine. When engine starts, release ignition key unloading relay contact (wire P159) and the start
to RUN position. relay (wire 189). When the parking brake is ON
current is supplied to the park brake and
If the engine stalls during operation of the vehicle,
unloading relay (wire 159A). The park brake and
the key must be turned to the OFF position to
unloading relay closes and current is supplied to
reset the ignition switch before the engine can be
the start relay contact (wire P147) and to the main
restarted.
pump unloading valve (wire 135). The main
Refer to simplified START CIRCUIT DIAGRAMS pump unloading valve energizes to unload the
in THIS SECTION. Refer also to machine main pump (standby pressure only will be
ELECTRICAL SCHEMATICS in SECTION 6. available while the parking brake is ON).
The start relay closes and supplies current to 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.

PARKING
BRAKE
START SWITCH
OFF RUN

•• • •• •
START
MOTOR
•
SOLENOID

•
PARKING BRAKE ~
630C-241X DISENGAGED POSITION 620C-50 START MOTOR AND SOLENOID

7.10
Tigercat 635C Skidder Engine start and stop
When the battery disconnect switch is ON, the
parking brake is OFF and the key switch is
turned to the RUN position, current is supplied
to the parking brake & unloading relay contact
(wire P159) and the engine ECM (wire 53). When
the parking brake is OFF no current is supplied to
the park brake and unloading relay (wire 159A).
The main pump unloading valve is not energized.
The main pump will be fully loaded (main pump
POR pressure available while the parking brake is
OFF). When the parking brake is off current is
supplied to the parking brake valve solenoid (wire
159C) which supplies pilot pressure to release the
driveline parking brake.

••
SOLENOID,
INTEGRATED
MAIN PUMP
UNLOADING
VALVE
•
MAIN PUMP

MAIN PUMP
630C-252 (6350531 TO 6351000)

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 135 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 part of the main pump.
When the parking brake is ON and the main
pump unloading valve is energized the standby
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.

7.11
Tigercat 635C Skidder Engine start and stop
START CIRCUIT -AT REST

6350621 TO 6351000

E620C-07

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

6350621 TO 6351000

E620C-07A

7.12
Tigercat 635C Skidder Engine start and stop
START CIRCUIT
BATTERY DISCONNECT ON
PARKING BRAKE ON
IGNITION KEY-START POSITION

6350621 TO 6351000

E620C-07B

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

6350621 TO 6351000

E620C-07C

7.13
Tigercat 635C Skidder Engine start and stop

7.14
Tigercat 635C Skidder

SECTION 8 - DRIVE
OCTOBER 2008
CONTENTS - SECTION 8
AXLES & DIFFERENTIAL LOCKS. ....................................... SEE SECTION 15
CAB SUPPORT BRACE .................................................................... 8.30, 8.35
CHARGE PUMP
6350501 TO 6350510 ................................................................................. 8.6
CIRCUIT DESCRIPTION ............................................................................... 8.3
DRIVE CIRCUIT DIAGRAM
6350501 TO 6350510 ............................................................................... 8.16
6350511 TO 6350530 ............................................................................... 8.18
6350531 TO 6351000 ............................................................................... 8.19
DRIVE CIRCUIT HYDRAULIC SCHEMATIC
6350501 TO 6350510 ............................................................................... 8.17
6350511 TO 6351000 ............................................................................... 8.21
DRIVE COUPLING ...................................................................................... 8.40
DRIVE MOTOR ............................................................................................ 8.10
DRIVE MOTOR SPEED VERIFICATION ..................................................... 8.23
DRIVE PUMP
6350501 TO 6350510 ................................................................................. 8.4
6350511 TO 6351000 ................................................................................. 8.7
DRIVE PUMP PRESSURE CHECKS .......................................................... 8.22
HYDRAULIC OIL HEATING PROCEDURE ................................................. 8.39
HYDROSTATIC SETUP PROCEDURE ....................................................... 8.24
SETUP PREPARATION ........................................................................... 8.25
DRIVE PUMP CHARGE PRESSURE ....................................................... 8.26
DRIVE PUMP HIGH PRESSURE RELIEF ................................................ 8.27
DRIVE PUMP POR ................................................................................... 8.29
MOTOR MAXIMUM SPEED/MINIMUM DISPLACEMENT ....................... 8.33
DRIVE MOTOR MAX CURRENT ............................................................. 8.37
DRIVE PUMP MAX CURRENT ................................................................ 8.35
MAXIMUM SPEED CONTROL DIAL ........................................................... 8.14
STARTUP PROCEDURE AFTER MAJOR MAINTENANCE. . SEE SECTION 3
TRANSMISSION .......................................................................................... 8.15
TRAVEL/ENGINE SPEED PEDALS
6350501 TO 6350530, 6350537 TO 6351000 ........................................... 8.12
6350531 TO 6350536 ............................................................................... 8.13
Tigercat 635C Skidder Drive

8.2
Tigercat 635C Skidder Drive
HYDROSTATIC DRIVE SYSTEM A hydraulic system is termed closed loop when
the hydraulic oil returning from the motor is fed
The primary components of the 635C hydrostatic
straight back to the pump without first returning to
drive system are a hydraulic pump and two
tank. When the machine is travelling forward, one
hydraulic motors connected together by four
side of the closed loop is a high pressure supply
hydrostatic hoses. The pump converts the
while the other side is a low pressure return. The
mechanical power of the diesel engine into
supply and return will alternate from side to side
hydraulic power. This high pressure flow of
of the closed loop as the direction of travel of the
hydraulic oil is then transmitted to the hydraulic
vehicle goes from forward to reverse.
motors through the first two connecting hoses.
The motors then reconvert the hydraulic power Hydrostatic drives are used because they offer
back into the mechanical power used to propel enhanced operator control of vehicle speed and
the machine. Low pressure hydraulic oil flow then tractive effort. As well hydrostatic drive systems
returns from the motors to the pump through the give flexibility in the positioning of components
other two connecting hoses thereby completing a within the machine when compared to mechanical
continuous closed loop hydraulic circuit. drive systems.

BENT AXIS
PISTON MOTOR

TO VEHICLE
DRIVE

SWASHPLATE,
AXIAL PISTON
PUMP

FROM DIESEL
ENGINE

BENT AXIS
PISTON MOTOR

TO VEHICLE
DRIVE

630C-
CONTINUOUS CLOSED LOOP HYDRAULIC CIRCUIT
12

8.3
Tigercat 635C Skidder Drive
DRIVE PUMP (EARLIER DESIGN) TO MOTORS TO MOTORS
B REVERSE A FORWARD
(6350501 TO 6350510) (CCW) (CW)

The hydrostatic drive pump is mounted to the FROM CHARGE

engine flywheel via a torsional drive shaft coupling PUMP VIA
CHARGE
and has a through shaft to the main pump and FILTER

multisection gear pumps. TO

SUCTION ••
The drive pump is a variable displacement,
STRAINER
PROPORTIONAL
SOLENOID
• CHARGE
RELIEF

swashplate, axial piston type pump. This pump is

made variable by slipping the pump pistons
VALVES
•• ••
against a tiltable swashplate cradle. The volume • PORT

and direction of oil flow from the piston pump is

ACTUATION
PISTON •• RELIEFS

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 PILOT •
decreases until there is no flow at an angle of
VALVE
••
zero (0°). Continuing to angle the swashplate past
this neutral position steplessly reverses the SWASH
PLATE
direction of flow from the piston pump.
A separate charge pump (part of the multisection 630C-13 DRIVE PUMP SCHEMATIC
gear pump assembly) provides charge oil via the
charge filter for the drive pump controls. Charge pressure side of the closed loop to replenish
oil continuously introduces oil from the hydraulic losses due to internal leakage in the hydrostatic
tank back into the hydrostatic drive system. The pump and motor. This same flow acts as a
charge relief valve (in the drive pump) maintains a cooling fluid for the piston pump and motors to
constant charge pressure for use by the ensure peak hydrostatic drive performance and
swashplate control system. In addition, the charge long service life.
pump oil is used as make up oil to the low Excess charge pump oil is relieved by the charge

ELECTRO-HYDRAULIC MZ
CONTROL

• ••

DRIVE SHAFT

•
SWASHPLATE

DRIVE PUMP
AP175

8.4
Tigercat 635C Skidder Drive
pump relief valve back into the case of the piston
pump. The charge pump pressure filter ensures
that only clean charge pump oil is introduced into
the closed loop hydrostatic circuit and the
swashplate control system. Should this pressure
filter become clogged with debris, charge pump
flow is diverted to tank thus preventing the entry of
unfiltered charge pump oil.
The drive pump is equipped with an electro-
hydraulic control which consists of two
proportional solenoid valves (Mz and My), an
actuation piston and a pilot valve.
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.
When a travel foot pedal is operated a VOLTAGE
IN (Drive Pedal Fwd or Drive Pedal Rev) signal is
sent to the computer control system. The
computer control system generates a
corresponding signal (CURRENT OUT - Drive
Pump) and sends it to one of the drive pump
proportional solenoid valves (forward or reverse). 630C-15 DRIVE PUMP ELECTRICAL SCHEMATIC
A magnetic force is generated at the solenoid coil,
and supplies charge pressure to the control piston
in the proportional valve a pressure corresponding
connected to the swashplate. The opposite
to the solenoid signal is sent to the actuation
control piston is relieved to tank. The swashplate
piston. The actuation piston shifts accordingly.
tilts in the corresponding direction. If the signal at
Fluid on the opposite side is discharged to tank via
the solenoid is lessened, the proportional valve
the proportional valve. The pilot valve is moved
reduces pressure to the actuation piston and the
swash plate angle becomes smaller.
DRIVE PUMP CHARACTERISTICS
The drive footpedal control functions only when
• Start of Control: 0 cc / 450 mA / 58 psi
the parking brake lever is in the OFF position. A
Non-Adjustable (0 cc 450 mA /4 Bar)
proximity sensor (earlier machines) or limit switch
• End of Control : 135cc / 1200 mA / 232 psi (later machines) is attached to the parking brake
Non-Adjustable (135cc / 1200 mA /16 Bar) lever. Drive prevent logic in the computer control
• High Pressure Relief: 6090 psi (420 Bar) system uses the parking brake signal (DIGITAL IN
differential (Non-Adjustable) - Park Brake Sensor) to prevent driving the
machine when the parking brake is ON.
• Charge Pressure Relief: 305 psi (21 Bar)
(Non-Adjustable) The hydrostatic piston pump is equipped with two
combined high pressure relief/charge check
• Coil Resistance : 6.6 ohms (make-up) valves to protect the closed loop
hydrostatic drive components from excessive
Drive Pump Characteristics
pressure. These relief valves are cartridge style,
135 factory set and nonadjustable.
120
105 In addition forward and reverse pressure sensors
Displacement cc

90
connected to the drive pump provide feedback
75
60
signals (VOLTAGE IN - Drive PSI REV and
45 VOLTAGE IN - Drive PSI FWD) to the computer
30 control system for use in overall control of the
15
0
drive circuit and protection of the system from
0 200 400 600 800 1000 1200 pressure spikes during operation.
(46) (93) (139) (186) (232)
Control Current mA
ma
Control Presure (psi)

8.5
Tigercat 635C Skidder Drive
CHARGE PUMP (EARLIER DESIGN)
(6350501 TO 6350510)
On earlier machines the charge pump is a fixed
displacement gear pump. It is part of the
multisection gear pump which includes the
cooling, fan, charge and axle pumps. This pump
stack is driven off the power take off of the main
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.

OUTLET
DRIVEN DRIVE
(IDLER) GEAR
GEAR

• •

INLET

GEAR1 TYPICAL GEAR PUMP

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.

COOLING
FAN PUMP
PUMP
CHARGE OIL
PUMP COOLER
AXLE BYPASS
PUMP
•• ••
•
••
••

MULTISECTION GEAR PUMP

630C-175 (EARLIER DESIGN )
Later machines have a drive pump with an
integrated charge pump. Refer to DRIVE PUMP
(LATER DESIGN) in THIS SECTION.

8.6
Tigercat 635C Skidder Drive
DRIVE PUMP (LATER DESIGN) pump) maintains a constant charge pressure for
use by the swashplate control system. In addition,
(6350511 TO 6351000)
the charge pump oil is used as make up oil to the
low pressure side of the closed loop to replenish
MAIN
losses due to internal leakage in the hydrostatic
PUMP DRIVE pump and motor. This same flow acts as a
PUMP
cooling fluid for the piston pump and motors to
ensure peak hydrostatic drive performance and
long service life.
•
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
630C-239 DRIVE PUMP (LATER DESIGN) of unfiltered charge pump oil.
The hydrostatic drive pump is mounted to the The drive pump is equipped with an electrical
engine flywheel via a torsional drive shaft coupling control with proportional solenoid valves (A and
and has a through shaft to the main pump and B).
multisection gear pumps. When no current is flowing to either of the
The hydrostatic drive pump is actually two proportional solenoid valves the pump will remain
separate hydraulic pumps mounted in a common in the neutral position with the swashplate at an
case and driven by the same input driveshaft. angle of zero and no flow.
The primary pump is a variable displacement, When a travel foot pedal is operated a VOLTAGE
swashplate, axial piston type. This pump is made IN (Drive Pedal Fwd or Drive Pedal Rev) signal is
variable by slipping the pump pistons against a sent to the computer control system. The
tiltable swashplate cradle. The volume and computer control system generates a
direction of oil flow from the piston pump is corresponding signal (CURRENT OUT - Drive
determined by the angle of this
swashplate. When the CHARGE
PUMP
swashplate is stroked to a
maximum displacement angle, TO TO MOTORS (B) TO MOTORS (A)
SUCTION
the piston pump will produce STRAINER
maximum flow in one direction
in the closed loop. As the
CHARGE
FILTER
• •
swashplate is de-stroked the
flow smoothly decreases until
there is no flow at an angle of
• • PRESSURE
OVERRIDE

zero (0°). Continuing to angle CHARGE

the swashplate past this neutral HIGH PRESSURE
RELIEF VALVE 'B'
• • RELIEF

position steplessly reverses the HIGH PRESSURE

direction of flow from the piston PROPORTIONAL
RELIEF VALVE 'A'

pump.
SOLENOID
• •• • •
The secondary pump is a fixed CONTROL

displacement, internal gear

SPOOL
•• STROKING
type which provides charge oil PISTON

via the charge filter for the drive ••

pump controls. Charge oil PROPORTIONAL
••
continuously introduces oil from SOLENOID
• HYDROSTATIC
PUMP
the hydraulic tank back into the
hydrostatic drive system. The
charge relief valve (in the drive DRIVE PUMP SCHEMATIC
630C-65

8.7
Tigercat 635C Skidder Drive

630C-15
625C-61
DRIVE PUMP ELECTRICAL SCHEMATIC DRIVE PUMP ELECTRICAL SCHEMATIC
(6350511 TO 6350530) (6350531 TO 6351000)

DRIVE PUMP CHARACTERISTICS DRIVE PUMP CHARACTERISTICS

(6350511 TO 6350530) (6350531 TO 6351000)
• Start of Control: 0 cc / 400 mA • Start of Control: 0 cc / 200 mA
(Non-Adjustable) (Non-Adjustable)
• End of Control : 140 cc/ 1200 mA • End of Control : 140 cc/ 600 mA
(Non-Adjustable) (Non-Adjustable)
• High Pressure Relief: 6250 psi (430 Bar ) • High Pressure Relief: 6250 psi (430 Bar )
differential (Adjustable) differential (Adjustable)
• Pressure Override: 5800-6000 psi • Pressure Override: 5800-6000 psi
(400-415 Bar) (Adjustable) (400-415 Bar) (Adjustable)
• Charge Pressure Relief: 350-360 psi • Charge Pressure Relief: 350-360 psi
(24-25 Bar) (Adjustable) (24-25 Bar) (Adjustable)
• Coil Resistance : 5.5 ohms • Coil Resistance : 22.7 ohms

Drive Pump Characteristics Drive Pump Characteristics

160 160

140 140

120 120
Displacement cc

Displacement cc

100 100

80 80

60 60

40 40

20 20

0 0
0 200 400 600 800 1000 1200 1400 0 100 200 300 400 500 600 700
Control Current ma Control Current ma

8.8
Tigercat 635C Skidder Drive
Pump) and sends it to one of the drive pump The two high pressure relief valves at ‘A’ and ‘B’
proportional solenoid valves (forward or reverse). ports are intended only to act as pressure limiting
A magnetic force is generated at the solenoid safety devices in the event that the P.O.R. valve
coil, in the proportional valve a pressure malfunctions or does not respond quickly enough
corresponding to the solenoid signal acts on the to high pressure surges. For this reason the high
control spool. The control spool then directs pressure relief valves are always adjusted higher
control oil in and out of the stroking piston to than the P.O.R. valve setting. The high pressure
stroke the pump as required. A feedback lever, relief valves always dump oil from the high
connected to the stroking piston, maintains the pressure to the low pressure side of the closed
pump flow for any given current within the control loop thereby keeping the hydraulic oil within the
range. If the signal at the solenoid is lessened, closed loop.
the control spool reduces pressure to the stroking In addition forward and reverse pressure sensors
piston and the swash plate angle becomes connected to the drive pump provide feedback
smaller. signals (VOLTAGE IN - Drive PSI REV and
MACHINES WITH PARKING BRAKE LEVER VOLTAGE IN - Drive PSI FWD) to the computer
(6350511 TO 6350620) control system for use in overall control of the
drive circuit and protection of the system from
The drive footpedal control functions only when
pressure spikes during operation.
the parking brake lever is in the OFF position. A
limit switch is attached to the parking brake lever.
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.
MACHINES WITH PARKING BRAKE SWITCH
(6350621 TO 6351000)
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 (P.O.R.) valve to protect the
closed loop hydrostatic drive components from
excessive pressure. When the tractive effort
requirements of the vehicle are demanding then
pressure on the high side of the closed loop can
reach maximum. At this pressure the P.O.R. valve
signals the swashplate control valve to destroke
the swashplate, reducing piston pump flow and
maintaining system pressure at the P.O.R. setting.
The P.O.R. prevents continuous dumping of high
pressure oil across the piston pump high pressure
relief valves. This eliminates unnecessary heating
of the oil and protects the pump and motors
during rapid acceleration and deceleration or
when the drive system stalls.

8.9
Tigercat 635C Skidder Drive
DRIVE MOTOR
FLUSHING
VALVE
Two motors are used to drive the skidder. 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 TEST
PORT
• BEGIN OF
DISPLACEMENT
with the pump.
High pressure oil from the pump enters the motor
via port 'A' or port 'B', depending on the direction •• TO SUCTION
of travel. The oil is directed to the back of a set of STRAINER

pistons in the motor's rotary group. The pistons POR

push against the back of the drive shaft at an •
angle causing it to rotate.
The angle of the pistons relative to the drive shaft
determine the speed of the motor and the
available torque. Reducing the angle provides
increased speed with less torque. Increasing the
angle will reduce the speed and provide more
torque. FROM DRIVE
PUMP PORT P
FROM DRIVE
PUMP PORT S

The angle of the pistons is variable and is 630C-14 DRIVE MOTOR SCHEMATIC
changed by an internal control cylinder that
proportional electrical control will cause the
receives high pressure oil via the MOTORS'
displacement control spool to return to the neutral
pressure override valve (POR) and a
position, shutting off the pressure to the
displacement control spool.
displacement control cylinder thus increasing
The displacement control spool is operated by an displacement to maximum.
electrical control with proportional solenoid. The
For this application the POR valve is set at a high
control is proportional to the applied electrical
pressure so that it does not interfere with the
signal (CURRENT OUT - Drive Motor RH or Drive
operation of the computer control system. The
Motor LH or Motor Drive) from the computer
motor POR must be correctly set for the system
control system. When sufficient pressure from
to function properly. Refer to DRIVE MOTOR
the proportional electrical control is directed to the
PRESSURE SETTINGS for in THIS SECTION .
spool, it shifts against a spring and directs oil past
the POR valve to the displacement control A minimum displacement adjusting screw on the
cylinder thus decreasing the displacement of the outside of the motor housing limits the maximum
motor. Removal of the pressure signal from speed of the motor.
WARNING: Improper adjustment of Minimum
DRIVE MOTOR CHARACTERISTICS displacement adjusting screw can result in motor
• Start of Control : 160 cc / 400 mA and transmission failure due to overspeeding.
When installing a new motor always ensure
• End of Control : 30cc / 1050 mA stroke limiting screw is set correctly. Refer to SET
• Motor POR : Turn Fully In MOTOR MINIMUM DISPLACEMENT, in this
section.
• Coil Resistance: 5.5 ohms

Drive Motor Characteristics

160
140
120
Displacement cc

100
80
60
40
20
0
0 200 400 600 800 1000 1200

Control Current ma

8.10
Tigercat 635C Skidder Drive

630C-16 DRIVE MOTOR ELECTRICAL SCHEMATIC

A speed ring on the motor's drive shaft generates case. This action reduces the possibility of
a signal picked up by the speed sensor in the T particle build up in the loop by providing a
port of the right hand motor. The speed sensor continuous change of oil, it also assists with
signal (FREQUENCY IN - Drive Motor rpm) is cooling. Flushing occurs only when there is a
sent to the computer control system for use in pressure differential between the high pressure
controlling the drive system. and low pressure sides of the loop. This valve is
A flushing valve is incorporated into the motor. factory set (2.6 US gpm [9.8 L/min]) and requires
This valve provides a regulated flow of oil from no adjusting.
the low pressure side of the loop in the motor

PROPORTIONAL
SOLENOID

MINIMUM DISPLACEMENT
•
ADJUSTING SCREW
SPEED RING
•
DRIVE
SHAFT •
•

PORT PORT
'B' 'A'
• 'A'

ROTATING
GROUP
'E'
FLUSHING
VALVE
AQ083 • AQ083-
1
'E' VIEW 'A'
NOTE: ORIFICE MUST BE REMOVED
BEFORE INSTALLATION OF
REPLACEMENT MOTORS
(3 PARTS - ONE THROTTLE PIN AND
TWO THROTTLE SCREWS)

••

AQ083-3X
SECTION 'E-E'
DRIVE MOTOR ~ (160 CC SIZE)

8.11
Tigercat 635C Skidder Drive

635C-17
DRIVE PEDAL ELECTRICAL SCHEMATIC
635C-31 TRAVEL/ENGINE SPEED PEDALS Pedal motion is transmitted to the potentiometer
through a mechanical linkage. A spring return
TRAVEL/ENGINE SPEED PEDALS automatically returns the pedal to the neutral
(6350501 TO 6350530, 6350537 TO 6351000) position when not in use.
Two travel/engine speed pedals are located on The pedal moves through 17° of motion. The
the floor of the operator's cab. The right foot potentiometer signal ranges from 750 mV (at 0°)
pedal is used to move the machine in a forward to 3875 mV (at 17°) (VOLTAGE IN - Drive Pedal
direction. The left foot pedal is used to move the Fwd or Drive Pedal Rev). These signals are sent
machine in a reverse direction. A backup horn will to the IQAN XS module of the computer control
sound when travelling in reverse. A drive prevent system to control the travel/engine speed and
logic circuit built into the computer control system direction of travel of the machine. Through
prevents the machine from being driven when the internal logic the computer control system uses
parking brake is in the ON position. Refer also to the signal from the pedal to control engine speed,
PARKING BRAKE in SECTION 9 of THIS drive pump stroke and drive motor stroke.
MANUAL.
A three pin connector is used to connect each
FOOT PEDAL CHARACTERISTICS pedal to the machine electrical system:
• Electric Potentiometer Pin A: ground (white)
Pin B: signal
• Start of Control:0% / 0 Deg / 750 (±250) mV
Pin C: supply (red)
• End of Control:100%/ 17 Deg/ 3875 (±375) mV
The position of the foot pedal is directly
proportional to the travel/engine speed of the
Foot Pedal Characteristics
machine. Travel speed may also be limited by
the position of the maximum speed control dial.
4800
Refer MAXIMUM TRAVEL SPEED CONTROL
4000 DIAL in THIS SECTION for more information.
3200 Engine speed may also be controlled using the
Milli-Volts

2400
engine speed control switch to increase engine
speed when performing functions which do not
1600
require machine travel.
800

0
0 20 40 60 80 100

Pedal Position %

8.12
Tigercat 635C Skidder Drive

625C-69 TRAVEL/ENGINE SPEED PEDALS

TRAVEL/ENGINE SPEED PEDALS
(6350531 TO 6350536)
One travel / engine speed pedal is located on the
floor of the operator’s cab. It is a dual pedal Hall
Effect foot pedal. The right foot pedal is used to
move the machine in a forward direction. The left
foot pedal is used to move the machine in a
reverse direction. A backup horn will sound when
625C-68
travelling in reverse. A drive prevent logic circuit
DRIVE PEDAL ELECTRICAL SCHEMATIC
built into the computer control system prevents the
machine from being driven when the parking brake The position of the foot pedal is directly
is in the ON position. Refer also to PARKING proportional to the travel/engine speed of the
BRAKE in SECTION 9 of THIS MANUAL. machine. Travel speed may also be limited by the
position of the maximum speed control dial.
Pedal motion is transmitted to the Hall Effect
Refer MAXIMUM TRAVEL SPEED CONTROL
sensor. The pedals travel a total of 11 degrees. A
DIAL in THIS SECTION for more information.
spring automatically returns the pedal to the
neutral position when not in use. The sensor power Engine speed may also be controlled using the
supply is 5V +/- 5%. The voltage in the idle position engine speed control switch to increase engine
is 2500mV +/- 100mV. The voltage in the full pedal speed when performing functions that do not
stroke position is 700mV +/- 150mV. The output require machine travel.
signals are sent to the XS module through pin 11
and pin 12 in the connector (See Below). These
signals control the travel/engine speed and FOOT PEDAL CHARACTERISTICS
direction of travel of the machine. Through internal
• Sensor Power Supply = 5V +/- 5%
logic the computer control system uses the signal
from the pedal to control engine speed, drive pump • Idle Position=2500mV +/- 100mV / 0 Degrees
stroke and drive motor stroke. • Full Pedal Stroke=700mV+/-150mV /11
A 12 pin Deutsch connector is used to connect Degrees
each pedal to the machine electrical system:
Foot Pedal Characteristics
Pin 1 = violet = not used
Pin 2 = black = not used 4800
Pin 3 = green = + 5 VDC 1
4000
Pin 4 = maroon = + 5VDC2
Pin 5 = red = Ground 2 3200
Milli-Volts

Pin 6 = not used 2400

Pin 7 = pink = not used
1600
Pin 8 = grey = not used
Pin 9 = white = not used 800
Pin 10 = yellow = not used 0
Pin 11 = red blue = Signal Out 1 0 20 40 60 80 100
Pin 12 = pink grey = Signal Out 2
Pedal Position %

8.13
Tigercat 635C Skidder Drive
MAXIMUM SPEED CONTROL DIAL
MAXIMUM SPEED
CONTROL DIAL
The maximum speed control dial is located on the
control panel in the operator's cab. 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.
Turn the dial clockwise to increase the maximum
travel speed.
Turn the dial counterclockwise to decrease the 635C-03
CONTROL PANEL
maximum travel speed of the machine.
This control can be used while the machine is in
motion.
Caution: Turning the maximum speed control dial
completely counterclockwise (minimum setting)
lowers maximum travel speed only, it will NOT
prevent the machine from travelling when the
forward or reverse travel pedals are used.
This control dial is a potentiometer with 330° of
rotation. The signal generated by the control dial
position (VOLTAGE IN - Travel Speed) is sent to
the IQAN XS module of the computer control
system to limit the travel speed of the machine MAXIMUM SPEED CONTROL DIAL
based on the rotational position of the dial. 630C-18 ELECTRICAL SCHEMATIC
A 3 pin connector is used to connect this control
to the machine electrical system.
Refer also to TRAVEL/ENGINE SPEED PEDALS
in THIS SECTION.

Maximum Speed Control Dial Characteristics

100%

90%

80%
Drive Motor Output (%)

70%

60%

50%

40%

30%

20%

10%

0%
0 1000 2000 3000 4000 5000
Dial Position (Milli-volts)

8.14
Tigercat 635C Skidder Drive
TRANSMISSION
The transmission drives both the front and rear
1
axles of the machine. Power is supplied by two 2
4
hydraulic motors mounted to the input side of the •
transmission. The output shafts transmit the • 3
power to both the front and rear axles.
•
•
•
The gears and bearings in the transmission are
lubricated by splash lubrication inside the case.
The oil level in the transmission must always be TEST PORT COMPARTMENT
BELOW RIGHT CAB DOOR
kept up to the proper level indicated on the 635C-25 6350501 TO 6350550
dipstick. Refer SECTION 3 of this manual for the
recommended lubricant.
The transmission disconnect lever is used to shift
1
the transmission between the DRIVE and 2
NEUTRAL positions, e.g. NEUTRAL for towing
the machine. • •
• 3
The transmission disconnect lever is accessed •
from the right side, between the cab and heat
exchanger assembly. A short bar is placed
TEST PORT COMPARTMENT
through the hole in the lever and pulled upwards BELOW RIGHT CAB DOOR
to put the transmission into neutral. 635C-25X 6350551 TO 6351000

IMPORTANT
When the transmission is in neutral, never
DISCONNECT
tow the machine at over 2 mph (3.2 km/h) LEVER
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

8.15
Tigercat 635C Skidder Drive

DRIVE CIRCUIT
635C-03A (6350501 TO 6350510)
8.16
Tigercat 635C Skidder Drive

DRIVE CIRCUIT HYDRAULIC SCHEMATIC

635C-16 (6350501 TO 6350510)
8.17
Tigercat 635C Skidder Drive

DRIVE CIRCUIT
635C-42 (6350511 TO 6350530)

8.18
Tigercat 635C Skidder Drive

DRIVE CIRCUIT
635C-43 (6350531 TO 6351000)

8.19
Tigercat 635C Skidder Drive

8.20
Tigercat 635C Skidder Drive

DRIVE CIRCUIT HYDRAULIC SCHEMATIC

630C-83 (6350511 TO 6351000)

8.21
Tigercat 635C Skidder Drive
DRIVE PUMP PRESSURE CHECKS DRIVE PUMP PRESSURE CHECKS
(6350501 TO 6350510) (6350511 TO 6351000)
The drive pump is electro-hydraulically controlled CHECK CHARGE PRESSURE
and factory set. It requires no adjustment.
1. Park machine on level ground. Install
NOTE: Charge pressure is regulated by a articulation lock. Parking brake ON, grapple
nonadjustable cartridge style relief valve in the and dozer blade down and engine OFF.
drive pump . BELOW RIGHT
HAND CAB DOOR
CHECK CHARGE PRESSURE
MAIN ACCU AXLE
1. Park machine on level ground. Install
articulation lock. Parking brake ON, grapple LM1 RM1 CHARGE
and dozer blade down and engine OFF. • • •
BELOW RIGHT
HAND CAB DOOR
• • •
MAIN ACCU AXLE TEST PORT COMPARTMENT
BELOW RIGHT CAB DOOR
LM1 RM1 CHARGE 635C-25 6350511 TO 6350550
• • •
BELOW RIGHT
HAND CAB DOOR
• • •
MAIN ACCU AXLE
TEST PORT COMPARTMENT
CHARGE
BELOW RIGHT CAB DOOR LM1 RM1 • •
635C-25 6350501 TO 6350510 •
2. Connect a 0 -70 Bar (0-1000 psi) gauge to the • • •
'CHARGE' test port.
TEST PORT COMPARTMENT
3. Start engine and allow to idle. BELOW RIGHT CAB DOOR
4. Ensure that hydraulic oil is at operating
635C-25X 6350551 TO 6351000
temperature. Refer to HYDRAULIC OIL 2. Connect a 0 -70 Bar (0-1000 psi) gauge to the
HEATING PROCEDURE in THIS SECTION. 'CHARGE' test port.
5. Check charge pressure. 3. Start engine and allow to idle.
Reading should be 305 psi (21 Bar) at an 4. Ensure that hydraulic oil is at operating
engine speed of 750 rpm. temperature. Refer to HYDRAULIC OIL
6. If charge pressure readings are not correct HEATING PROCEDURE in THIS SECTION.
check the charge filter for proper operation 5. Check charge pressure.
before taking further corrective action.
Reading should be 350-360 psi (24-25 Bar)
at an engine speed of 750 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.

8.22
Tigercat 635C Skidder Drive
DRIVE MOTOR SPEED VERIFICATION
Drive motor speed should be checked prior to CHECK FOR CORRECT MOTOR MINIMUM
making any drive motor pressure checks or DISPLACEMENT
adjustments. 1. Start the engine.
Fasten your seat belt and move the machine to 2. Set the maxiimum speed control dial to its
a suitable test area, where it can be safely driven highest setting ( ).
at full speed for approximately 150 ft (45 m).
Grapple UP, CLOSED and ROTATED TO 3. Use the IQAN MDM to view motor speed
CENTER. Dozer blade UP. information from the cab. Use the MEASURE
MENU and select INPUTS ~ FREQUENCY IN
CHECK FOR FULL DRIVE PUMP FLOW ~ DRIVE MOTOR RPM to view drive motor
1. Start the engine. rpm readings. Refer to MEASURE MENU
OPERATION in SECTION 6 of THIS
2. Set the maximum speed control dial to its
MANUAL for more information.
lowest setting ( ).
4. Drive the machine forward with the drive
3. Use the IQAN MDM to view motor speed
pedal fully depressed. The drive motor rpm
information from the cab. Use the MEASURE
display should read 3800-4000 rpm.
MENU and select INPUTS ~ FREQUENCY IN
~ DRIVE MOTOR RPM to view drive motor 6. A correct reading indicates the motor
rpm readings. Refer to MEASURE MENU minimum displacement is set correctly.
OPERATION in SECTION 6 of THIS An incorrect reading indicates the motor
MANUAL for more information. minimum displacement requires adjustment
4. Drive the machine forward with the drive or drive motor max current settings may be
pedal fully depressed. The drive motor rpm out of calibration.
display should read 925-975 rpm. Refer to HYDROSTATIC SETUP
5. A correct reading indicates the there is full PROCEDURE in THIS SECTION.
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.

8.23
Tigercat 635C Skidder Drive
HYDROSTATIC SETUP PROCEDURE G. Drive Pump Max Current
DO NOT adjust drive motor and drive pump Drive pump max current may be adjusted
pressure settings without first confirming the independently of other procedures.
need to do so.
H. Drive Motor Max Current
All motor adjustments must be performed on
BOTH MOTORS. Drive motor max current may be adjusted
independently of other procedures.
The hydrostatic setup procedure is a series of
steps that must be done in a proper sequence to
achieve optimum performance from the machine. IMPORTANT
Any deviation from the procedures could present
The adjustment or set-up procedure is a
a safety hazard, damage components and/or
series of steps that must be done in a proper
affect the operation of the machine.
sequence to achieve optimum performance
A. Setup Preparation. from the machine. Any deviation from the
Setup preparation is required prior to procedures could present a safety hazard,
performing all drive pump and drive motor damage components and/or affect the
adjustments (sections B,C,D,E). operation of the machine. All adjustments
must be performed on BOTH MOTORS.
B. Drive Pump Charge Pressure.
Drive pump charge pressure may be checked IMPORTANT
independently of other procedures. Refer
also to DRIVE PUMP PRESSURE CHECKS • When installing a new or rebuilt motor,
in THIS SECTION. ensure minimum displacement screw is set
correctly.
C. Drive Pump High Pressure Relief. • Improper adjustment of min. displacement
Drive pump high pressure relief may be adjusting screw can result in motor failure
checked and adjusted independently due to overspeeding.
(sections A,C,D,G,H in order). Note that drive • It may be necessary to verify the length of
pump POR must be reset after this adjusting screw used by removing and
procedure. measuring the screw.
D. Drive Pump POR • Also note that an orifice must be removed
on all replacement motors for proper
Drive pump POR may be check and adjusted operation. Failure to remove this orifice will
independently, however it is recommended cause the motor to function erratically with
that drive pump high pressure relief settings the electronic controller. Refer to DRIVE
be checked prior to performing this procedure MOTOR in THIS SECTION for illustration
(sections A,C,D,G,H in order). showing location of parts to be removed.
E. Motor Begin of Displacement Control
Pressure
Motor Begin of displacement may be checked WARNING
and adjusted independently (sections A,E,G,H
in order). Note that drive motor max current
To prevent injury caused by accidental
must be reset after this procedure.
steering of the machine when setting
F. Motor Maximum Speed/Minimum pressures, make sure the articulation lock
Displacement pin is held securely in place by the lynch pins
Motor maximum speed/minimum provided.
displacement may be checked and adjusted
independently (sections A,F,G,H in order).
Note that drive motor max current must be
reset after this procedure.

8.24
Tigercat 635C Skidder Drive
A. SETUP PREPARATION If you are not updating the IQAN program, get
the application from the MDM. Refer to GET
1. Park machine on level ground. Install
APPLICATION USING A PC/LAPTOP in
articulation lock. Parking brake ON, grapple
SECTION 6 of THIS MANUAL.
and dozer blade down and engine OFF.
Note that update of the IQAN program may
2. The shifting time of the Drive Motors is
be required as a result of PSB updates,
controlled by the IQAN software, not using
program improvement updates or other
hydraulic timing orifices.
component updates.
If installing a new or rebuilt motor has been
replaced ensure orifices are out of M1 port on
both Drive Motors.

M1 PORTS
LOCATED ON
BOTTOM LEFT
HAND SIDE OF
EACH MOTOR
BEGIN OF
REGULATION
SCREW
620C-104

MINIMUM 8. For accurate setup it is necessary to

DISPLACEMENT
SCREW temporarily increase the pump maximum
current setting.
Use the IQAN MDM to adjust the Pump Max
POR
SCREW •• • Current as high as it will go (ie. 650 mA, 700
FIGURE 1
•• DRIVE MOTORS mA or 1300 mA) and press OK. Using the
IQAN MDM navigate to the PROPERTIES
3. Ensure that the drive motor minimum
MENU~OTHER~FUNC. PARAM ~Pump Max
displacement screws on both the left and right
Current. Refer to PROPERTIES MENU
drive motors are set to approximately 17mm
OPERATION in SECTION 6 of THIS
(with 90mm screw – measured from end of
MANUAL for more information.
screw to top of jam-nut) as follows. These
measurements are a starting point and may
have to be adjusted for proper calibration.
4. On both the left and right drive motors, turn
the drive motor POR adjusting screw all the
way IN until lightly seated, then back out 1/4
turn.
5. Turn the keyswitch to the RUN position to
provide power to the computer system.
620C-106

6. Connect a PC/Laptop to the IQAN MDM

module using the proper communication 9. For accurate setup it is necessary to
cable, open the IQANdevelop program. Refer temporarily increase the motor maximum
to SECTION 6 of THIS MANUAL for current setting.
connection information. Use the IQAN MDM to adjust the Motor Max
7. If you are updating the IQAN program Current as high as it will go (ie. 1000 mA or
refer to the Tigercat Dealer Website and open 1050 mA) and press OK. Using the IQAN
the appropriate application for the machine MDM navigate to the PROPERTIES
then send it to the MDM. Refer to IQAN MENU~OTHER~FUNC. PARAM ~Motor Max
SOFTWARE~UPDATING THE IQAN Current. Refer to PROPERTIES MENU
APPLICATION~FROM A PC/LAPTOP and OPERATION in SECTION 6 of THIS
DOWNLOADING APPLICATIONS FROM MANUAL for more information.
DEALER WEBSITE in SECTION 6 of THIS 10. Ensure that hydraulic oil is at operating
MANUAL. temperature. Refer to HYDRAULIC OIL
HEATING PROCEDURE in THIS SECTION.

8.25
Tigercat 635C Skidder Drive
B. DRIVE PUMP CHARGE PRESSURE 15. EARLIER MACHINES-LINDE DRIVE PUMP
(6350501 TO 6350510)
BELOW RIGHT
HAND CAB DOOR Turn the engine off and remove the gauge from
MAIN ACCU AXLE the charge pressure test port.
The Linde charge pressure is non-adjustable.
LM1 RM1 CHARGE
• • • The Linde drive pump is not equipped with a
mechanical POR—for machines equipped with
• • • a Linde pump proceed to Step 45.
TEST PORT COMPARTMENT LATER MACHINES-REXROTH DRIVE PUMP
BELOW RIGHT CAB DOOR (6350511 TO 6351000)
635C-25 6350501 TO 6350550
If necessary, adjust the charge pressure
BELOW RIGHT adjustment screw on the drive pump.
HAND CAB DOOR

MAIN ACCU AXLE Turning the screw IN will increase the pressure.
Turning the screw OUT will decrease the
CHARGE
LM1 RM1 • • • pressure.
Repeat steps 12 to 15 and verify correct
• • • pressure reading.
TEST PORT COMPARTMENT
BELOW RIGHT CAB DOOR
635C-25X 6350551 TO 6351000
11. Connect a 0-1000 psi gauge to the 'CHARGE'
test port.
12. Start engine and allow to idle.
13. Check charge pressure.
EARLIER MACHINES-LINDE DRIVE PUMP
(6350501 TO 6350510)
Reading should be 305 psi (21 Bar) or higher
at an engine speed of 750 rpm.
LATER MACHINES-REXROTH DRIVE PUMP
(6350511 TO 6351000)
Reading should be 350-360 psi (24-25 Bar) at
an engine speed of 750 rpm.
14. If charge pressure readings are not correct
check the charge filter for proper operation
before taking further corrective action.

8.26
Tigercat 635C Skidder Drive
C. DRIVE PUMP HIGH PRESSURE RELIEF
CHARGE PRESSURE
ADJUSTMENT
ON OPPOSITE SIDE
•

POR 620C-113
ADJUSTMENT
18. Use the IQAN MDM to view engine speed
information from the cab. Use the MEASURE
MENU and select INPUTS ~ CAN ANALOG ~
DRIVE PUMP
(6350511 TO 6351000) Engine Speed. Refer to MEASURE MENU
FIGURE 2-630C OPERATION in SECTION 6 of THIS
16. To check the high pressure relief valve MANUAL for more information.
settings it is necessary to temporarily turn the 19. Ensure that a PC/Laptop is still connected to
drive pump POR screw all the way IN (until the IQAN MDM with IQAN develop program
lightly seated). open and the correct application program on
Note the number of turns to turn the POR screen as described in step 6.
adjusting screw fully IN. Once the high
pressure reliefs have been set the POR
adjusting screws will need be returned to their
original position as a starting point to reset
POR.

620C-112
FIGURE 10

17. Use the IQAN MDM to change the Program 20. On the laptop use the pointer on the laptop to
Mode to Mode #4 (POR Setup Mode) and reset selected items for graphing.
press OK. Using the IQAN MDM navigate to From the main menu select Measure then
the PROPERTIES MENU~OTHER~FUNC. choose Reset Selected from the drop
PARAM ~Program Mode ~ Mode #4. Refer to down menu.
PROPERTIES MENU OPERATION in
SECTION 6 of THIS MANUAL for more
information.
NOTE: When program modes 2,3 and 4 are
used a "For Service Use Only" warning
message is shown on the electronic display,
an alarm will sound and the alarm warning
light will flash. In addition the arch and boom
are deactivated in program modes 2,3 and 4.

8.27
Tigercat 635C Skidder Drive
XT2-A0 TAB
LEFT CLICK ON BOX TO
• DISPLAY DIGITAL READING

•• DRAG TIME MARKERS

• MAINTAIN CONSTANT
PRESSURE AT 2200 RPM
••
DRIVE PSI FWD [PSI] TRUE
RMS

STAT
TAB

FIGURE 3A FIGURE 5 ••
21. Click on the XT2-A0 tab and left click on Drive 28. Drag the time markers to select the section
PSI Fwd [psi] to display the digital reading. where the forward drive pressure was held
constant at an engine speed of 2200 rpm.
29. To find the average relief pressure, select the
• •• •• Drive PSI Fwd [psi] channel tab (the graph
data for the selected channel will be
STOP
MEASURE highlighted or bold when selected), and click
GRAPH TAB the Stat tab.
START
MEASURE The True RMS of the selected portion of the
graph should read between 6500 – 6600 psi.

CHARGE PRESSURE
ADJUSTMENT
ON OPPOSITE SIDE
••
FIGURE 4A

22. Click on the graph tab. Click on the START

MEASURE button (green arrow) on the toolbar,
or hit F4. POR
ADJUSTMENT
23. Release the parking brake.
24. Apply left foot firmly against service brake and
apply the forward drive pedal with the right foot.
DRIVE PUMP
Build and maintain an engine speed of about FIGURE 2-630C
(6350511 TO 6351000)
2200 rpm on the MDM.
25. The forward drive pressure will rise and then If the reading is correct proceed to step 30.
level once the forward high pressure relief If the pressure is not in this range, adjust the
setting is met. forward high pressure relief setting screw on
Maintain this pressure level for 3 seconds. the pump.
26. Release the forward drive pedal and the Turning the screw IN will increase the
service brake. Apply the parking brake. pressure
27. On the laptop, click the STOP MEASURE Turning the screw OUT will decrease the
button (red square) on the toolbar, or hit F4. pressure.
Repeat steps 23– 29 until the correct reading
is obtained.
30. Repeat steps 21 –29 for the reverse direction
to set the reverse high pressure relief (Drive
PSI Rev).
Proceed to step 31 to reset drive pump POR.

8.28
Tigercat 635C Skidder Drive
D. DRIVE PUMP POR 34. Release the parking brake.
CHARGE PRESSURE 35. Apply left foot firmly against service brake
ADJUSTMENT and apply the forward drive pedal with the
ON OPPOSITE SIDE
•• right foot.
Build and maintain an engine speed of about
2200 rpm on the MDM.
36. The forward drive pressure will rise and then
POR level off as the pump POR activates.
ADJUSTMENT
Maintain this pressure level for 3 seconds.
37. Release the forward drive pedal and the
service brake. Apply the parking brake.
DRIVE PUMP
(6350511 TO 6351000) 38. On the laptop, click the STOP MEASURE
FIGURE 2-630C
button (red square) on the toolbar, or hit F4.
31. To set the drive pump POR, begin by turning
the pump POR screw OUT the number of
turns noted in step 17 (when it was
temporarily turned in). DRAG TIME MARKERS
This setting is a starting point, you will need to
adjust it as detailed below. MAINTAIN CONSTANT
PRESSURE AT 2200 RPM
••
XT2-A0 TAB TRUE
LEFT CLICK ON BOX TO RMS
• DISPLAY DIGITAL READING

•
STAT
•• TAB

DRIVE PSI FWD [PSI]

FIGURE 5 ••
39. Drag the time markers to select the section
where the forward drive pressure was held
constant at an engine speed of 2200 rpm.
40. To find the average POR pressure, select the
FIGURE 3A
Drive PSI Fwd [psi] channel tab (the graph
data for the selected channel will be
32. Click on the XT2-A0 tab, left click on Drive highlighted or bold when selected), and click
PSI Fwd [psi] to display the digital reading. the Stat tab.
The True RMS of the selected portion of the
•• •• •• graph should read between 5800 and 6000
psi.
STOP
MEASURE If reading is correct proceed to step 41.
GRAPH TAB
START
MEASURE

FIGURE 4A

33. Click on the Graph tab. Click on the START

MEASURE button (green arrow) on the
toolbar, or hit F4.

8.29
Tigercat 635C Skidder Drive
CHARGE PRESSURE
42. If the engine torque is higher than 20 – 40%
ADJUSTMENT during the POR test, the drive pump is actually
ON OPPOSITE SIDE
operating on the high pressure reliefs, not the
• POR. This will cause significant heat increase
and substantially higher fuel consumption.
Either the POR must be lowered slightly or the
high pressure reliefs raised.
POR
ADJUSTMENT

DRIVE PUMP
(6350511 TO 6351000)
FIGURE 2-630C

If the pressure is not in this range, adjust the

620C-109
drive pump POR setting.
Turning the screw IN will increase the 43. Use the IQAN MDM to change the Program
pressure. Mode back to Mode #1 (Normal mode) and
press OK. Using the IQAN MDM navigate to
Turning the screw OUT will decrease the
the PROPERTIES MENU~OTHER~FUNC.
pressure.
PARAM ~Program Mode ~ Mode #1. Refer to
Repeat steps 32 to 40 until the correct reading PROPERTIES MENU OPERATION in
is obtained. SECTION 6 of THIS MANUAL for more
information.
41. If, after adjusting the POR screw, the pressure
does not stabilize within the specified range or NOTE: When program modes 2,3 and 4 are
the engine appears to lug down excessively*, used a "For Service Use Only" warning
contact Tigercat customer service for further message is shown on the electronic display, an
assistance. alarm will sound and the alarm warning light
will flash. In addition the arch and boom are
*Note that normal engine torque during POR
deactivated in program modes 2,3 and 4.
Test should be 20 – 40%.

IMPORTANT
Machine must be in Program Mode 1
(Normal mode) to operate normally.

Program modes 2,3 and 4 are used for

service/setup procedures only.
620C-114 When program modes 2,3 and 4 are used a
"For Service Use Only" warning message is
Use the IQAN MDM to view % Engine shown on the electronic display, an alarm
Torque information from the cab. Use the will sound and the alarm warning light will
MEASURE MENU and select INPUTS ~ flash. In addition the arch and boom are
CAN ANALOG ~ % Engine Torque. Refer deactivated in program modes 2,3 and 4.
to MEASURE MENU OPERATION in
44. Turn the engine off and remove the gauge
SECTION 6 of THIS MANUAL for more
from the charge pressure test port.
information.

8.30
Tigercat 635C Skidder Drive
E. MOTOR BEGIN OF DISPLACEMENT NOTE: When program modes 2,3 and 4 are
CONTROL PRESSURE used a "For Service Use Only" warning
CAB
message is shown on the electronic display, an
CAB SUPPORT
BRACE (3291B).
LOCKING
PIN •• alarm will sound and the alarm warning light
will flash. In addition the arch and boom are
MUST USE CAB &
CHASSIS LUGS deactivated in program modes 2,3 and 4.
SHOWN

••
ARTICULATION
LOCK CAB
LOCKING
PIN •
PARTIAL TILT WITH
630C-124 • CAB SUPPORT BRACE 620C-115

45. Tilt the cab over and install the cab tilt safety 49. Use the IQAN MDM to view motor drive
bar. current out information from the cab. Use the
MEASURE MENU and select OUTPUTS ~
M1 PORTS CURRENT OUT ~ Motor Drive COUT (or
LOCATED ON
BOTTOM LEFT Motor Drive LH COUT). Refer to MEASURE
HAND SIDE OF
EACH MOTOR MENU OPERATION in SECTION 6 of THIS
BEGIN OF MANUAL for more information.
REGULATION
SCREW
50. Ensure that a PC/Laptop is still connected to
the IQAN MDM, IQAN develop program open
MINIMUM
DISPLACEMENT
and the correct application program on screen
SCREW as described in step 6.

POR
SCREW • ••
FIGURE 1 • DRIVE MOTORS
46. Connect two 0-5000 psi gauges to the RM1
(Right Motor M1) and LM1 (Left Motor M1) test
ports.
47. Turn the keyswitch to the RUN position to
provide power to the computer system.

FIGURE 10

51. Use the pointer on the laptop to reset selected

items for graphing.
From the main menu select Measure then
620C-111
choose Reset Selected from the drop
48. Use the IQAN MDM to change the Program down menu.
Mode to Mode #3 (Motor Setup Mode) and
press OK. Using the IQAN MDM navigate to
the PROPERTIES MENU~OTHER~FUNC.
PARAM ~Program Mode ~ Mode #3. Refer to
PROPERTIES MENU OPERATION in
SECTION 6 of THIS MANUAL for more
information.

8.31
Tigercat 635C Skidder Drive
XT2-A0 TAB 58. The drive motors will not begin to displace
LEFT CLICK ON BOX TO until the LM1 and RM1 control pressures
•• DISPLAY DIGITAL READING
on the gauges reach half of the system
•• pressure.
For example, if the system pressure stabilizes
•• at 4000 psi while holding the service brake and
DRIVE PSI FWD [PSI] forward drive pedal in program mode 3, the
motors will not be physically shifting until the
control pressure reaches 2000 psi.
59. Slowly turn the maximum speed control dial
towards .
FIGURE 3A On the MDM display, the motor current reading
should start increasing from 0 mA.
52. Click on the XT2-A0 tab and left click on Drive
PSI Fwd [psi] to display the digital reading. Continue turning the maximum speed control
dial up until one of the M1 gauges reaches half
53. Start the engine. Set the maximum speed of system pressure. Note the current value
control dial to its lowest setting ( ). displayed on the MDM for the first motor.
54. Release the parking brake. 60. Continue turning the maximum speed control
dial up until the second M1 gauge reaches half
• •• of system pressure. Again note the current
value displayed on the MDM for the second
STOP motor.
MEASURE
GRAPH TAB 61. Although both motors do not have to reach half
START of system pressure at the same time or
MEASURE
amperage, each motor should reach half of
system pressure no earlier than 390 mA
and no later than 420 mA.
If both motors are set correctly, proceed to
Step 65.
FIGURE 4A If either motor does not meet this requirement
the begin of displacement screw on the
55. Click on the graph tab. Click on the START motor(s) must be adjusted, proceed to next
MEASURE button (green arrow) on the step.
toolbar, or hit F4.
NOTE: It is NOT NECESSARY for both motors
56. Apply left foot firmly against service brake and to have the same settings. Motors may
apply the forward drive pedal all the way to the perform differently from one machine to
floor with the right foot. another or even from one motor to another on
The engine rpm should only reach 1050 rpm. the same machine.
57. The drive system should build and then 62. With the service brake and forward drive pedal
maintain a constant pressure between still fully applied, turn the maximum speed
3000-5500 psi. The wheels may creep at a control dial so that Motor Drive COUT (or
slow speed. Motor Drive LH COUT) is 405 mA.
With the aid of an assistant maintain this
condition and adjust the lefthand motor
beginning of regulation screw until the gauge
pressure is half of the Drive PSI Fwd [psi]
value.
Adjust the right hand motor to the same
pressure.
Release the drive pedal and service brake.

8.32
Tigercat 635C Skidder Drive
63. Note: While adjusting the second motor, it may F. MOTOR MAXIMUM SPEED/MINIMUM
be difficult to achieve exactly half of the Drive DISPLACEMENT
PSI Fwd [psi] value—while trying to zero in
69. Turn the keyswitch to the RUN position to
the pressure, the gauge will continue to move
provide power to the computer system.
and settle either above or below half of system
pressure. If this is the case, have the 70. Use the IQAN MDM to ensure the Program
beginning of regulation screw set as close as Mode is set to Mode #1 (Normal mode) and
possible to this “switch point”. press OK. Using the IQAN MDM navigate to
the PROPERTIES MENU~OTHER~FUNC.
64. Return the maximum speed control dial to its
PARAM ~Program Mode ~ Mode #1. Refer to
lowest setting ( ).
PROPERTIES MENU OPERATION in
SECTION 6 of THIS MANUAL for more
information.
NOTE: When program modes 2,3 and 4 are
used a "For Service Use Only" warning
message is shown on the electronic display, an
alarm will sound and the alarm warning light
will flash. In addition the arch and boom are
deactivated in program modes 2,3 and 4.
620C-109
71. Ensure that a PC/Laptop is still connected to
Repeat steps 55– 63 until each motor reaches the IQAN MDM, IQAN develop program open
half of system pressure no earlier than 390 mA and the correct application program on screen
and no later than 420 mA. as described in step 6.
65. Click on the STOP MEASURE button (red 72. Start the engine. Release the parking brake
square) on the toolbar, or hit F4. and turn the maximum speed control dial to
.
66. Use the IQAN MDM to change the Program
Mode back to Mode #1 (Normal mode) and 73. Fasten your seat belt and move the machine
press OK. Using the IQAN MDM navigate to to a suitable test area, where it can be safely
the PROPERTIES MENU~OTHER~FUNC. driven at full speed for approximately 200 feet.
PARAM ~Program Mode ~ Mode #1. Refer to Grapple UP, CLOSED and ROTATED TO
PROPERTIES MENU OPERATION in CENTER. Dozer blade UP.
SECTION 6 of THIS MANUAL for more If a 200 ft (60 m) stretch of flat hard ground is
information. not available (ie. road or parking lot), lift the
NOTE: When program modes 2,3 and 4 are machine’s tires off of the ground using the
used a "For Service Use Only" warning dozer and grapple. When lifting the machine
message is shown on the electronic display, an off the ground, the difflocks will need to be
alarm will sound and the alarm warning light engaged and the front axle should be
will flash. In addition the arch and boom are prevented from oscillating.
deactivated in program modes 2,3 and 4.
67. Remove the cab tilt safety bar and return the
cab to its normal position.
68. Apply the parking brake, turn the engine off
and remove the gauges from the motor test
ports.

8.33
Tigercat 635C Skidder Drive
77. Fully apply the forward drive pedal, allow the
machine to reach top speed and maintain for 3
seconds. Release the forward drive pedal and
allow the machine to stop.
78. Click on the STOP MEASURE button (red
square) on the toolbar, or hit F4.

DRAG TIME MARKERS

SMOOTH SECTION
••
WITH MACHINE AT
TOP SPEED
FIGURE 10
TRUE
74. Use the pointer on the laptop to reset selected RMS
items for graphing. STAT
TAB
From the main menu select Measure then
choose Reset Selected from the drop FIGURE 7 •
down menu.
79. Set all four wheels back on the ground.
XT2-A0 TAB
LEFT CLICK ON BOX TO 80. Drag the time markers to select a smooth
•• DISPLAY DIGITAL READING
section of the graph where the machine was at
• top speed.
81. To find the average maximum drive motor rpm
at , select the Drive Motor [rpm] channel
tab (the graph data for the selected channel
•• will be highlighted or bold when selected), and
DRIVE MOTOR [RPM] click the Stat tab.
82. The True RMS of the selected portion of the
graph should read 3900–4000 rpm.
FIGURE 3A If the value recorded does not fall into this
range, the minimum displacement screw must
75. Click on the XT2-A0 tab and left click on Drive be adjusted on the RH and LH drive motor.
Motor [rpm] to display the digital reading.
83. If the average top speed is acceptable,
proceed to Step 88.

• •• CAB

STOP
CAB SUPPORT
BRACE (3291B).
LOCKING
PIN •
MEASURE MUST USE CAB &
GRAPH TAB CHASSIS LUGS
SHOWN
START
MEASURE

•
ARTICULATION
LOCK CAB

FIGURE 4A
LOCKING
PIN ••
PARTIAL TILT WITH
76. Click on the graph tab. Click on the START 630C-124 •• CAB SUPPORT BRACE
MEASURE button (green arrow) on the
84. Tilt the cab and install the safety bar.
toolbar, or hit F4.

8.34
Tigercat 635C Skidder Drive
G. DRIVE PUMP MAX CURRENT
M1 PORTS
LOCATED ON 89. Start the engine. Release the parking brake
BOTTOM LEFT
HAND SIDE OF and turn the maximum speed control dial to
EACH MOTOR
.
BEGIN OF
REGULATION
SCREW 90. Ensure that a PC/Laptop is still connected to
the IQAN MDM, IQAN develop program open
MINIMUM
and the correct application program on screen
DISPLACEMENT
SCREW
as described in step 6.
91. Ensure that the graph is displaying Drive
Motor [rpm].
POR
SCREW •• ••
FIGURE 1 • DRIVE MOTORS
XT2-A0 TAB
LEFT CLICK ON BOX TO

85. Adjust the RH and LH drive motors as

• DISPLAY DIGITAL READING

required. Turning each screw out 1/4 turn •

should increase the top speed by
approximately 100 RPM. Turning each screw
in 1/4 turn should decrease the top speed by
approximately 100 RPM.
86. Remove the cab tilt safety bar and return the
cab to its normal position.
87. Repeat steps 73 to 86 until the average top
speed falls between 3900-4000 rpm FIGURE 3A

88. Apply the parking brake and turn the engine 92. Click on the XT2-A0 tab and left click on
off. Motor Drive COUT [%] or (Motor Drive LH
COUT [%]) to display the digital reading.
93. Click on the XT2-A0 tab and left click on Drive
Pump COUT [%] to display the digital reading.
Note: if Drive Pump COUT [%] is not on the
XT2-A0 module, it will be found on the XP2-A0
module.

•• •• ••
STOP
MEASURE
GRAPH TAB
START
MEASURE

FIGURE 4A

94. Click on the graph tab. Click on the START

MEASURE button (green arrow) on the
toolbar, or hit F4.

8.35
Tigercat 635C Skidder Drive
95. Fully apply the forward drive pedal, allow the
machine to reach top speed and maintain for
3 seconds.
Release the forward drive pedal and allow the
machine to stop an apply the park brake.
96. Click on the STOP MEASURE button (red
square) on the toolbar, or hit F4.
620C-104

DRAG TIME MARKERS

100.Use the IQAN MDM to reset the Pump Max
Current as follows. Using the IQAN MDM
navigate to the PROPERTIES
SMOOTH SECTION
• MENU~OTHER~FUNC. PARAM ~Pump Max
WITH MACHINE AT Current. Refer to PROPERTIES MENU
TOP SPEED
OPERATION in SECTION 6 of THIS
TRUE MANUAL for more information.
RMS

STAT 101.Lower the pump max current in 5 mA

TAB
increments repeating steps 94-99 until the
FIGURE 7 •• drive motor rpm drops at least 10 rpm from
the initial value found in step 99.
97. Drag the time markers to select a smooth 102.Once the average maximum drive motor rpm
section of the graph where the machine was at has dropped by 10 rpm, change the
at top speed. pump max current back to the last value used
98. To find the average maximum drive motor rpm prior to the drop. This will ensure that the
at , select the Drive Motor [rpm] channel drive pump is fully stroking and drawing
tab (the graph data for the selected channel maximum horsepower, but will prevent
will be highlighted or bold when selected), and excess current from delaying the pump
click the Stat tab. response.

99. The True RMS of the selected portion of the Example results are shown in Table 1.
graph should be approximately 950 rpm. 103. Set all four wheels back on the ground and
apply the parking brake.

Table 1: Example results for setting Drive Pump Max Current

Drive Pump COUT Drive Motor RPM @ TURTLE
MAX CURRENT (True RMS @ Top Speed) Notes
1300 mA 948 rpm
1295 mA 952 rpm
1290 mA 946 rpm
1285 mA 943 rpm
1280 mA 947 rpm
1275 mA 951 rpm
1270 mA 942 rpm
1265 mA 947 rpm
1260 mA 946 rpm - Set Pump Max Current to 1260 mA
1255 mA 921 rpm
1250 mA 890 rpm
8.36
Tigercat 635C Skidder Drive
H. DRIVE MOTOR MAX CURRENT 108.With the maximum speed control dial set to
, release the park brake and fully apply the
104.Ensure that a PC/Laptop is still connected to
forward drive pedal.
the IQAN MDM, IQAN develop program open
and the correct application program on Allow the machine to reach top speed and
screen as described in step 6. maintain for 5 seconds.
105.Ensure the following channels are still Release the forward drive pedal and allow the
displaying a digital readout in IQAN develop: machine to stop and apply the park brake.
Drive Motor COUT [%] (or Motor Drive LH
COUT [%]) and Drive Pump COUT [%].

•• •• •• DRAG TIME MARKERS

STOP
MEASURE SMOOTH SECTION
••
GRAPH TAB WITH MACHINE AT
TOP SPEED
START
MEASURE TRUE
RMS

STAT
TAB

FIGURE 7 •
FIGURE 4A
109.Click the STOP MEASURE button (red
square) on the toolbar, or hit F4.
106.To find the appropriate maximum current for Drag the time markers to select a smooth
the drive motors, click on the graph tab. Click section of the Drive Motor [rpm] graph where
on the START MEASURE button (green the machine was at top speed.
arrow) on the toolbar, or hit F4.
110.To find the average top speed at , select
107.Fasten your seat belt and move the the Drive Motor [rpm] channel tab (the graph
machine to a suitable test area, where it can data for the selected channel will be
be safely driven at full speed for highlighted or bold when selected), and click
approximately 200 feet. Grapple UP, the Stat tab.
CLOSED and ROTATED TO CENTER.
Dozer blade UP. 111.Initially, the True RMS of the selected portion
of the graph should read between
If a 200 ft (60 m) stretch of flat hard ground is 3900-4000 rpm.
not available (ie. road or parking lot), lift the
machine’s tires off of the ground using the
dozer and grapple. When lifting the machine
off the ground, the difflocks will need to be
engaged and the front axle should be
prevented from oscillating.

8.37
Tigercat 635C Skidder Drive

620C-106

112.Use the IQAN MDM to reset the Motor Max

Current. Using the IQAN MDM navigate to the
PROPERTIES MENU~OTHER~FUNC.
PARAM ~Motor Max Current. Refer to
PROPERTIES MENU OPERATION in
SECTION 6 of THIS MANUAL for more
information.
113.Lower the motor max current in 5 mA
increments repeating steps 109 – 112 until the
drive motor rpm drops by at least 50 rpm
from the initial value found in step 111. Leave
the motor max current at this value as it will
ensure the drive motors will be responsive to
sudden changes in torque load.
114.The top speed must be at least 3800 rpm in
the forward drive direction.
Example results are shown in Table 2.
115.Set all four wheels back on the ground and
apply the parking brake.
116.Apply the parking brake and turn the engine
off.

Table 2: Example results for setting Drive Motor Max Current

Drive Motor COUT Drive Motor RPM @ TURTLE
MAX CURRENT (True RMS @ Top Speed) Notes
1000 mA 3945 rpm
995 mA 3941 rpm
990 mA 3927 rpm
985 mA 3918 rpm
980 mA 3935 rpm
975 mA 3932 rpm
970 mA 3940 rpm
965 mA 3911 rpm
960 mA 3875 rpm - Set Motor Max Current to 960 mA
955 mA 3760 rpm
8.38
Tigercat 635C Skidder Drive
HYDRAULIC OIL HEATING
PROCEDURE DRIVE
PUMP
There is a specific procedure to heat up the
hydraulic oil in the machine in preparation for
performing pressure measurements and
setups.
CONNECTORS •
1. Park machine on level ground, lower grapple
and dozer and engage parking brake. Install ••
articulation lock pin and stop engine
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 DISCONNECT TWO CONNECTORS
radiator and charge air cooler must remain ON DRIVE PUMP PRIOR TO
uncovered to prevent engine overheating. PERFORMING PROCEDURE
635C-11
(6350501 TO 6350510)
4. Start the engine (full throttle).
5. Make sure that the area is clear operate
CONNECTORS ARE
EITHER the arch out or boom down in LOCATED ON THE
BOTTOM OF PUMP.
function (whichever you have chosen) and PUMP SHOWN WITH
HOSES REMOVED
HOLD in the operating position, while FOR CLARITY CONNECTORS
(2 PLACES)
monitoring the ENGINE coolant temperature
and the HYDRAULIC oil temperature.
Temperatures can be monitored on the
INFORMATION CENTER - IQAN MDM ••
COMPUTER DISPLAY (ENGINE TEMP, HYD
DISCONNECT TWO CONNECTORS
OIL TEMP). This should be done at full ON DRIVE PUMP PRIOR TO
throttle and will take 10 to 45 minutes. PERFORMING PROCEDURE
(6350511 TO 6351000)
IMPORTANT
DO NOT leave the machine while heating the
oil, as overheating of engine or oil can cause
serious damage.

6. Ensure that the hydraulic oil temperature is

between 120 and 130°F (49 and 54°C).
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.

8.39
Tigercat 635C Skidder Drive
DRIVE COUPLING (LATER DESIGN) COUPLING GUARD
PUMP STACK
The coupling is marked with arrows which indicate
the proper orientation for balanced assembly Note ••
that these arrows may be difficult to see due to
paint buildup. If disassembling this u-joint
coupling for ANY reason always paint mark shaft,
yokes and flanges across the disassebly location •
to ensure that it will be reassembled in the same
orientation. Reassembling incorrectly will cause FRONT

balance problems in the drive coupling. 630C-172 COUPLING GUARD AT PUMP STACK
Refer to LUBRICATION AND SERVICE POINTS
chart in SECTION 3 of THIS MANUAL for
scheduled maintenance information.
ORIENTATION
ARROWS (DARKENED
••
FOR PHOTO CLARITY)
COUPLING GUARD FRONT

•• ••
630C-171 COUPLING GUARD AT FLYWHEEL
1/16"-1/8" (1.5-2.0 mm) GAP
BETWEEN COUPLING AND
FRONT FACE OF DRIVE PUMP
MATCH ARROWS FOR
635C-38 PROPER ORIENTATION
GREASE •
FITTINGS
GREASE
FITTING •
• •
••
635C-36
635C-37
GREASE FITTINGS GREASE FITTING 3/4" DOG POINT SET
SCREWS (2-PLACES)
PUMP STACK SIDE ENGINE SIDE 150-160 lbf-ft (203-217 Nm)

635C-34 SET SCREWS PUMP STACK SIDE

ALWAYS MARK SHAFT BEFORE
DISSASEMBLY TO ENSURE CORRECT
ORIENTATION WHEN REASSEMBLED FLYWHEEL BOLTS
•
3/8"-16 (8 PLACES)
33-36 lbf-ft (44-49 Nm)

• •
••
• ••
YOKE FLANGE BOLTS
M10 (8-PLACES) YOKE FLANGE BOLTS
49-57 lbf-ft (66-77 Nm) M10 (8-PLACES)
49-57 lbf-ft (66-77 Nm)
PUMP STACK ENGINE
635C-35 DRIVE COUPLING ASSEMBLY (LATER DESIGN)

8.40
Tigercat 635C Skidder

SECTION 9 - BRAKES
NOVEMBER 2008

CONTENTS-SECTION 9
ACCUMULATOR
ACCUMULATOR ........................................................................................ 9.4
CHARGING AND TESTING DEVICE ......................................................... 9.4
CHARGING THE ACCUMULATOR ........................................................... 9.4
CHECKING GAS PRESSURE ................................................................... 9.4
BRAKES
BRAKE PEDAL VALVE .............................................................................. 9.3
FRONT AXLE BRAKE. ...................................................... SEE SECTION 15
PARKING BRAKE, DRIVELINE (6350621 TO 6351000) ......................... 9.18
BRAKE ASSEMBLY REMOVAL ............................................................ 9.19
PARKING BRAKE VALVE ....................................................................... 9.5
SPRING APPLIED HYDRAULIC RELEASE ......................................... 9.18
PARKING BRAKE, LEVER (6350501 TO 6350620) ................................ 9.14
CABLE ADJUSTMENTS ....................................................................... 9.16
CHECKING FOR PROPER ADJUSTMENT ......................................... 9.16
LIMIT SWITCH ADJUSTMENT ............................................................ 9.17
PROXIMITY SENSOR ADJUSTMENT ................................................. 9.17
CHARGING VALVE, ACCUMULATOR .......................................................... 9.4
CIRCUIT DESCRIPTION ..................................................................... 9.6, 9.10
CIRCUIT DIAGRAM
6350501 TO 6350510 ................................................................................. 9.7
6350511 TO 6350620 ................................................................................. 9.8
6350621 TO 6351000 ............................................................................... 9.11
CIRCUIT HYDRAULIC SCHEMATIC
6350501 TO 6350620 ................................................................................. 9.9
6350621 TO 6351000 ............................................................................... 9.13
MAIN PUMP ................................................................................................... 9.2
MAIN PUMP UNLOADING VALVE. ........................................ SEE SECTION 7
PRESSURE SETTINGS, MAIN PUMP ........................................................ 9.23
PRIORITY VALVE. ................................................................ SEE SECTION 11
SERVICE BRAKE, FRONT AXLE. ........................................ SEE SECTION 15
Tigercat 635C Skidder Brakes
MAIN PUMP
The main pump is driven off the power take off of
the drive pump. ••
The main pump provides hydraulic oil to the brake SOLENOID,
circuit and priority valve, which in turn provides INTEGRATED
MAIN PUMP
hydraulic oil to the steer circuit, brake circuit and UNLOADING
VALVE
control valve (winch, arch, dozer, grapple, boom)
circuits. •
The main pump is a variable displacement pressure
compensated axial piston pump. This pump is MAIN PUMP

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 MAIN PUMP
decreases until there is no flow at an angle of 635C-27 (6350501 TO 6350530)
zero (0°).
The pressure compensator is mounted directly onto
the pump and has a STANDBY pressure
adjustment and a POR (pressure override)
••
adjustment. An integrated unloading valve is SOLENOID,
INTEGRATED
sandwiched between the POR valve and the main MAIN PUMP
UNLOADING
pump to effectively de-stroke the swashplate when VALVE
an electric signal is provided. •
The STANDBY adjusting screw is factory set at
200-250 psi (14-17 Bar) @ 750rpm. MAIN PUMP

The POR is adjusted to operate at 3000-3100 psi

(207-214 Bar) @ 2200 rpm.
The pressure compensator provides maximum
pump flow until the main pump reaches the preset MAIN PUMP
main pump POR setting. The pressure 630C-252 (6350531 TO 6351000)
compensator then regulates output flow to match
machine requirements for the steering, brake, TO ACCUMULATOR, STANDBY MAIN PUMP
BRAKE AND VALVE POR VALVE
winch, arch, grapple, boom and dozer functions. PRIORITY VALVE

When the parking brake is ON and the integrated

main pump unloading valve is energized the
standby 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. •
TO
SUCTION
STRAINER
INTEGRATED
FROM HYDRAULIC UNLOADING
TANK SUCTION LINE VALVE

620C-19 MAIN PUMP HYDRAULIC SCHEMATIC

9.2
Tigercat 635C Skidder Brakes
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 front axle from the accumulator.
A reaction piston in the valve senses this increase
in brake pressure and relays feedback to the
operator, i.e. as brake pressure increases the
pedal effort increases proportionately.
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 front 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

CROSS SECTION
OF VALVE BODY
MO-01

BRAKE VALVE

9.3
Tigercat 635C Skidder Brakes
ACCUMULATOR CHARGING THE ACCUMULATOR
The accumulator is bladder type and is installed
with a nitrogen pre-charge pressure of WARNING
approximately 750 psi (52 Bar). USE ONLY NITROGEN for charging
accumulators, NEVER USE OXYGEN OR AIR,
WARNING due to the risk of explosion.
Hydraulic circuits with accumulators store NOTE: A detailed instruction sheet is provided with
hydraulic oil under pressure, therefore the the charging and testing device. The following is
system may remain pressurized after the only a suggested guide.
engine is turned off.
NITROGEN PRESSURE
Prior to performing any maintenance or system BOTTLE GAUGE*
HOSE*
modifications, exercise CAUTION and release
stored system pressure by stopping the engine
and fully applying the brake foot pedal 50 times ADAPTER*
ADAPTER*
or more.
VALVE GUARD ACCUMULATOR
VALVE CAP ASSEMBLY PART NO. 90254 INCLUDES PARTS SHOWN *

GAS VALVE ACCU-2 CHARGING AND TESTING DEVICE

• Close the drain valve on the charging and
testing device and connect the hose to the
BODY nitrogen bottle.
• Remove the valve guard and cap.
BLADDER • Screw the charging and testing device onto the
gas valve.
• Open the gas shut-off valve on the nitrogen
POPPET
bottle and allow gas to flow slowly into the
(Seats against oil port accumulator.
after oil evacuation)
HYDRAULIC
CONNECTION • Close the shut-off valve frequently and check
ACCU-1 ACCUMULATOR (BLADDER TYPE) the value of the pre-charge by depressing the
button on the charging device and observe the
CHECKING THE GAS gauge.
PRE-CHARGE PRESSURE
• If the pre-charge pressure is too high, it may
Bleed off the system pressure as stated earlier. be reduced by opening the drain valve and
After the accumulator has been put in service, the carefully depressing the button on the charging
pre-charge pressure should be checked with an device.
accumulator charging and testing device. Note: The pre-charge pressure will vary
Install the charging and testing device onto the gas dependant upon the temperature. Once the
valve. While depressing the button on the charging desired pre-charge is reached, wait two
device, observe gas pressure reading on gauge. minutes for the gas temperature to equalize.
Re-check pre-charge and adjust if necessary.
If the gas pre-charge is low, investigate cause and
correct. Possible causes of lost pre-charge • Disconnect hose from nitrogen bottle.
pressure include leaking or damaged gas valve, or • Remove charging and testing device from
damaged bladder. accumulator and install valve cap and guard,
torque to 175-350 lbf-in (20-40 N-m).
WARNING • Check to ensure there are no leaks, if gas
The accumulator must not be altered. DO valve is leaking, it should be replaced. Use
NOT weld or machine the pressure vessel. only valves approved for accumulator service.
NEVER USE AN AUTOMOTIVE TYPE VALVE.

9.4
Tigercat 635C Skidder Brakes
PARKING BRAKE VALVE LOCATED ON THE RIGHT SIDE
(6350621 TO 6351000) OF THE FRONT CHASSIS IN THE
ENGINE ENCLOSURE
(NEAR THE PRIORITY VALVE)
The parking brake valve controls parking brake
function on machines equipped with a driveline
parking brake.
This valve is a 3-way direct acting hydraulic PARKING
directional valve. BRAKE
VALVE

• PARKING
BRAKE
SUPPLY HOSE

•
635C-40 PARKING BRAKE VALVE
FROM CHARGE PUMP

TO DRIVELINE
PARKING BRAKE

PARKING BRAKE VALVE

635C-03 SCHEMATIC

9.5
Tigercat 635C Skidder Brakes
CIRCUIT DESCRIPTION
(6350501 TO 6350620)
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 front
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
front 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 front 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 later machines (6350551 to 6351000)
are 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.
For more information about the front axle service
brakes refer to SECTION 15 - AXLES AND
DIFFERENTIAL LOCKS in THIS MANUAL.

9.6
Tigercat 635C Skidder Brakes

BRAKE CIRCUIT
635C-04 (6350501 TO 6350510)

9.7
Tigercat 635C Skidder Brakes

BRAKE CIRCUIT
630C-69A (6350511 TO 6350620)

9.8
Tigercat 635C Skidder Brakes

BRAKE CIRCUIT HYDRAULIC SCHEMATIC

635C-29
(6350501 TO 6350620)

9.9
Tigercat 635C Skidder Brakes
CIRCUIT DESCRIPTION DRIVELINE PARKING BRAKE
(6350621 TO 6351000)
Pilot oil is supplied to the parking brake valve from
BRAKE the charge pump which is part of the drive pump.
Refer to DRIVE PUMP in SECTION 8 for charge
Oil is supplied by a variable displacement piston
pump information.
pump (main pump). Oil is directed through a check
valve to the brake accumulator. The oil from the The driveline parking brake is spring applied and
brake accumulator side of the check valve is sent hydraulically released.
to the brake foot control valve to operate the front
When the parking brake switch is in the ON
brakes. The main pump also supplies oil to the
position the parking brake is spring applied. A
priority valve for steering and control valve
signal is sent to the park brake and unloading
functions.
valve relay which in turn sends an electrical signal
The brake accumulator ensures that the brake to the main pump unloading valve to unload the
remains responsive at all times by maintaining an main pump and a signal (DIGITAL IN - Park Brake
optimum pressure to the brake foot control valve. Sensor) to the computer control system to indicate
The brake accumulator holds sufficient pressure that the parking brake is ON. An electrical signal is
for up to 5 brake applications after the engine also sent directly to the park brake warning light on
stalls or is shut down. Beyond this the pressure the intrument panel to indicate to the operator that
drops substantially. the parking brake is engaged.
As the brake pedal is depressed, pressure from When the parking brake switch is in the OFF
the accumulator is provided to the brakes in the position an electrical signal is sent directly to
front axle. A reaction piston in the valve senses activate the parking brake solenoid valve and
this increase in brake pressure and relays provide pilot oil to hydraulically release the drive
feedback to the operator; i.e. as brake pressure line parking brake. In addition the parking brake
increases the pedal effort increases pressure switch sends a signal (VOLTAGE IN -
proportionately. Park Brake PSI On) to the computer control
system to indicate that parking brake is OFF.
A positive stop in the brake valve limits the brake
pressure to a preset value. Refer also to START CIRCUIT DIAGRAMS in
SECTION 7 or ELECTRICAL SCHEMATICS in
This preset value is determined by the
SECTION 6 of THIS MANUAL for more detailed
requirements of the brakes in the front axle, which
information.
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 is 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.
For more information about the front axle service
brakes refer to SECTION 15 - AXLES AND
DIFFERENTIAL LOCKS in THIS MANUAL.

9.10
Tigercat 635C Skidder Brakes

BRAKE CIRCUIT
630C-69A (6350621 TO 6351000)

9.11
Tigercat 635C Skidder Brakes

9.12
Tigercat 635C Skidder Brakes

BRAKE CIRCUIT HYDRAULIC SCHEMATIC

635C-44 (6350621 TO 6351000)

9.13
Tigercat 635C Skidder Brakes
PARKING BRAKE, LEVER
(6350501 TO 6350620) PARKING BRAKE
CABLE
BRAKE
The parking brake lever is located to the left of the PROXIMITY
operator’s seat. It is connected by a cable to a SENSOR ••
main disc brake caliper assembly mounted on the (EARLIER
output side of the transmission. MACHINES)

Pulling up on the parking brake lever engages the

brake caliper on the brake disc. A proximity
sensor (earlier machines) or limit switch (later
machines) mounted on the side of the parking
brake lever is also activated.
PROXIMITY
Pushing down on the lever releases the brake SENSOR

and de-activates the proximity sensor or limit

switch.
•• •• PARKING
BRAKE
The proximity sensor or limit switch signal LEVER

(DIGITAL IN - Park Brake Sensor) is sent to the

computer control system. The computer control METAL
system uses the parking brake input signal for BAR
three main functions:
1. Enable engine start. The parking brake must
be ON to start the engine.
••
337-21
Note: Earlier machines equipped with a
proximity switch may experience cold weather
starting difficulty due to a voltage drop across
the proximity switch. Refer to PSB 1518 for
more information on correcting this problem.
2. Drive prevent logic. The parking brake must
be OFF to travel.
3. Main pump unloading valve control. When LIMIT
SWITCH
the parking brake is ON, the main pump
unloading valve is energized and standby
pressure is available (main pump destroked). • METAL
BAR
When the parking brake is OFF, the main
pump unloading valve is de-energized and the
main pump is fully loaded (full pressure
available for functions). ••
PARKING
BRAKE
PARKING
BRAKE •• LIMIT
SWITCH
LEVER
(LATER
MACHINES)
620C-68

9.14
Tigercat 635C Skidder Brakes

CENTER CALIPER
ADJUSTING MOUNTING
BOLT NUTS (2)

REAR CALIPER
TORQUE PLATE
• •
CARRIER AND
• LINING ASSEMBLY

•
•
CALIPER MOUNTING BOLTS (2)
•
INNER SEAL
(RUBBER)

SLEEVES (2) • BALL BEARINGS (3)

• •
SPRING
RUBBER BOOT
•
• THRUST
SLEEVE
SEAL (2) • WASHER
• STAINLESS
• • WASHER
FRONT CALIPER INNER CAM
TORQUE PLATE • HARDENED
RETAINER • WASHER
• •
OUTER CAM
• ••
LEVER

WASHER (2) INNER

BRAKE SPRING OUTER
ADJUSTING ADJUSTING
CABLE NUT NUT
• • •
• • •
•
NUT (3) COTTER
CLEVIS PIN

CLEVIS
PIN

PARKING
BRAKE LEVER

ADJUSTING
KNOB

LOCKING
• • SET
SCREW
•
METAL BAR ••
LIMIT
SWITCH

635C36
PARKING BRAKE ASSEMBLY

9.15
Tigercat 635C Skidder Brakes
CHECKING FOR PROPER PARKING BRAKE PARKING BRAKE CABLE ADJUSTMENTS
CABLE ADJUSTMENT
LEVER END ADJUSTMENT:
The parking brake is properly adjusted when
Turn the knob on the end of the brake lever to
Resistance is encountered half way through the
increase or decrease braking effect. (Set screw
brake lever’s travel.
on side of adjusting knob will lock the setting)

•• ADJUSTING
½” GAP
KNOB

SET SCREW

PARKING BRAKE ~
•
620C-97
E620C-08 ENGAGED POSITION
PARKING BRAKE HANDLE ADJUSTMENT

CALIPER END ADJUSTMENT:

WARNING
1. Remove the set screw in the parking brake
All brake adjustments and service must be
handle.
followed by a test drive using these
procedures and then checked for proper 2. Turn the parking brake handle knob clockwise
caliper "float". to back off the cable tension. Continue turning
the knob clockwise until the pin is
The parking brake must be kept properly adjusted approximately 1/2 in (12 mm) from the end of
at all times and should be lubricated every 500 the slot closest to the handle pivot point.
hours under normal operating conditions.

BRAKE CALIPER
ADJUSTMENT NUT BRAKE
CALIPER
•• LEVER

BRAKE
CALIPER
••
LOCKNUT
•
ADJUST CLEVIS ••
FOR ¼”GAP • • ENSURE PIN IS
CLEVIS INSERTED IN
JAM NUT CLEVIS OUTER HOLE
620C-96

PARKING BRAKE CALIPER ADJUSTMENT

3. Remove the clevis from the brake caliper

lever.
4. Loosen the clevis jam nut.
5. Thread the clevis as far onto the cable as
possible. Leave a 1/4 in (6 mm) gap between
the spring tension jam-nut and the clevis jam-
nut. (NOTE: This ensures that the overall
cable length is as short as possible and results
in additional brake handle adjustment.)

9.16
Tigercat 635C Skidder Brakes
6. Reattach the clevis to the brake caliper lever. LIMIT SWITCH (LATER MACHINES):
Ensure it is installed in the outer hole on the
The parking brake limit switch should be adjusted
brake caliper lever. (NOTE: At this step the
so that there is between 1/32 - 1/16 in (1-1.5 mm)
brake pads should be starting to or very close
travel left when the parking brake is OFF. Do not
to clamping onto the brake disc.)
adjust the switch so that the switch bottoms out
7. Tighten the clevis jam nut. before the parking brake mechanism as this may
result in premature switch failure.
8. Using a set of feeler gauges measure the
clearance between the brake pad face and the After making adjustments verify that the switch will
brake disc. Clearance should be operate the drive prevent logic circuit when the
parking brake is in the ON position.
approximately .020+−..000
005
in ( . 500 +− ..125
000 mm).
PROXIMITY SENSOR (EARLIER MACHINES):
9. If clearance is correct proceed to step 13.
The parking brake proximity sensor should be
If clearance needs to be adjusted proceed to adjusted so that the distance measured between
step 10. the end of the sensor and the metal actuating bar
10. Loosen the brake caliper lock nut. of the brake lever is 1/8 in (3 mm) with the parking
brake in the OFF position. The sensor can be
11. Turn the adjustment nut clockwise to reduce adjusted by loosening the two jamnuts and
clearance or counterclockwise to increase adjusting the location of the sensor.
clearance.
After making adjustments verify that the sensor will
12. Once the clearance is correct, tighten the jam- operate the drive prevent logic circuit when the
nut. Double-check the clearance after parking brake is in the ON position.
tightening the jam-nut.
Do not allow the sensor and the metal actuating
13. Turn the parking brake handle knob counter bar make contact with each other.
clockwise pulling up on the brake lever
approximately every 5 turns.
The parking brake should take approximately
60–80 lbf (265-355 N) to activate brake.
14. Apply the parking brake by pulling up on the
lever.
15. Once the cable tension is adjusted correctly,
insert the handle set screw to lock the setting.

9.17
Tigercat 635C Skidder Brakes
PARKING BRAKE
(6350621 TO 6351000)

PARKING
BRAKE
ASSEMBLY

••

604-63

635C-41

SPRINGS STATIONARY
DISCS

DRIVE
SHAFT
•• • ROTATING
DISCS

•• •

724E-007
724E-008
724E-016 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.

610-11 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'.

9.18
Tigercat 635C Skidder Brakes
PARKING BRAKE PARKING
BRAKE
The spring applied and hydraulically released ASSEMBLY
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
604-63
of worn or damaged parts and reinstallation of the
brake assembly.
BRAKE ASSEMBLY REMOVAL
1. Park machine on level ground, lower grapple
and dozer blade to the ground, install
articulation lock bar, shut engine off.

635C-41

SPRINGS STATIONARY
DISCS

DRIVE
SHAFT
• •• ROTATING
DISCS

635C-46 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. 724E-007

4. Disconnect the hydraulic hose and breather

hose at the brake assembly. Plug the hose PARKING BRAKE
ends and ports on the brake housing.
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. BL026

7. Lower the brake assembly out of the rear

chassis.

9.19
Tigercat 635C Skidder Brakes

1 - ASSEMBLY

••
24 6 7

•
724E-008 17 20 28 26 27
•
• •

• •
• •
23
•
19
13 •
22 20 16 14 2
• •

• •
• • • •

•
21 25
14

• •

•
•
• 14 4 21 22

•
• 29
•
18
•
• •
16 •
•
12 •
9 •
10 • •
11 •
•
24 •
•
6 • 15 5 8 3 25
•
•

BL026

9.20
Tigercat 635C Skidder Brakes
PARTS DESCRIPTION
Item Qty. Description Item Qty. Description
1 1 ASSEMBLY 16 5 . Disk, stationary
2 1 . Disk, primary 17 1 . Gasket
3 1 . Cap, end 18 1 . Housing
4 7 . Bolt, hex. 19 6 . Bolt
5 as req. . Shim 20 2 . Pin, torque
6 2 . Bearing, tapered roller 21 2 . Ring, retaining
7 1 . Shaft, splined 22 2 . Spacer
8 1 . O-ring 23 1 . Plug, protective
9 18 . Spring, outer 24 2 . Seal, oil
10 18 . Spring, inner 25 2 . Seal, oil
11 13 . Spring, inner * 26 1 . O-ring
12 1 . Retainer, spring 27 1 . Piston
13 1 . Plate, power 28 1 . O-ring
14 5 . Disk, rotating 29 1 . Valve, pressure relief
15 2 . Plug
* Item 11 used on later design only.

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 (13)
up, the side with the mounting lugs. 2. Pre-lube O-rings, piston and cylinder of the
power plate with hydraulic oil.
3. Remove spacers (22) from each end.
Piston Assembly
4. Remove the bolts alternately and slowly,
keeping power plate parallel to the housing to 3. Assemble piston into power plate using a
prevent damage to the bearings. Use extreme shop press. Take care not to damage O-ring
caution springs (9, 10 and 11*) can cause or teflon back-up rings.
power plate to pop off housing.
4. Visually align the centre of the cutouts in the
5. After the bolts have been removed, remove piston with the torque pin holes in the power
the power plate assembly from brake. plate.
6. Remove shaft and disk stack from the brake. CAUTION: The depth the piston is installed
If the disk stack is to be serviced use a shop into the power plate is critical. The surface of
press to remove the bearing cones from the the piston at the cutouts must be flush to 3.05
shaft. mm (0.120") below the surface of the power
plate or the piston will cock resulting in
7. Remove primary plate (2), springs and spring
complete loss of braking.
retainer from housing spring pocket.
Bearing Assembly
8. Remove piston (27) from power plate by
using Low Pressure air 1 Bar (15 psi) through 5. Using a shop press install one cone on the
hydraulic inlet. Make sure the piston is shaft, bearing must be seated tight against
directed away from the operator. the stop. Press only on the inner race of the
bearing cone, not on the rollers.
9. Remove O-rings from the OD and ID of the
groove of the piston. 6. Install the disk in the order shown in the parts
illustration. Install the other bearing cone on
NOTE: If the bearings or seals are removed
the shaft observing the preceding cautions.
both must be replaced. Seal can be removed
by prying it out with an appropriate tool taking
care not to damage the bore.
10. Thoroughly clean all the parts.
11. Inspect and replace any worn, damaged or
defective parts.

9.21
Tigercat 635C Skidder Brakes
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 216-
237 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
724E-007
lbf/ft ).
5. Install the cover plate on the bottom of the
Lip Seal Assembly rear chassis.
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).

9.22
Tigercat 635C Skidder Brakes
PRESSURE SETTINGS MAIN PUMP DRIVE
PUMP
POR AND STANDBY PRESSURES CONNECTORS
1. Park the machine on level ground, lower
grapple and dozer blade to the ground,
engage parking brake, and shut off the engine. • •
Install articulation lock.
BELOW RIGHT
HAND CAB DOOR

MAIN ACCU AXLE •

LM1 RM1 CHARGE
• • •
DISCONNECT TWO CONNECTORS
• • • ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
TEST PORT COMPARTMENT (6350501 TO 6350510)
635C-11
BELOW RIGHT CAB DOOR
635C-25 6350501 TO 6350550
CONNECTORS ARE
BELOW RIGHT LOCATED ON THE
HAND CAB DOOR BOTTOM OF PUMP.
PUMP SHOWN WITH
MAIN ACCU AXLE HOSES REMOVED
FOR CLARITY CONNECTORS
(2 PLACES)
CHARGE
LM1 RM1 • • •

• • • ••
TEST PORT COMPARTMENT DISCONNECT TWO CONNECTORS
BELOW RIGHT CAB DOOR ON DRIVE PUMP PRIOR TO
635C-25X 6350551 TO 6351000 PERFORMING PROCEDURE
(6350511 TO 6351000)
2. Connect a 0-345 Bar (0-5000 psi) gauge to
the ‘MAIN’ test port. All pressure readings for 4. Prior to performing this procedure disconnect
this procedure will be read from the 'MAIN' test the two connectors on the drive pump. This is
port. a safety precaution to prevent the machine
from travelling.
3. Ensure that the hydraulic oil is at operating
Continued on next page
temperature. See HYDRAULIC OIL HEATING
PROCEDURE in SECTION 8 of THIS
MANUAL.

9.23
Tigercat 635C Skidder Brakes
5. Start the engine. Set engine speed to 2200
rpm.
6. Disengage parking brake. This deactivates ••
the main pump unloading valve. The main
SOLENOID,
pump must be fully loaded to correctly set the INTEGRATED
main pump POR. MAIN PUMP
UNLOADING
VALVE
7. Set the main pump POR to 3000-3100 psi
(207-214 Bar) @ 2200 rpm. •
8. Set engine speed to 750 rpm.
MAIN PUMP
9. Engage parking brake to activate the main
pump unloading valve. The main pump must
be unloaded to correctly set the main pump
standby pressure.
10. Set the standby pressure to 200-250 (14-17
Bar) psi @ 750 rpm.
11. Turn off the engine, reconnect two connectors MAIN PUMP
635C-27 (6350501 TO 6350530)
on drive pump, remove gauge, reinstall plugs
on test ports, and replace the covers. Remove
articulation lock.
••
SOLENOID,
INTEGRATED
MAIN PUMP
UNLOADING
VALVE
•
MAIN PUMP

MAIN PUMP
630C-252 (6350531 TO 6351000)

9.24
Tigercat 635C Skidder

SECTION 10-OIL COOLER/RADIATOR AND CROSS-FLOW FAN

OCTOBER 2008

CONTENTS - SECTION 10
CIRCUIT DESCRIPTION
FAN ........................................................................................................................ 10.18
OIL COOLER ............................................................................................................ 10.8
CIRCUIT DIAGRAM
FAN CIRCUIT
6350501 TO 6350510 ......................................................................................... 10.20
6350511 TO 6351000 .......................................................................................... 10.21
OIL COOLER CIRCUIT
6350501 TO 6350510 ........................................................................................... 10.9
6350511 TO 6350530 .......................................................................................... 10.10
6350531 TO 6351000 ......................................................................................... 10.11
COOLING PUMP ........................................................................................................ 10.4
FAN MANIFOLD ........................................................................................................ 10.16
FAN MOTOR .............................................................................................................. 10.17
FAN PUMP ................................................................................................................. 10.15
FAN SPEED CHECKS ............................................................................................... 10.24
CHECK FOR NO A/C DURING CLEAN MODE ...................................................... 10.24
FAN 'CLEAN' SPEED ............................................................................................. 10.24
FAN FULL ON SPEED ........................................................................................... 10.24
MINIMUM FAN SPEED WITH A/C "ON" ................................................................ 10.24
FILTER, HYDRAULIC TRIPLE ELEMENT ................................................................... 10.5
HYDRAULIC CIRCUIT SCHEMATIC
COOLING CIRCUIT
6350501 TO 6350510 ......................................................................................... 10.12
6350511 TO 6351000 .......................................................................................... 10.13
FAN CIRCUIT
6350501 TO 635510 ........................................................................................... 10.22
6350511 TO 6351000 .......................................................................................... 10.23
HYDRAULIC OIL TANK, MAIN .................................................................................... 10.5
OIL COOLER CIRCUIT DIAGRAM .............................................................................. 10.9
OIL COOLER/ RADIATOR/ CHARGE AIR COOLER .................................................. 10.2
SUCTION STRAINER .................................................................................................. 10.7
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
OIL COOLER/ RADIATOR/ CHARGE CHARGE
AIR
AIR COOLER COOLER A/C CONDENSER
(CAC) RADIATOR
The hydraulic oil cooler and engine radiator and
charge air cooler (CAC) are mounted side by side
as an assembly. The assembly is mounted
longitudinally in the front chassis to provide cross ••
flow ventilation. The A/C condenser core is OIL COOLER
mounted in front of these three units and on
hinges to facilitate cleaning. The cooling fan is
•• ••
mounted behind the oil cooler/radiator assembly
and draws air from the left side of the machine. ••
The air passes through the oil cooler/radiator/
LEFT SIDE - A/C CONDENSER,
CAC and A/C condenser core and exhausts on OIL COOLER, RADIATOR AND
the right side of the machine. 630C-62
CHARGE AIR COOLER
The fan drive system is reversible to facilitate
cleaning by blowing air in the opposite direction
through the cooling assembly This cooling
assembly must be checked daily for
accumulation of debris.
The complete oil cooler/radiator/CAC/A-C
condenser/fan drive assembly is rubber isolation
mounted to reduce the transmission of noise and
to isolate the components from vibration.
For detailed cleaning procedures, refer to
CLEANING A/C CONDENSER AND COOLING
ASSEMBLY in SECTION 2 of the OPERATOR’S 635C-20 RIGHT SIDE - CROSS-FLOW FAN
MANUAL.

10.2
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

OIL COOLER A/C CONDENSER RADIATOR

CHARGE AIR
COOLER
(CAC)
•
•

COOLER
TANK

•
•
•
FAN
•
SHROUD

FAN
FINGER
GUARD

••

• •

FAN
MOTOR

FAN DRIVE
SUPPORT

NOTE: REGULARLY
CHECK FOR DEBRIS
ACCUMULATION
BETWEEN RADIATOR/
OIL COOLER AND A/C
CONDENSER
630C-22 COOLING ASSEMBLY INSTALLATION
10.3
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
COOLING PUMP
COOLING
The cooling pump is a fixed displacement gear FAN PUMP
PUMP
pump. It is part of the multisection gear pump, CHARGE OIL
PUMP COOLER
which includes the cooling, fan, charge (*if BY-PASS
AXLE
equipped) and axle pumps. This pump stack is
driven off the power take off of the main pump.
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). MULTISECTION GEAR PUMP
(6350501 TO 6350510)
630C-175
OUTLET
DRIVEN DRIVE
(IDLER) GEAR
GEAR COOLING
FAN PUMP
PUMP
OIL
COOLER
• • AXLE
PUMP
BY-PASS

•• ••
•
••

MULTISECTION GEAR PUMP

INLET (6350511 TO 6351000)
630C-236

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.
* Note: Later machines are equipped with a drive
pump which includes an integrated charge pump.

10.4
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
MAIN HYDRAULIC OIL TANK TRIPLE ELEMENT FILTER
Located at the rear of the engine enclosure, the The hydraulic oil cooling circuit contains a triple
hydraulic tank has a capacity of 28 US gal (106L). filter head with a built in visual restriction indicator
and a 25 psi bypass valve. It is recommended
A sight gauge, accessible through the right front
that all machines use two different types of filter
quick access lift out panel, indicates the HIGH
elements:
and LOW level of the main hydraulic oil tank.
1 blue, Tigercat water absorbing, full flow
Always keep the hydraulic oil level between the
hydraulic oil filter element.
HIGH and LOW calibrations. A low hydraulic oil
level can result in severe damage to pumps. 2 white, Tigercat high performance, full flow
hydraulic oil filter elements.
A hydraulic oil level switch is connected to the
IQAN computer control system. This switch For additional information on these filters refer to
triggers the hydraulic oil level low warning. Refer FILTERS and SERVICE AND LUBRICATION
also to INFORMATION CENTER ~ SYSTEM POINTS in SECTION 3.
WARNING MESSAGES in SECTION 2 of THE
OPERATOR'S MANUAL.
IMPORTANT
BLUE
ELEMENT
WATER Note that the 635C skidder has two separate
TRIPLE ABSORBING
ELEMENT hydraulic systems (the main hydraulic
FILTER SIGHT system and the axle circuit). These two
GAUGE
hydraulic systems require two different types
of hydraulic oil that MUST NOT BE
•• INTERCHANGED under any circumstances.
• Always use the correct type of hydraulic oil
• for the circuit you are filling. Refer to
APPROVED HYDRAULIC OILS in SECTION 3
of THIS MANUAL.

• MAIN
HYDRAULIC
TANK

•
••
CHARGE
AXLE PRESSURE
FILTER FILTER

HYDRAULIC TANK, FILTERS AND

635C-23 SIGHT GAUGE

10.5
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

10.6
Tigercat 635C Skidder Oil Cooler and Cross-flow 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
motors), brake valve drain line, priority valve, fan
motor, charge filter 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.

10.7
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
OIL COOLER CIRCUIT DESCRIPTION
The suction strainer collects hydraulic oil from
case drains (drive pump, main pump, and drive
motors), brake valve drain line, priority valve, fan
motor, charge filter and rear chassis (winch and
grapple) drain line. This oil 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
triple element filter and back to the hydraulic tank.
Oil is added to the hydraulic reservoir using the
hydraulic hand fill pump located in the step
compartment on the left side of the machine. Oil
is pumped through the triple 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.

10.8
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

OIL COOLER CIRCUIT

635C-05
(6350501 TO 6350510)

10.9
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

OIL COOLER CIRCUIT

630C-70
(6350511 TO 6350530)

10.10
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

OIL COOLER CIRCUIT

630C-70A
(6350531 TO 6351000)

10.11
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

OIL COOLER CIRCUIT HYDRAULIC SCHEMATIC

630C-84 (6350501 TO 6350510)

10.12
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

OIL COOLER CIRCUIT HYDRAULIC SCHEMATIC

630C-85
(6350511 TO 6351000)

10.13
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

10.14
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
FAN PUMP
COOLING
The fan pump is a fixed displacement gear pump. FAN PUMP
PUMP
It is part of the multisection gear pump which CHARGE OIL
PUMP COOLER
includes the cooling, fan, charge (*if equipped) BY-PASS
AXLE
and axle pumps. This pump stack is driven off
the power take off of the main pump.
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.

OUTLET MULTISECTION GEAR PUMP

DRIVEN DRIVE (6350501 TO 6350510)
(IDLER) 630C-175
GEAR
GEAR

COOLING
• • FAN
PUMP
PUMP

OIL
COOLER
AXLE BY-PASS
PUMP
•• ••
•
••
INLET

GEAR1 TYPICAL GEAR PUMP MULTISECTION GEAR PUMP

630C-236 (6350511 TO 6351000)
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.
* Note: Later machines are equipped with a drive
pump which includes an integrated charge pump.

10.15
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

TO FAN MOTOR DIRECTIONAL

SOLENOID
VALVE

•
REVERSE
PRESSURE
LINE
DIRECTIONAL
SOLENOID VALVE
(FAN DIRECTION- SV1)
•
••
••
• TO
TANK ••
• •• FORWARD
PRESSURE PROPORTIONAL
LINE SOLENOID VALVE FROM FAN PUMP
FROM (WITH PRESSURE
FAN TO
TANK PROPORTIONAL RELIEF)
PUMP
SOLENOID VALVE
(FAN SPEED-SV2) FAN MANIFOLD LATER DESIGN
C635C-18 HYDRAULIC SCHEMATIC
635C-30 FAN MANIFOLD

FAN MANIFOLD
The fan manifold controls speed and direction of fan
rotation. Oil from the fan pump passes through the
P port into the fan manifold and is directed to the fan
motor.
The direction of fan rotation is controlled by the flow
of oil through the directional solenoid valve (SV1),
which is operated by the fan control switch (DIGITAL
IN - Fan Purge) via the computer control system
(DIGITAL OUT - Fan Purge). The directional FAN MANIFOLD LATER DESIGN
solenoid valve is a cartridge style valve, which is 630C-24 ELECTRICAL SCHEMATIC
factory set and nonadjustable.
The speed of fan rotation is controlled by the flow of
oil through the proportional solenoid (SV2) valve,
which is operated by an electrical signal (PWM OUT
- Fan Speed) generated by the computer control
system. The computer control system generates a
fan speed electrical signal based on the position of
the fan control switch (full on, automatic or clean),
the air conditioning controls (on/off), hydraulic oil
temperature sensor readings, engine coolant
temperature sensor readings and charge air cooler
temperature sensor readings. The proportional
solenoid valve also is a cartridge style valve which is
factory set and nonadjustable. The proportional
solenoid valve cartridge also contains pressure
relief valve which protects the fan circuit. Note that
if a wire is cut fan speed will default to full rpm.
Return oil from the fan motor passes back through
the fan manifold and back to tank via the T port.
Coil resistance for both solenoids is approximately 8
ohms.

10.16
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
FAN MOTOR

635C-20 FAN MOTOR

The fan drive motor is a fixed displacement gear

type motor. The fan drive motor is driven by
hydraulic pressure from the fan pump via the fan
manifold and in turn directly drives the cross-flow
fan.

TO SUCTION
STRAINER

FROM FAN FROM FAN

MANIFOLD (REV) MANIFOLD (FWD)

630C-26 FAN MOTOR HYDRAULIC SCHEMATIC

10.17
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
FAN CIRCUIT DESCRIPTION The computer control system begins to regulate
the fan speed at the following temperature sensor
The fan "cooling" circuit is an open loop hydraulic
readings:
system consisting of a fixed displacement pump,
fan manifold and a fixed displacement motor. Coolant 190°F (88°C)
Oil from the fan pump passes through the P port Charge Air Cooler 100°F (38°C)
into the fan manifold and is directed to the fan Hydraulic Oil 129°F (54°C)
motor. The computer control system will continue to
Return oil from the fan motor passes back increase fan speed until the following temperature
through the fan manifold and back to tank via the sensor readings are reached:
T port. Coolant 205°F (96°C)
The direction of fan rotation is controlled by the Charge Air Cooler 160°F (71°C)
flow of oil through the directional solenoid valve Hydraulic Oil 160°F (71°C)
(SV1), which is operated by the fan control switch
(DIGITAL IN - Fan Purge) via the computer When any one of these three readings are
control system (DIGITAL OUT - Fan Purge). reached, the fan will be at maximum speed.

The speed of fan rotation is controlled by the flow With the fan control switch in the:
of oil through the proportional solenoid (SV2) AUTOMATIC POSITION - AUTOMATIC is the
valve, which is operated by an electrical signal normal operating position for the fan control
(PWM OUT - Fan Speed) generated by the switch. When the switch is in the AUTOMATIC
computer control system. position, the fan will operate completely in an
The computer control system generates a fan automatic mode. It will start, speed up, or slow
speed electrical signal based on the position of down all based on the temperature of the charge
the fan control switch (full on, automatic or clean), air, engine coolant and/or the temperature of the
the air conditioning controls (on/off), hydraulic oil hydraulic oil. The electronic control module
temperature sensor readings, engine coolant automatically adjusts fan speed to the minimum
temperature sensor readings and charge air required level to maintain optimal operating
cooler temperature sensor readings. conditions, and default to fan at full speed if an
error in the controller exists.
The cooling fan is designed to run only as fast as
needed to achieve the optimum operating When the switch is in the AUTOMATIC position
temperatures for the engine coolant, engine and the fan runs at minimum speed due to low
intake air and hydraulic oil. These optimum charge air, engine coolant or hydraulic oil
temperatures are dictated by the engine and temperatures, turning ON the A/C will cause the
hydraulic component manufacturers for maximum fan control to increase the cooling fan speed
life and efficiency of their components. Significant when engine is at high idle. This is to ensure that
power savings and reduced warmup times can be sufficient air flow is available for the cab A/C even
realized by not turning the fan at full speed when while the machine is still warming up.
not needed.
The operating temperature of the engine and
hydraulic system will vary greatly depending on
the operating conditions and cannot be
specifically stated. Factors such as ambient
temperature, hydraulic oil viscosity, type of wood
harvested, undergrowth and operator technique
all have a major impact on the effectiveness of
the cooling system.

10.18
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
FULL ON POSITION - When the switch is in the
FULL ON position, the fan control system is
overridden and the fan will run at FULL speed for
cooling regardless of charge air, coolant or oil
temperature sensor readings (DIGITAL IN- Fan
Full Speed). Normally the fan control switch is
placed in the AUTO position for optimal cooling.
The FULL ON position is intended for use in the
event of a temporary failure of the fan control.
CLEAN POSITION - Momentarily pressing the
switch to the CLEAN position will start automatic
reversing the direction of fan rotation (there is no
need to hold the switch down). Reverse rotation is
used to clean the charge air cooler, radiator, oil
cooler, A/C condenser and air intake access panel
screens. By "reversing" the flow of the fan, air
flow is propelled in the opposite direction, thereby
forcing dust and debris off of the cooling
assembly and access panel screens.
The computer control system will also turn the
A/C system OFF for as long as long as the fan is
in the CLEAN mode.
Note: The CLEAN cycle also operates
automatically via the timed purge function of the
computer control system (frequency is
adjustable). Refer also to COMPUTER ~
INFORMATION MESSAGES and COMPUTER
~DIAGNOSTIC ~ ADJUST FUNCTION
PARAMETERS in THIS SECTION.
For more information about the computer control
system and detailed electrical schematics refer to
SECTION 6 of THIS MANUAL.

10.19
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

FAN CIRCUIT
(6350501 TO 6350510)
635C-06

10.20
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

FAN CIRCUIT
630C-71
(6350511 TO 6351000)

10.21
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

FAN CIRCUIT HYDRAULIC SCHEMATIC

635C-37
(6350501 TO 6350510)
10.22
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan

FAN CIRCUIT HYDRAULIC SCHEMATIC

630C-86 (6350511 TO 6351000)

10.23
Tigercat 635C Skidder Oil Cooler and Cross-flow Fan
FAN SPEED CHECKS
FAN
MINIMUM FAN SPEED WITH A/C "ON" CONTROL
SWITCH
NOTE:
A calibrated "electronic photo tachometer" is
required for this procedure.
NOTE ALSO:
••
To perform a valid check of fan speed based on
switch position only it is necessary to prevent the
fan from rotating due to temperature sensor
signals. Therefore, ensure that engine coolant,
hydraulic oil and charge air cooler temperatures
are well below the fan speed regulation
temperature readings throughout the entire test. FAN CONTROL SWITCH
630C-42
The computer control system begins to regulate
fan speed when the following temperature sensor
5. With the help of an assistant press and hold
readings are reached: 88°C (190°F) Coolant,
the fan control switch in CLEAN position.
100°F (38°C) Charge Air Cooler and 129°F (54°C)
Hydraulic Oil. Refer also to COOLING FAN 6. Use a photo-tachometer to measure the
CIRCUIT DESCRIPTION in THIS SECTION. speed of rotation of the fan blade, it should be
1600-1800 rpm.
1. Park machine on level ground, lower grapple
and dozer and engage parking brake. Install 7. With the help of an assistant press and hold
articulation lock pin and stop engine. the fan switch in the CLEAN position and
visually check clutch on A/C compressor. It
2. Place a piece of reflecting tape on the fan
should be disengaged and compressor not
hub.
running.
3. Start the engine. Leave the parking brake ON.
8. When the CLEAN switch is released the
4. Set engine speed to 2200 rpm. clutch on the A/C compressor should engage
5. Place FAN switch in AUTOMATIC position. and the compressor should be running.

6. Place A/C switch in ON position. FAN FULL ON SPEED

7. Use a photo-tachometer to measure the NOTE:

speed of rotation of the fan blade, it should be A calibrated "electronic photo tachometer" is
1400-1600 rpm. required for this procedure.

FAN 'CLEAN' SPEED AND CHECK FOR NO A/C 1. Park machine on level ground, lower grapple
DURING CLEAN MODE and dozer and engage parking brake. Install
articulation lock pin and stop engine.
NOTE:
A calibrated "electronic photo tachometer" is 2. Place a piece of reflecting tape on the fan
required for this procedure. hub.

1. Park machine on level ground, lower grapple 3. Start the engine. Leave the parking brake ON.
and dozer and engage parking brake. Install 4. Set engine speed to 2200 rpm.
articulation lock pin and stop engine.
5. Place FAN switch in FULL ON position.
2. Place a piece of reflecting tape on the fan
6. Use a photo-tachometer to measure the
hub.
speed of rotation of the fan blade, it should be
3. Start the engine. Leave the parking brake ON. 2100-2300 rpm.
4. Set engine speed to 2200 rpm.

CAUTION
Before placing the fan switch in the CLEAN
position make sure that there are no
personnel on the left side of the machine in
the area where the fan will expel debris
10.24
Tigercat 635C Skidder

SECTION 11 - STEERING AND CENTER JOINT

OCTOBER 2008
CONTENTS - SECTION 11
CENTER JOINT
CHECKING CENTER JOINT VISUALLY FOR LOOSENESS ................ 11.10
CHECKING THE CENTER JOINT PRELOAD
CENTER JOINT PRELOAD ADJUSTMENT ....................................... 11.11
DIAGRAM ............................................................................................... 11.11
GREASE SEALS - ORIENTATION ........................................................ 11.12
LUBRICATION ....................................................................................... 11.10
MAINTENANCE ..................................................................................... 11.10
PRIORITY VALVE ........................................................................................ 11.5
STEER CONTROL VALVE
METERED STEERING ............................................................................. 11.2
QUICK STEER ......................................................................................... 11.4
STEERING
CIRCUIT DIAGRAM
6350501 TO 6350510 ........................................................................... 11.8
6350511 TO 6351000 ............................................................................ 11.9
CIRCUIT HYDRAULIC SCHEMATIC
6350501 TO 6351000 ........................................................................... 11.7
TESTING THE STEERING OPERATION .................................................. 11.13
Tigercat 635C Skidder Steering and Center Joint
STEERING
METERED STEER CONTROL VALVE
This is a manually operated directional control
valve. The steering wheel is directly connected
to the steer valve through the floor of the cab.
The use of load sensing power steering and a
priority valve provides smooth pressure
compensated steering that is unaffected by axle
response or steering rate.
The output flow of the steering control unit varies
with the speed that the steering wheel is rotated.
When moving the wheel slowly the output of the STEER CONTROL VALVE
steering control is low, causing the machine to 630C-160 (BELOW CAB)
steer slowly. When the wheel is turned rapidly the
output of the steering control is high, causing the CK
LO ORIGIN
machine to steer much faster. TO
S
RN
TU
Fast steering (turning the steering wheel rapidly) BL
E
A
is necessary when operating in the woods to RI
VA
provide the required maneuverability.
Travelling on the road requires a slower steering
response (turning the steering wheel slowly),
making it easier to make minor corrections when
travelling in a straight line.
The cylinder ports 'L' and 'R' contain built-in anti-
cavitation valves to protect against vacuum
(cavitation) conditions.
• 4 turns (steering quickly ) from full lock
OPERATING DESCRIPTION position to full lock position
The steering control valve has a spool that is able • 8+ turns (steering slowly)
to rotate inside a sleeve. When the steering wheel
is stationary, the unit is in the neutral position and 620C-98 METERED STEER CONTROL VALVE
the spool is aligned in the sleeve so that oil
between the steering valve and priority valve,
cannot flow through the valve. The steering
drains oil out of the load sense port in the priority
cylinders to the rear chassis are prevented from
valve. The oil drains to tank through an orifice
moving by the oil that is trapped on both sides of
located between the sleeve and gerotor on the
the pistons.
steer valve.
When the steering wheel is turned, the spool
When the steering wheel has stopped moving, the
rotates inside the sleeve and opens passages to
gerotor gear continues to move and turns the
allow oil flow through the spool/sleeve assembly.
sleeve until the sleeve moves to its center
This oil flows to the Gerotor section of the valve,
(neutral) position and stops sending oil to the
causing the gerotor to rotate and then continues
gerotor. The valve is no longer sending oil to the
back into the valve and out the work port to the
cylinders.
end of each steer cylinder.
The speed that the steering wheel is rotated,
There is a small, variable bypass orifice in the
determines the speed that the machine will turn.
spool/sleeve assembly that allows a small amount
Turning the steering wheel slowly causes the
of oil into the pressure side of the steering valve.
variable orifice to decrease in size and it will take
This will suppress the initial pressure surge when
more turns of the wheel from stop to stop. If the
the steering wheel is partially turned. The orifice
wheel is turned quickly the orifice opens and it will
is closed off when the wheel is fully turned.
take fewer turns of the wheel from stop to stop.
The return oil from the cylinders enters back in
the other work port, through the spool/sleeve
assembly and back to tank. A load sense line,

11.2
Tigercat 635C Skidder Steering and Center Joint

'LS' LOAD SENSING PORT

'R' RIGHT 'P' PRESSURE

'L' LEFT

•• •
'T' TANK ••

••
STEERING
COLUMN
CONNECTION

LEFT RIGHT PUMP IN

PUMP RETURN
(TANK)

•T • •R •P
L

HOUSING

•
BEARING

SPOOL

•
•

•
• • •

•
• •
STEERING
COLUMN •
CONNECTION
• •

CENTERING SLEEVE PIN CHECK DRIVE WEAR GEROTOR SPACER END CAP
SPRINGS VALVE PLATE RING AND
STAR
AT027-1 STEER CONTROL VALVE

11.3
Tigercat 635C Skidder Steering and Center Joint
QUICK STEER CONTROL VALVE (OPTIONAL)
This is a manually operated gerotorless
directional control valve. The steering wheel is
directly connected to the steer valve through the
floor of the cab.
The use of load sensing power steering and a
priority valve provides smooth pressure
compensated steering that is unaffected by axle
response or steering rate.
The quick steer control valve enables the operator
to put the vehicle in full lock while only turning the STEER CONTROL VALVE
steering wheel 50 degrees in either direction. 620C-100 (BELOW CAB)
Steering is accomplished by deflecting only the 0°
spool.
Steering speed (output flow of the control valve) is
a function of steering wheel angle. Turning the 0°
steering wheel ±50° results in controlled flow, +5
from zero to full steering flow.
The cylinder ports 'L' and 'R' contain built-in anti-

-50°
cavitation valves to protect against vacuum
(cavitation) conditions.
OPERATING DESCRIPTION
The steering control valve has a spool that is able
to rotate inside a sleeve. When the steering wheel
is stationary, the unit is in the neutral position and
the spool is aligned in the sleeve so that oil
cannot flow through the valve. The steering
cylinders to the rear chassis are prevented from • Full lock by turning the steering wheel ±50°
moving by the oil that is trapped on both sides of
the pistons. 620C-99 QUICK STEER CONTROL VALVE
When the steering wheel is turned, the spool When the steering wheel has stopped moving the
rotates inside the sleeve and opens passages to valve is no longer sending oil to the cylinders.
allow oil flow through the spool/sleeve assembly.
This oil flows to an internal cylinder relief valve The angle that the steering wheel is rotated
and out the work port to the end of each steer determines the speed that the machine will turn.
cylinder. Turning the steering wheel only a few degrees
allows a more limited flow to the steering
There is a small, variable bypass orifice in the cylinders and steers the machine more slowly. If
spool/sleeve assembly that allows a small amount the wheel is turned fully (± 50°) full flow will result
of oil into the pressure side of the steering valve. in quick steering and full lock of the steering
This will suppress the initial pressure surge when cylinders.
the steering wheel is partially turned. The orifice
is closed off when the wheel is fully turned.
The return oil from the cylinders enters back in
the other work port, through the spool/sleeve
assembly and back to tank. A load sense line,
between the steering valve and priority valve,
drains oil out of the load sense port in the priority
valve. The oil drains to tank.

11.4
Tigercat 635C Skidder 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
LS
valve and on to the steer cylinders, or the grapple,
dozer or winch functions.
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
EF CF
feedback circuit from the steer valve to the priority
valve. AT028-2 PRIORITY VALVE
By splitting the system into two independent Back flow into the steering system is prevented by
circuits, pressure transients are isolated in each a check valve in the steer control valve.
circuit and only the flow required for steering goes The priority valve contains a built-in relief valve
to the steering circuit. The remaining flow is which is factory set to 2750 psi* (190 Bar). When
available for the grapple, dozer and winch this relief setting is exceeded, most of the flow will
functions. This provides safe, reliable operation be directed to the auxiliary circuit (EF).
because the steering circuit always has flow and
pressure priority. *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 P
CARTRIDGE SHOWN)

RETURN
OIL TO
TANK T
•

LS

•
AT028-1
LOAD SENSE
CONNECTION
TO STEER
VALVE

EF CF

HIGH PRESSURE CARRYOVER TO STEER

TO GRAPPLE, WINCH AND VALVE
DOZER VALVE SECTIONS

PRIORITY VALVE
AT028

11.5
Tigercat 635C Skidder Steering and Center Joint

STEER2 SYSTEM DIAGRAM

11.6
Tigercat 635C Skidder Steering and Center Joint

STEER CIRCUIT HYDRAULIC SCHEMATIC

635C-24 (6350501 TO 6351000)
11.7
Tigercat 635C Skidder Steering and Center Joint

STEER CIRCUIT
635C-07 (6350501 TO 6350510)
11.8
Tigercat 635C Skidder Steering and Center Joint

STEER CIRCUIT
630C-72
(6350511 TO 6351000)

11.9
Tigercat 635C Skidder Steering and Center Joint
CENTER JOINT CHECKING THE CENTER JOINT PRELOAD
MAINTENANCE OF CENTER JOINT 1. Park the machine on level ground, lower
Maintenance in this area is usually limited to: grapple and dozer blade to the ground,
engage parking brake, and shut off the engine.
a) Regular lubrication of the two center joint
grease fittings (item 11) to purge the pivot 2. Torque the top and bottom retainer bolts (items
bearings of debris and water. Refer to 1 and 2) to 282-310 lbf-ft (393-420 Nm).
SCHEDULED MAINTENANCE in THIS Pin retainers use 4 bolts each.
SECTION for lubrication intervals. Use only
high quality, lithium based EP2 grease
FRONT
containing molybdenum disulphide. DIAL B CHASSIS

b) Visually checking the center joint pivot for

INDICATOR
PLUNGER ••
looseness every 48 hours. With an observer
on the ground, keeping well clear of the
•
center joint area, perform the following test to DIAL
check for looseness of center joint. REAR
INDICATOR
CHASSIS
1. Have operator lift the dozer blade off the
ground and then rapidly raise and lower
blade several times to "bounce" machine.
2. As machine bounces, check for motion DIAL
between the front and rear chassis frame INDICATOR
lugs. Also check for a "clunking" sound at
BASE •
the center joint area.
A
3. Movement between front and rear chassis
lugs or clunking of the pivot indicates a DIG-06 CHECK PRELOAD
loose joint and preload must be checked. 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
REAR chassis upper lug 'B' as close to center pin as
CHASSIS possible. Zero the dial indicator.
5. Fully loosen only the bottom pin retainer bolts
CHECK FOR
FRONT (item 2) that were torqued in step 2. DO NOT
MOVEMENT IN
THIS JOINT AREA CHASSIS REMOVE BOLTS.
6. The dial indicator should now show a
change between lug 'A' and 'B' within the
preload setting range. Refer to chart for
CENTER JOINT PRELOAD CHECK
DIG-003 proper bearing preload settings for your
machine.
This is the proper bearing preload setting.
A change of less than the lower preload
range limit indicates that the bearing preload
is too low. No change on the dial indicator is
the result of a loose center joint. In these
cases, proceed to CENTER JOINT PRELOAD
ADJUSTMENT.

B EA RING PREL O A D RA NG E
TY PE L O W ER UPPER
0 .0 1 9 in 0 .0 2 0 in
(A A 142)
.4 8 3 m m .5 0 8 m m

11.10
Tigercat 635C Skidder Steering and Center Joint
CENTER JOINT PRELOAD ADJUSTMENT 11. A change within the bearing preload setting
Before making any adjustments to the center range should register on the dial indicator.
joint, please follow CHECKING THE CENTER Refer to chart for proper bearing preload
JOINT PRELOAD procedure in THIS SECTION. 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), a) If change in dial indicator reading is greater
the bottom pin retainer plate (item 3) and all than upper preload range limit the shim
of the shims in the shim pack (items 10). removed (in step 8) may not have been the
CAUTION: Keep upward pressure on the thinnest shim in the pack. Repeat steps 7
bottom pin (item 9) and do not allow pin to fall through 11, replacing this shim and removing
out of bearing. These pivot pins are very only the thinnest shim from the bottom shim
heavy, block the pin in place if necessary. pack (item 10).
b) If the change in the dial indicator reading is
8. Remove the thinnest shim from the pack.
less than lower preload range limit another
9. Reinstall the remaining shims, the retainer shim will have to be removed. Repeat steps
plate and the bolts. Leave the bolts loose. 7 through 11, removing additional shims but
only the thinnest shim each time, until the
10. Zero the dial indicator again and torque the
change in the reading on dial indicator is
bottom bolts in sequence to 282-310 lbf-ft
within the proper range.
(393-420 Nm). Continued on page 12

1
TORQUE TO
• 1 3
4 BOLT
282-310 LBF-FT (393-420 NM) TIGHTENING
NO LOCTITE REQUIRED SEQUENCE
(NOTE: EARLIER STYLE NOT
SHOWN USED 6 BOLTS) 4 2

FRONT
11 CHASSIS

••
•
SEAL
ORIENTATION

REAR CHASSIS
• 9

• 10

• 3
• 2
6
TORQUE TO
• 4 • 282-310 LBF-FT (393-420 NM)
• NO LOCTITE REQUIRED
(EARLIER STYLE NOT SHOWN
5
USED 6 BOLTS)
• 8
• •
TORQUE TO
11 7 80-88 LBF-FT (109-119 NM)
• USE 243 LOCTITE (REMOVABLE)

625C-95 CENTER JOINT

11.11
Tigercat 635C Skidder Steering and Center Joint
Continued from page 11
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) and an
inner seal retainer (item 11). 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).

11.12
Tigercat 635C Skidder Steering and Center Joint
TESTING THE STEERING OPERATION:
QUICK STEER STEERING VALVE
METERED STEERING VALVE
1. Move the skidder to a suitable, level and
1. Move the skidder to a suitable, level and
smooth test area, where it can be safely
smooth test area, where it can be safely
operated at full throttle. Grapple UP,
operated at full throttle. Grapple UP,
CLOSED and ROTATED TO CENTER.
CLOSED and ROTATED TO CENTER.
Dozer blade UP.
Dozer blade UP.
2. With the parking brake disengaged,
2. With the parking brake disengaged,
differential locks OFF, NO service brakes
differential locks OFF, NO service brakes
applied and full throttle.
applied and full throttle, turn the steering
completely one way until it hits the stop. 3. Articulate the machine all the way to the left.
Return the steering wheel to the neutral point.
3. Turn the steering wheel the opposite way, as
Turn the wheel to the right just enough to start
SLOWLY as possible, until it hits the end
turning the machine (5 to 10 degrees).
stop. This should take 7 1/2 to 8 turns of the
wheel. It should take approximately 20 to 27
seconds to fully articulate the machine to the
4. Turn the wheel back to the other end stop,
right.
very slowly to verify the 7 1/2 - 8 turns.
4. Articulate the machine all the way to the right.
5. Turn the wheel back to the other end stop, as
Return steering wheel to the neutral point.
fast as possible. Resistance to turning the
Turn the wheel to the left just enough to start
wheel will be felt during this operation. This
turning the machine (5 to 10 degrees).
should take 3 1/2 to 4 turns of the wheel.
It should take approximately 20 to 27
6. Turn the wheel back to the other end stop, as
seconds to fully articulate the machine to the
fast as possible to verify the 3 1/2 - 4 turns.
left.
7. If these values are not obtained, check the
Note that it may be difficult to consistently get
priority valve and/or steering control unit.
an accurate timing for the low speed steering
test as results may vary operator to operator.
It is more important to get timed values that
are approximately the same for steering right
and steering left.
5. Articulate the machine all the way to the right.
Turn the steering wheel back all the way to
the left (full speed turn).
It should take approximately 4 seconds to
fully articulate the machine stop to stop.
6. Articulate the machine all the way to the left.
Turn the steering wheel back all the way to
the right (full speed turn).
It should take approximately 4 seconds to
fully articulate the machine stop to stop.
7. If these values are not obtained, check the
priority valve and/or steering control unit.

11.13
Tigercat 635C Skidder Steering and Center Joint

11.14
Tigercat 635C Skidder

SECTION 12 - GRAPPLE, ARCH AND BOOM

OCTOBER 2008

CONTENTS - SECTION 12
CIRCUIT DESCRIPTION
ARCH/BOOM ............................................................................................ 12.8
GRAPPLE ............................................................................................... 12.16
CIRCUIT DIAGRAMS
ARCH/BOOM
6350501 TO 6350510 ........................................................................... 12.9
6350511 TO 6351000 .......................................................................... 12.10
GRAPPLE
6350501 TO 6350510 ......................................................................... 12.18
6350511 TO 6351000 .......................................................................... 12.19
CONTROL VALVE ....................................................................................... 12.2
CONTROL VALVE CHARACTERISTICS .................................................... 12.5
CONTROL VALVE ELECTRICAL SCHEMATIC .......................................... 12.5
GRAPPLE SNUBBER MAINTENANCE .................................. SEE SECTION 3
HYDRAULIC SCHEMATIC .......................................................................... 12.7
IQAN MODULES ..................................................................... SEE SECTION 6
JOYSTICK (6-BUTTON) .............................................................................. 12.6
MAIN PUMP ............................................................................ SEE SECTION 9
PRESSURE CHECKS AND ADJUSTMENTS
ARCH IN/OUT ........................................................................................ 12.11
BOOM UP/DOWN .................................................................................. 12.13
GRAPPLE ROTATE .............................................................................. 12.20
GRAPPLE OPEN/CLOSE ....................................................................... 12.22
GRAPPLE ROTATE SPEED CHECK ..................................................... 12.22
PRIORITY VALVE ................................................................. SEE SECTION 11
SNUBBER MAINTENANCE - GRAPPLE ................................ SEE SECTION 3
Tigercat 635C Skidder Grapple, Arch and Boom
CONTROL VALVE PILOT PRESSURE
CONNECTION FOR
FRONT EXTERNAL USE
PRESSURE
OIL IN REDUCING
OIL OUT VALVE
INLET CARTRIDGE
SECTION (INTERNAL
PILOT
• • • SUPPLY)
•
A •• A

IN A WINCH B

OUT A ARCH B IN
CROSS SECTION
VIEW TOWARD
UP A B DOWN INLET SECTION
DOZER

INTERNAL
OPEN A GRAPPLE B CLOSE
PILOT
PRESSURE
SUPPLY
CW A ROTATE B CCW
•
UP A BOOM B DOWN
SECTION A-A

END
END SECTION
SECTION 630C-162 (INTERNAL PILOT SUPPLY)
•
HIGH PRESSURE
SUPPLY
CONTROL VALVE REDUCING
620C-27
(dual function arch) VALVE AND

• PRESSURE
RELIEF (PILOT
The control valve is located on the rear chassis
above the rear axle and under the cover plate.
•• SUPPLY)

This control valve consists of an inlet section; five SAFETY

VALVE
or six spool sections (depending on machine
options chosen); and an end section with integrated
•
pilot supply.
COARSE
FILTER WITH
The inlet section receives oil from the pump and
supplies the control valve sections through the •• BY-PASS
(FOR PILOT
SUPPLY)
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
INTERNAL PILOT
PRESSURE SUPPLY
• PILOT PRESSURE
CONNECTION FOR
EXTERNAL USE
gallery for closed center operation of the valve.
The inlet section is equipped with relief valve which END SECTION
630C-40 (INTERNAL PILOT SUPPLY)
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.
••
MANUAL
Pilot pressure of 35 bar (508 psi) is generated by OVERRIDE
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 630C-218A MANUAL OVERRIDE
12.2
Tigercat 635C Skidder Grapple, Arch and Boom
pressure for external use (if required by machine Pressure relief ports in each spool are equipped
options). Tank ports T1, T3 and TP are plugged to differently according to the machine function
redirect tank oil back to the inlet section port T2. controlled. The arch, dozer, grapple open/close
and boom spool sections are equipped with
Spool sections are equipped with double acting
pressure relief cartridges on both the A and B
three position spools blocked in the neutral position.
sides. On earlier machines (6350501 to 6350530)
Spool sections are operated by electro-hydraulic
the grapple rotate spool section is equipped with
proportional spool actuators with spring centering.
anticavitation valves on the A side and B side. On
Each solenoid valve is equipped with manual
later machines (6350531 to 6351000) the grapple
override and air bleeding functions. Each spool
rotate section is equipped with pressure relief
section's pressure gallery is fitted with a load-hold
cartridges on both the A and B sides.
check valve to prevent load sinking of a heavy load
while a light load is operated. The winch spool section is equipped with a
pressure relief cartridge on the A side and a plug
PORT RELIEF & on the B side. All relief valves are cartridge style,
HIGH PRESSURE ANTICAVITATION
SUPPLY VALVE
factory set for each function and nonadjustable.
Spool limiting set screws are factory set for all
spool sections. (Factory settings are: dozer
LOAD
HOLD
• section 5mm from the end of the screw to the
CHECK
VALVE •• tightened jam nut, all other sections 10 mm)
DOUBLE
••
ACTING
SPRING ••
CENTRED
SPOOL ••

GRAPPLE
ROTATE
• •• •• SECTION

•• ••
•• ORIFICE
CHECK
630C-218 VALVES
ELECTRO HYDRAULIC INTERNAL PILOT
PRESSURE SUPPLY
SPOOL ACTUATOR GRAPPLE ROTATE SECTION
630C-39 SPOOL SECTION EQUIPPED WITH ORIFICE CHECK VALVES
MANUAL MANUAL
OVERRIDE OVERRIDE
SERVICE LOAD HOLD SERVICE
PORT B CHECK VALVE PORT A

ELECTRO HYDRAULIC • • ELECTRO HYDRAULIC

SPOOL ACTUATOR
PORT B • • • SPOOL ACTUATOR
PORT A
• •
PILOT OIL
RESTRICTOR PILOT OIL
RESTRICTOR
•• •• 'X' SET SCREW
ADJUSTMENT
•• •
SPOOL
LIMITING
•• SPOOL
LIMITING
SET SCREW SET SCREW

PORT B •• • PORT A
RELIEF VALVE RELIEF VALVE
CARTRIDGE CARTRIDGE
DOUBLE ACTING
SPRING CENTRED
NOTE: CROSS SECTION VIEW SPOOL
TOWARD END SECTION
630C-163 CROSS SECTION OF SPOOL SECTIONS
12.3
Tigercat 635C Skidder Grapple, Arch and Boom
OPERATING DESCRIPTION pressure applied to the end of the spool. Shifting
the spool directs oil from the pressure gallery to
Oil is supplied by a variable displacement piston
operate the function required. Return oil from the
pump (main pump) via the priority valve. The
function in use is directed through the control valve
priority valve directs oil to the control valve (winch,
to the inlet section T2 port where it returns to tank.
arch, dozer, grapple, boom). The control valve is
When more than one function is operating at the
equipped with an inlet relief valve which acts as a
same time there will be reduced flow to each.
main relief.
To prevent over pressurizing of the operating
Oil enters the inlet section and is allowed to pass
circuits, some of the work ports in the spool
through the closed center spool sections to the
sections have a port relief valve cartridge. All relief
end section and is prevented from returning to tank
valves are cartridge style, factory set for each
by a plugs in the T1, T3 and TP ports. Internal pilot
function and nonadjustable. All relief valves are
pressure supply is generated by a pressure
anti-cavitation relief valves.
reducing valve in the end section for use in
operating the spool sections. If none of the *NOTE: There are two variations of the control
functions of the control valve are in use there will valve in use, depending on whether the machine
be no oil flow through the valve, therefore oil flow has a winch included.
to the control valve will be regulated to zero as the
A winch will add a spool section to the grapple
piston pump de-strokes to a zero angle.
control valve, making it a six spool section valve.
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

FRONT

OIL OUT OIL IN

FRONT
INLET
SECTION OIL OUT OIL IN
• • • INLET
SECTION
• • •
IN A WINCH B

A OUT A ARCH B IN
OUT ARCH B IN

UP A B DOWN UP A DOZER B DOWN

DOZER

OPEN A GRAPPLE B CLOSE

OPEN A GRAPPLE B CLOSE

CW A ROTATE B CCW CW A ROTATE B CCW

B UP A BOOM B DOWN
UP A BOOM DOWN

END END
SECTION
SECTION
• •
CONTROL VALVE CONTROL VALVE
620C-27 (dual function arch) 630C-27 (dual function arch - no winch)
12.4
Tigercat 635C Skidder Grapple, Arch and Boom

CONTROL VALVE CHARACTERISTICS

(6350501 TO 6350530)
• 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)
• Coil Resistance : 5.4 ohms
Control Valve Characteristics

50
45
40
35

Flow gpm
30
25
20
15
10
5
0
0 200 400 600 800 1000 1200 1400 1600
CONTROL VALVE ELECTRICAL SCHEMATIC (107) (164) (220) (277) (334) (390)
(6350501 TO 6350530) mA
Control Current ma
Control Presure (psi)
625C-77

CONTROL VALVE CHARACTERISTICS

(6350531 TO 6351000)
• Control Pressure Relief : 500 psi (34 Bar)
(Non-Adjustable)
• Start of Control : 0 gpm / 300ma /102 psi
(0 L/min / 300mA / 7 Bar)
• End of Control : 46.5 gpm/ 780 mA / 348 psi
(176 L/min/ 780 mA /24 Bar)
• Coil Resistance : 21.7 ohms
Control Valve Characteristics

50
45
40
35
Flow gpm

30
25
20
15
10
5
0
0 200 400 600 800 1000
(153) (255) (358)
Control Current mA
Control Pressure (psi)
CONTROL VALVE ELECTRICAL SCHEMATIC
(6350531 TO 6351000)
625C-78

12.5
Tigercat 635C Skidder Grapple, Arch and Boom
JOYSTICK (6-BUTTON) JOYSTICK BASE 4-PIN CONNECTOR
PIN WIRE # FUNCTION
1 54 5VDC POWER SUPPLY
2 G54 12VDC GROUND
3 254 X- ARCH +IN/-OUT
4 255 Y-BOOM +UP/-DOWN

JOYSTICK HANDLE 12 PIN CONNECTOR

PIN WIRE # FUNCTION
1 66 5VDC POWER SUPPLY
6 2 186 TRIGGER - THROTTLE
3 206 BUTTON 1 - ROTATE CW
• 4 207 BUTTON 2 - ROTATE CCW
5 208 BUTTON 3 - GRAPPLE OPEN
6 209 BUTTON 4 - GRAPPLE CLOSE
7 165 BUTTON 5 - CONSTANT PRESSURE
8 150 BUTTON 6 - DIFF LOCK ON/OFF
9 - NOT USED
10 - NOT USED
11 P186 12VDC POWER SUPPLY
12 G186 12VDC GROUND

One button is used to turn the differential lock

JOYSTICK CONTROL LEVER function on and off. Refer to SECTION 15 for
635C-02 MOUNTED ON ARMREST more differential lock function information.
The trigger switch is used to increase engine
The joystick is mounted on the operator's seat speed when performing machine functions which
armrest. The joystick consists of a dual axis do not require machine travel.
analog joystick base and a six button joystick
handle with a trigger switch. Refer also to CONTROL LEVER in SECTION 2 of
the OPERATOR'S MANUAL for more detailed
Movement of the joystick controls the arch and function information.
boom functions. Five of the buttons control the
grapple functions. The grapple, arch and boom
functions are described in THIS SECTION.

635C-20 JOYSTICK ELECTRICAL SCHEMATIC

12.6
Tigercat 635C Skidder Grapple, Arch and Boom

635C-25 GRAPPLE, ARCH AND BOOM HYDRAULIC CIRCUIT SCHEMATIC

12.7
Tigercat 635C Skidder Grapple, Arch and Boom
ARCH/BOOM CIRCUIT DESCRIPTION solenoid. The corresponding solenoid shifts the
actuator and allows the spool to be shifted by
Oil is supplied by a variable displacement piston
internal pilot pressure applied to the end of the
pump (main pump) via the priority valve. The
spool. Shifting the spool directs oil from the
priority valve directs oil to the control valve (winch,
pressure gallery to either end of the two cylinders
arch, dozer, grapple, boom). The control valve is
to move the BOOM DOWN or UP. The boom
equipped with an inlet relief valve which acts as a
section of the control valve is equipped with
main relief.
cartridge style relief valves to protect the boom
Oil enters the inlet section of the control valve and circuit from over pressurizing.
is allowed to pass through the closed center spool
Return oil is directed through the control valve to
sections to the end section and is prevented from
the inlet section T2 port where it returns to tank.
returning to tank by a plugs in the T1, T3 and TP
ports. Internal pilot pressure supply is generated Refer also to SECTION 6 of THIS MANUAL for
by a pressure reducing valve in the end section for complete electrical schematics and more detailed
use in operating the spool sections. information about the computer control system.
Two cylinders are used to move the ARCH IN and
OUT and two cylinders are used to move the
BOOM UP and DOWN.
Each electro-hydraulically controlled spool section
has a closed centered 3-position spool with spring
centering.
When the operator moves the joystick to the
LEFT or RIGHT a signal (VOLTAGE IN -
JOYSTICK X Arch %) is sent to the computer
control system. The computer control system
generates a signal (CURRENT OUT - Arch In-/
Out+) which is sent out to a solenoid on the arch
section of the control valve activating the ARCH IN
or ARCH OUT function.
When the ARCH IN or ARCH OUT 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 ARCH IN or OUT. The arch section
of the control valve is equipped with cartridge style
relief valves to protect the arch circuit from over
pressurizing.
When the operator moves the joystick FORWARD
or BACK a signal (VOLTAGE IN -JOYSTICK Y
Boom %) is sent to the computer control system.
The computer control system generates a signal
(CURRENT OUT - Boom Up-/Dn+) which is sent
out to a solenoid on the arch section of the control
valve activating the BOOM DOWN or BOOM UP
function.
When the BOOM DOWN or BOOM UP function is
activated electrical current from the computer
control system creates a magnetic force
proportional to the current supplied within the
12.8
Tigercat 635C Skidder Grapple, Arch and Boom

ARCH/BOOM CIRCUIT
635C-09 (6350501 TO 6350510)
12.9
Tigercat 635C Skidder Grapple, Arch and Boom

ARCH/BOOM CIRCUIT
630C-74 (6350511 TO 6351000)
12.10
Tigercat 635C Skidder Grapple, Arch and Boom
DUAL ARCH/BOOM PRESSURE ARCH IN/OUT RELIEF PRESSURE CHECK
1. Park the machine on level ground. Before
shutting off the engine position grapple as
WARNING described in step 2.
Do not stand above or below the arch 2. IMPORTANT: To prevent lifting of the rear
assembly, grapple or between the arch and wheels when the arch is moved out during this
rear chassis during this procedure. procedure it is necessary to position the
Before performing work on the arch assembly, grapple as follows.
lower it to the ground and/or use proper Close grapple and rotate it to center. Lower
support devices. grapple slowly to the ground and slowly move
the machine backward while continuing to
IMPORTANT lower the grapple. This will fold the grapple
under (towards the machine) and allow the
Avoid blowing oil over the relief for longer arch to be fully extended in its out position
than 5 seconds, as this will cause excessive without lifting the rear wheels off the ground.
heating of the hydraulic fluid and possible Take care to avoid damaging hydraulic hoses
damage to hydraulic components. while positioning the grapple.
POSITION GRAPPLE
WARNING FOR ARCH IN/OUT
PRESSURE SETTINGS
Use caution when working on top of the rear
chassis, as there are many pinch areas between
the arch, arch cylinders and winch. DO NOT
move arch when workers are in this area.

WARNING
Do not work under the arch without properly
supporting the arch/grapple assembly. NEVER
move the arch/grapple assembly when
workers are in this area.
625C-79

WARNING 3. Lower the dozer blade to the ground, engage

Park machine on level ground, stop engine, parking brake and shut off the engine.
engage parking brake, lower dozer and BELOW RIGHT
grapple to the ground and block wheels. HAND CAB DOOR

MAIN ACCU AXLE

CHARGE
LM1 RM1 • • •

• • •

TEST PORT COMPARTMENT

635C-25X BELOW RIGHT CAB DOOR
4. 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.

12.11
Tigercat 635C Skidder Grapple, Arch and Boom
5. Ensure that the hydraulic oil is at operating 9. It is necessary to temporarily increase the
temperature. See HYDRAULIC OIL HEATING pressure of the main pump to
PROCEDURE in SECTION 8 of THIS 4250psi @ 2200 rpm (300 Bar @ 2200 rpm).
MANUAL.
a. Turn the main relief (located in control
valve inlet) valve IN all the way until lightly
seated.
DRIVE
PUMP
b. Set the main pump POR to 4250 psi
@2200 rpm (300 Bar @ 2200 rpm).
Note: The Eng % Torque gauge (on the
CONNECTORS •• IQAN MDM computer display) should be
monitored while main pump POR is raised.
•• If Eng % Torque readings jump by 15-30 %
oil is flowing over the main relief.. Main
pump POR will need to be turned back to a
pressure below this jump point in order to
acurately set pressures.
••

DISCONNECT TWO CONNECTORS

ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
635C-11
(6350501 TO 6350510)

TEMPORARILY DISABLE
CONNECTORS ARE
LOCATED ON THE AUTO RPM FUNCTION
BOTTOM OF PUMP.
PUMP SHOWN WITH
HOSES REMOVED 10. It is also necessary to temporarily disable the
FOR CLARITY CONNECTORS
(2 PLACES) Auto RPM function to check pressure
readings. Using the IQAN MDM navigate to
the PROPERTIES MENU~OTHER~FUNC.
PARAM ~Auto RPM~change value to 0.0.
•• Refer to PROPERTIES MENU OPERATION in
DISCONNECT TWO CONNECTORS SECTION 6 of THIS MANUAL for more
ON DRIVE PUMP PRIOR TO information.
PERFORMING PROCEDURE
(6350511 TO 6351000) 11. Set engine speed to 750 rpm.
12. Make sure that the area is clear.
6. Prior to performing this procedure disconnect
the two connectors on the drive pump. This is 13. With the aid of an assistant, operate the ARCH
a safety precaution to prevent the machine OUT control and hold pressure.
from travelling. 14. ARCH OUT pressure reading should be 2538-
7. Start the engine. Set engine speed to 2200 2838 psi @ 750 rpm (175-195 Bar @ 750
rpm. rpm).

8. Disengage the parking brake. This 15. With the aid of an assistant operate the ARCH
deactivates the main pump unloading valve. IN control and hold pressure. NOTE: Care
The main pump must be fully loaded to set must be taken as this will unfold and lift the
main pump POR and accurately check grapple from the ground.
function pressure readings. 16. ARCH IN pressure reading should be 3843-
4143 psi @ 750 rpm (265-285 Bar @ 750
rpm).
17. Set engine speed to 2200 rpm.

12.12
Tigercat 635C Skidder Grapple, Arch and Boom
BELOW RIGHT
POR HAND CAB DOOR
ADJUSTMENT

••
MAIN ACCU AXLE

STANDBY CHARGE
PRESSURE LM1 RM1 • • •

• • •

TEST PORT COMPARTMENT

635C-25X BELOW RIGHT CAB DOOR
2. Connect a 0-345 Bar (0-5000 psi) gauge to the
630C-157 MAIN PUMP ‘MAIN’ test port. All pressure readings for this
SHOWN WITH
procedure will be read from the 'MAIN' test
HOSES REMOVED port.
FOR CLARITY
3. Ensure that the hydraulic oil is at operating
temperature. See HYDRAULIC OIL HEATING
MAIN PROCEDURE in SECTION 8 of THIS
INLET
RELIEF MANUAL.

•
DRIVE
PUMP
CONNECTORS

625C-80 CONTROL VALVE MAIN RELIEF

• ••
18. Reset the main relief to 4000-4200 psi @ 2200
rpm (275-290 Bar @2200 rpm).
19. Reset the main pump POR to 3000-3100 psi
@ 2200 rpm (207-214 Bar @ 2200 rpm). •
20. Enable the Auto RPM function. Using the
IQAN MDM navigate to the PROPERTIES
MENU~OTHER~FUNC. PARAM ~Auto
RPM~change value to 1.0. DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO
21. Turn off the engine, engage parking brake, PERFORMING PROCEDURE
remove gauge, reinstall plugs on test ports and 635C-11
(6350501 TO 6350510)
replace the covers. Remove articulation lock.
Note: All relief valves are cartridge style, CONNECTORS ARE
LOCATED ON THE
nonadjustable and factory set for each function. BOTTOM OF PUMP.
PUMP SHOWN WITH
Care should be taken to ensure that the proper HOSES REMOVED
FOR CLARITY CONNECTORS
relief valve cartridge is used for each function to (2 PLACES)
ensure proper operation and avoid damage to the
hydraulic circuit components due to pressure
spikes. •
BOOM UP/DOWN RELIEF PRESSURE CHECK
DISCONNECT TWO CONNECTORS
1. Park the machine on level ground, lower ON DRIVE PUMP PRIOR TO
grapple and dozer blade to the ground, PERFORMING PROCEDURE
(6350511 TO 6351000)
engage parking brake, and shut off the engine.
Install 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.

12.13
Tigercat 635C Skidder Grapple, Arch and Boom
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 set
main pump POR and accurately check
function pressure readings.

POR
TEMPORARILY DISABLE
ADJUSTMENT AUTO RPM FUNCTION

•• •
•
8. It is also necessary to temporarily disable the
STANDBY
PRESSURE Auto RPM function to check pressure
readings. Using the IQAN MDM navigate to
the PROPERTIES MENU~OTHER~FUNC.
PARAM ~Auto RPM~change value to 0.0.
Refer to PROPERTIES MENU OPERATION in
SECTION 6 of THIS MANUAL for more
information.
9. Set engine speed to 750 rpm.
630C-157 MAIN PUMP
10. Make sure that the area is clear, grapple is off
SHOWN WITH the ground, closed and rotated to center
HOSES REMOVED
FOR CLARITY position.
11. With the aid of an assistant, operate the
MAIN
BOOM UP control and hold pressure.
INLET
RELIEF 12. BOOM UP pressure reading should be 3480-
3780 psi @ 750 rpm (240-260 Bar @ 750
• rpm).
13. Move BOOM DOWN and maintain pressure.
(adjust the arch OUT to prevent the grapple
from touching the ground) and maintain
625C-80 CONTROL VALVE MAIN RELIEF pressure. CAUTION - This should NOT
7. It is necessary to temporarily increase the raise the rear wheels off the ground.
pressure of the main pump to 14. BOOM DOWN pressure reading should be
4250psi @ 2200 rpm (300 Bar @ 2200 rpm). 2538-2838 psi @ 750 rpm (175-195 Bar @
a. Turn the main relief (located in control 750 rpm).
valve inlet) valve IN all the way until lightly 15. Set engine speed to 2200 rpm.
seated.
16. Reset the main relief to 4000-4200 psi @ 2200
b. Set the main pump POR to 4250 psi rpm (275-290 Bar @2200 rpm).
@2200 rpm (300 Bar @ 2200 rpm).
17. Reset the main pump POR to 3000-3100 psi
Note: The Eng % Torque gauge (on the @ 2200 rpm (207-214 Bar @ 2200 rpm).
IQAN MDM computer display) should be
monitored while main pump POR is raised.
If Eng % Torque readings jump by 15-30 %
oil is flowing over the main relief.. Main
pump POR will need to be turned back to a
pressure below this jump point in order to
acurately set pressures.

12.14
Tigercat 635C Skidder Grapple, Arch and Boom
18. Enable the Auto RPM function. Using the
IQAN MDM navigate to the PROPERTIES
MENU~OTHER~FUNC. PARAM ~Auto
RPM~change value to 1.0.
19. Turn off the engine, engage parking brake,
remove gauge, reinstall plugs on test ports and
replace the cover plates. Remove articulation
lock.
Note: All relief valves are cartridge style,
nonadjustable and factory set for each function.
Care should be taken to ensure that the proper
relief valve cartridge is used for each function to
ensure proper operation and avoid damage to the
hydraulic circuit components due to pressure
spikes.

12.15
Tigercat 635C Skidder Grapple, Arch and Boom
GRAPPLE CIRCUIT DESCRIPTION Two flow control valves (orifice check valves)
installed in each line to the grapple rotate motor,
Oil is supplied by a variable displacement piston
reduce the flow of oil and maintain a steady
pump (main pump) via the priority valve. The
grapple rotate speed. They are located close to the
priority valve directs oil to the control valve (winch,
grapple rotate valve ports. The arrow on each of
arch, dozer, grapple, boom). The control valve is
these valves must point towards the valve.
equipped with an inlet relief valve which acts as a
main relief. The grapple rotate motor is a hydraulic gerotor
motor and has an adjustable double acting cross-
Oil enters the inlet section of the control valve and
line relief valve for protection. If external rotational
is allowed to pass through the closed center spool
pressure is applied to the head, this valve
sections to the end section and is prevented from
bypasses the oil to protect the motor and seals. In
returning to tank by a plugs in the T1, T3 and TP
addition the grapple control rotate valve is
ports. Internal pilot pressure supply is generated by
equipped with port relief valves to protect the
a pressure reducing valve in the end section for
motor and seals. The grapple rotate motor has a
use in operating the spool sections.
drain line which returns excess hydraulic oil to
GRAPPLE ROTATE WITH TIGERCAT GRAPPLE tank.
A hydraulic grapple rotate motor is mounted in the Return oil is directed through the control valve to
rotator box on the arch/boom, under a protective the inlet section T2 port where it returns to tank.
removable hood. It is used to rotate the grapple
Refer also to SECTION 6 of THIS MANUAL for
head clockwise or counterclockwise. The tigercat
complete electrical schematics and more detailed
grapple is capable of continuous 360° rotation
information about the computer control system.
clockwise or counterclockwise.
GRAPPLE OPEN/CLOSE
The grapple rotate motor is operated by push
buttons on the joystick. When the operator presses The grapple cylinders are operated by push
a grapple rotate button a signal (DIGITAL IN - buttons on the joystick. When the operator presses
Grapple Rotate CW or Grapple Rotate CCW) is grapple open or close button a signal (DIGITAL IN
sent to the computer control system. The - Grapple Open or Grapple Close) is sent to the
computer control system generates a signal computer control system. The computer control
(Earlier machines [6350501 to 6350530] - PWM system generates a signal (DIGITAL OUT -
OUT - Grapple Rotate OR Later machines Grapple Open or Grapple Close) which is sent out
[6350531 to 6351000] - DIGITAL OUT - Grapple to a solenoid on the grapple open/close section of
Rotate CW or Grapple Rotate CCW ) which is the control valve activating the GRAPPLE OPEN
sent out to a solenoid on the grapple rotate or CLOSE function.
section of the control valve activating the
Each electro-hydraulically controlled spool section
GRAPPLE ROTATE CW or CCW function.
has a closed centered 3-position spool with spring
Each electro-hydraulically controlled spool section centering.
has a closed centered 3-position spool with spring
When the GRAPPLE OPEN or CLOSE function is
centering. When the GRAPPLE ROTATE CW or
activated electrical current from the computer
CCW function is activated electrical current from
control system creates a magnetic force
the computer control system creates a magnetic
proportional to the current supplied within the
force proportional to the current supplied within the
solenoid. The corresponding solenoid shifts the
solenoid. The corresponding solenoid shifts the
actuator and allows the spool to be shifted by
actuator and allows the spool to be shifted by
internal pilot pressure applied to the end of the
internal pilot pressure applied to the end of the
spool. Shifting the spool directs oil from the
spool. Shifting the spool directs oil from the
pressure gallery to either end of the cylinders
pressure gallery to either side of the motor
causing the grapple arms to open or close. For
causing it to rotate clockwise/counterclockwise and
machines equipped with Tigercat continuous
rotate the grapple. The grapple rotate section of
rotation grapples the oil is directed to the cylinders
the control valve is equipped with cartridge style
via a rotary manifold mounted in the rotator box
anticavitation valves.
allowing continuous 360° rotation of the grapple.
The grapple open/close section of the control valve
is equipped with cartridge style relief valves to
protect the circuit from over pressurizing.

12.16
Tigercat 635C Skidder Grapple, Arch and Boom
A constant pressure switch on the joystick is used
to maintain a constant pressure hold on the
grapple load and prevent slipping. When the
constant pressure switch is activated it sends an
electrical signal (DIGITAL IN - Constant Pressure)
to the computer control system. The computer
control system generates a signal (DIGITAL OUT -
Grapple Close) which is sent out to the GRAPPLE
CLOSE solenoid on the control valve activating the
grapple close function. This will cause a constant
pressure to be applied to the closed grapple arms
to maintain a firm grip on the load and help prevent
slippage. To release the constant pressure to the
grapple, press the GRAPPLE OPEN button
momentarily.
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.

12.17
Tigercat 635C Skidder Grapple, Arch and Boom

GRAPPLE CIRCUIT
635C-10
(6350501 TO 6350510)

12.18
Tigercat 635C Skidder Grapple, Arch and Boom

GRAPPLE CIRCUIT
630C-75
(6350511 TO 6351000)

12.19
Tigercat 635C Skidder Grapple, Arch and Boom
GRAPPLE PRESSURE SETTINGS GRAPPLE ROTATE HYDRAULIC ADJUSTMENTS
1. Park the machine on level ground, lower
grapple and dozer blade to the ground,
WARNING engage parking brake, and shut off the engine.
Do not stand above or below the arch, boom Install articulation lock
or grapple assembly, or between the arch/ GRAPPLE CROSS-LINE
boom and rear chassis during this procedure. MOTOR
TEST PORT • RELIEF
ADJUSTING

Before performing work on the arch/boom •• • •• SCREW

assembly, lower it to the ground and/or use

proper support devices.
GRAPPLE
ROTATE MOTOR
IMPORTANT ••
Avoid blowing oil over the relief for longer
DRAIN GRAPPLE
than 5 seconds, as this will cause excessive LINE ROTARY
heating of the hydraulic fluid and possible MANIFOLD

damage to hydraulic components.

GRAPPLE ROTATOR BOX
625C-81 TIGERCAT GRAPPLE
WARNING 2. Connect a 0-345 Bar (0-5000 psi) to the test
port on the grapple rotate motor. Place gauge
Use caution when working on top of the rear
so that it can be read at a safe distance from
chassis, as there are many pinch areas
the grapple.
between the arch, arch cylinders boom, boom
cylinders and winch. DO NOT move arch or 3. Ensure that the hydraulic oil is at operating
boom when workers are in this area. temperature. See HYDRAULIC OIL HEATING
PROCEDURE in SECTION 8 of THIS
MANUAL.
WARNING
Do not work under the arch or boom without
DRIVE
properly supporting the arch/grapple PUMP
assembly. NEVER move the arch/grapple
assembly when workers are in this area.
CONNECTORS •
WARNING
Park machine on level ground, stop engine,
engage parking brake, lower dozer and
••
grapple to the ground and block wheels.

••

DISCONNECT TWO CONNECTORS

ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
635C-11
(6350501 TO 6350510)
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.

12.20
Tigercat 635C Skidder Grapple, Arch and Boom

CONNECTORS ARE
POSITION GRAPPLE
LOCATED ON THE ON GROUND TO
BOTTOM OF PUMP.
PUMP SHOWN WITH PREVENT ROTATION
HOSES REMOVED
FOR CLARITY CONNECTORS
(2 PLACES)

••
DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
(6350511 TO 6351000)
5. Start the engine. Set engine speed to 750
rpm. 625C-79

7. Make sure that the area is clear and position

the grapple on the ground to prevent it from
rotating.
8. First turn the cross-line port relief adjusting
screw OUT until the pressure reading falls well
below 1500-1600 psi (100-110 Bar) on the
motor test port gauge.
TEMPORARILY DISABLE
AUTO RPM FUNCTION 9. With the aid of an assistant activate the
grapple rotate controls in the direction which
6. It is also necessary to temporarily disable the
pressurizes the test gauge. Then turn the
Auto RPM function to check pressure
adjusting screw IN until pressure rises to 1500-
readings. Using the IQAN MDM navigate to
1600 psi (100-110 Bar) (no further) on the
the PROPERTIES MENU~OTHER~FUNC.
motor test port gauge and tighten the locknut.
PARAM ~Auto RPM~change value to 0.0.
Refer to PROPERTIES MENU OPERATION in Note: Ensure that this adjustment is made as
SECTION 6 of THIS MANUAL for more described above. It is possible to turn the
information. adjusting screw in further than required without
affecting the pressure reading on the gauge.
Over adjustment of the cross-line relief may
cause damage to the grapple rotate motor.
10. Enable the Auto RPM function. Using the
IQAN MDM navigate to the PROPERTIES
MENU~OTHER~FUNC. PARAM ~Auto
RPM~change value to 1.0.
11. Turn off the engine, remove gauge, reinstall
plugs on test ports and replace the cover
plates. Remove articulation lock.

POSITION GRAPPLE
ON GROUND TO
308-15 PREVENT ROTATION

12.21
Tigercat 635C Skidder Grapple, Arch and Boom
GRAPPLE ROTATE SPEED CHECK GRAPPLE OPEN/CLOSE RELIEF CHECK
1. Park the machine on level ground, lower 1. Park the machine on level ground, lower
grapple and dozer blade to the ground, grapple and dozer blade to the ground, set
engage parking brake, and shut off the engine. parking brake ON, and shut off the engine.
Install articulation lock Install articulation lock
2. Ensure that the hydraulic oil is at operating BELOW RIGHT
HAND CAB DOOR
temperature. See HYDRAULIC OIL HEATING
PROCEDURE in SECTION 8 of THIS MAIN ACCU AXLE

MANUAL.
CHARGE
DRIVE
LM1 RM1 • • •
PUMP
CONNECTORS
• • •

•• •• TEST PORT COMPARTMENT

635C-25X BELOW RIGHT CAB DOOR
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.
3. Ensure that the hydraulic oil is at operating
temperature. See HYDRAULIC OIL HEATING
DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO PROCEDURE in SECTION 8 of THIS
PERFORMING PROCEDURE MANUAL.
(6350501 TO 6350510)
635C-11 4. Prior to performing this procedure disconnect
DRIVE
CONNECTORS ARE PUMP
LOCATED ON THE CONNECTORS
BOTTOM OF PUMP.
PUMP SHOWN WITH
HOSES REMOVED
FOR CLARITY CONNECTORS
(2 PLACES)
•• ••

••
DISCONNECT TWO CONNECTORS ••
ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
(6350511 TO 6351000)
DISCONNECT TWO CONNECTORS
3. Prior to performing this procedure disconnect ON DRIVE PUMP PRIOR TO
the two connectors on the drive pump. This is PERFORMING PROCEDURE
a safety precaution to prevent the machine 635C-11
(6350501 TO 6350510)
from travelling.
4. Start the engine. Set engine speed to 750 rpm. CONNECTORS ARE
LOCATED ON THE
BOTTOM OF PUMP.
5. Raise grapple off the ground and rotate the PUMP SHOWN WITH
HOSES REMOVED
grapple. FOR CLARITY CONNECTORS
(2 PLACES)
6. Count the number of rotations in one minute.
7. The correct grapple rotate speed should be
approximately 10 rpm. ••
8. Turn off the engine, remove gauge, reinstall DISCONNECT TWO CONNECTORS
plugs on test ports and replace the cover ON DRIVE PUMP PRIOR TO
plates. Remove articulation lock. PERFORMING PROCEDURE
(6350511 TO 6351000)

12.22
Tigercat 635C Skidder Grapple, Arch and Boom
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 set main pump TEMPORARILY DISABLE
POR and accurately check function pressure AUTO RPM FUNCTION
readings.
8. It is also necessary to temporarily disable the
Auto RPM function to check pressure readings.
POR
ADJUSTMENT Using the IQAN MDM navigate to the
PROPERTIES MENU~OTHER~FUNC. PARAM
•• STANDBY
~Auto RPM~change value to 0.0. Refer to
PRESSURE PROPERTIES MENU OPERATION in SECTION
6 of THIS MANUAL for more information.
9. Set engine speed to 750 rpm.
10. Make sure that the area is clear, grapple is off
the ground, closed and rotated to center
position.
11. With the aid of an assistant, operate the
630C-157 MAIN PUMP GRAPPLE CLOSE control and hold pressure.

SHOWN WITH
12. GRAPPLE CLOSE pressure reading should be
HOSES REMOVED 3843-4143 psi @ 750 rpm (265-285 Bar @ 750
FOR CLARITY
rpm).
13. With the aid of an assistant, operate the
MAIN GRAPPLE OPEN control and hold pressure.
INLET
RELIEF
14. GRAPPLE OPEN pressure reading should be
•• 3480-3780 psi @ 750 rpm (240-260 Bar @ 750
rpm)..
15. Set engine speed to 2200 rpm.
16. Reset the main relief to 4000-4200 psi @ 2200
625C-80 CONTROL VALVE MAIN RELIEF rpm (275-290 Bar @2200 rpm).
7. It is necessary to temporarily increase the 17. Reset the main pump POR to 3000-3100 psi @
pressure of the main pump to 2200 rpm (207-214 Bar @ 2200 rpm).
4250psi @ 2200 rpm (300 Bar @ 2200 rpm).
18. Enable the Auto RPM function. Using the IQAN
a. Turn the main relief (located in control valve MDM navigate to the PROPERTIES
inlet) valve IN all the way until lightly seated. MENU~OTHER~FUNC. PARAM ~Auto
b. Set the main pump POR to 4250 psi @2200 RPM~change value to 1.0.
rpm (300 Bar @ 2200 rpm). 19. Turn off the engine, engage parking brake,
Note: The Eng % Torque gauge (on the remove gauge, reinstall plugs on test ports and
IQAN MDM computer display) should be replace the cover plates. Remove articulation
monitored while main pump POR is raised. lock.
If Eng % Torque readings jump by 15-30 % Note: All relief valves are cartridge style,
oil is flowing over the main relief.. Main nonadjustable and factory set for each function.
pump POR will need to be turned back to a Care should be taken to ensure that the proper relief
pressure below this jump point in order to valve cartridge is used for each function to ensure
acurately set pressures. proper operation and avoid damage to the hydraulic
circuit components due to pressure spikes.

12.23
Tigercat 635C Skidder Grapple, Arch and Boom

12.24
Tigercat 635C Skidder

SECTION 13 - WINCH
OCTOBER 2008

CONTENTS - SECTION 13
ALLIED WINCH
CIRCUIT DESCRIPTION
6350501 TO 6350530 ........................................................................... 13.8
6350531 TO 6351000 ......................................................................... 13.12
CIRCUIT DIAGRAM
6350501 TO 6350510 ........................................................................... 13.9
6350511 TO 6350530 .......................................................................... 13.10
6350531 TO 6351000 ......................................................................... 13.13
HYDRAULIC SCHEMATIC, CIRCUIT
6350501 TO 6350530 ......................................................................... 13.11
6350531 TO 6351000 ......................................................................... 13.15
PRESSURE REDUCING VALVE, ALLIED WINCH .................................. 13.4
WINCH ..................................................................................................... 13.5
WINCH FREE SPOOL. ............................................................................. 13.4
CONTROL VALVE ...................................................... SEE ALSO SECTION 12
WINCH SECTION .................................................................................... 13.2
MANIFOLD DIFFERENTIAL LOCK/ WINCH FREESPOOL
6350501 TO 6350530 ............................................................................... 13.6
6350531 TO 6351000 ............................................................................... 13.7
PRESSURE CHECKS
WINCH IN ............................................................................................... 13.16
WINCH CONTROL LEVER .......................................................................... 13.3
Tigercat 635C Skidder Winch
CONTROL VALVE
The control valve is located on the rear chassis
above the rear axle and under the cover plate.
This control valve consists of an inlet section;
four, five or six spool sections (depending on
machine options chosen); and an end section with
integrated pilot supply.
For detailed information and an operating
description of the control valve refer to CONTROL
VALVE in SECTION 12.
WINCH SECTION
The winch spool section is equipped with a
pressure relief cartridge on the A side and a plug
on the B side. All relief valves are cartridge style,
factory set for each function and nonadjustable.
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.
*NOTE: There two variations of the control valve
in use, depending on whether the machine has a CONTROL VALVE
a winch included. 620C-28 ELECTRICAL SCHEMATIC
A winch will add a spool section to the grapple
control valve, making it a six spool section valve.

FRONT

OIL OUT OIL IN

INLET
SECTION
• • •

IN A WINCH B

OUT A ARCH B IN

UP A DOZER B DOWN

OPEN A GRAPPLE B CLOSE

CW A ROTATE B CCW

UP A BOOM B DOWN

END
SECTION
•
CONTROL VALVE
620C-27 (dual function arch)
13.2
Tigercat 635C Skidder Winch
WINCH CONTROL LEVER
The winch control lever is located on the control
panel in the operator's cab. Pressing activation
swtich on top of lever and pulling and holding the
CONNECTOR C1
lever BACK winds in the winch cable. The control 1. GND
2. POWER (+5VDC)
lever will return to the center neutral position when 3. OUT A (0.5 VDC-4.5 VDC)
4. OUT B (4.5 VDC-0.5 VDC)
the handle is released. The neutral or center
position actuates the winch pinion brake and
prevents the drum from rotating.
Operating the WINCH FREE SPOOL function (on
control panel) permits the cable to unwind freely.
The cable can then be pulled from the drum by the
operator. Refer to WINCH CONTROL SWITCH in
THIS SECTION.
Refer also to OPERATING WINCH in SECTION 2
of THE OPERATOR'S MANUAL.
The winch control lever is a single axis joystick
designed for controlling hydraulic functions using
two contactless hall effect sensors that provide
mirrored voltage outputs for controlling proportional
valve drivers.

DOZER/WINCH LEVER CHARACTERISTICS 630C-01T CONTROL LEVER

• Contactless Hall Effect Sensors

• Start of Control (ie Dozer Up) : 0 % Lever
Movement In / Blade Stationary / 2500 mV
• End of Control (ie Dozer Up) : 100 % Lever
Movement In / Blade Up Max Rate / 4500 mV
• Start of Control (ie Dozer Dn) : 0 % Lever
Movement Out / Blade Stationary / 2500 mV
• End of Control (ie Dozer Dn) : -100 % Lever
Movement Out/ Blade Dn Max Rate / 500 mV

Dozer/Winch Lever Characteristics

4500
4000
3500
3000
Milli-Volts

2500
2000
1500
1000
500
0
-100 -75 -50 -25 0 25 50 75 100

Lever Position %

13.3
Tigercat 635C Skidder Winch
WINCH CONTROL SWITCH PRESSURE REDUCING VALVE
-ALLIED WINCH -ALLIED WINCH

WINCH
CONTROL
LEVER

• WINCH
CONTROL
SWITCH

•
635C-03
CONTROL PANEL

This is a two position switch labelled OFF/WINCH

FREE SPOOL. 630C-229 PRESSURE REDUCING VALVE
This rocker switch disconnects the winch drive
Machines equipped with an Allied Winch are
motor from the drum and allows the cable to be
equipped with a pressure reducing valve in the
freely pulled from the spool. The switch must be in
winch freespool pilot pressure line. This pressure
the OFF position activate the WINCH IN function.
reducing valve is adjustable and factory set to 250
Note: An alarm warning light will flash, "Winch psi for proper operation of the winch freespool
freespool on" will appear on the IQAN-MDM function.
computer display, and horn will sound whenever
Note: This pressure reducing valve should not
the winch control switch is in the FREE SPOOL
require adjusting. However, if adjustment is
position.
required always turn the adjusting screw out then
back in to a setting of 250 psi (17 Bar). Setting the
pressure any higher than 250 psi (17 Bar) will
cause seal damage in the winch.

635C-21 WINCH CONTROLS (SWITCH AND LEVER) ELECTRICAL SCHEMATIC

13.4
Tigercat 635C Skidder Winch
ALLIED WINCH
The winch is driven by a hydraulic motor through
the sprag clutch and winch drive components.
The pinion sprag holds the load in conjunction with
the free spool clutch to prevent reverse rotation of
the drum. The free spool clutch separates the
drum from other drive components and permits
the cable to unwind freely.
The winch is controlled through a variable position
lever and a winch control switch. The winch
control switch operates the free spool clutch,
allowing the cable to unwind freely from the drum.
The cable can now be pulled from the drum by the
operator.
The sprag clutch in conjunction with the free spool 630C-231 ALLIED WINCH
clutch holds the load and prevents the reverse
rotation of the drum and motor during the 'WINCH
IN' or 'HOLD' operation.
Refer to WINCH MAINTENANCE in SECTION 3
in THIS MANUAL. Refer also to manufacturer's
service manual for more information about the
winch.

DRIVE MOTOR

FREE
• SPOOL
CLUTCH

•• DRUM

SPRAG
•
CLUTCH

• •

RING GEAR
AND PINION
630C-232
CROSS SECTION OF WINCH (ALLIED)
13.5
Tigercat 635C Skidder Winch
MANIFOLD DIFFERENTIAL LOCK/
WINCH FREESPOOL
(6350501 TO 6350530)

FRONT
DIFFERENTIAL
LOCK SOLENOID

• ••
•• •
REAR
DIFFERENTIAL
LOCK SOLENOID

WINCH
FREESPOOL MANIFOLD WINCH FREESPOOL
SOLENOID AND DIFFERENTIAL LOCKS
DIFFERENTIAL LOCK/WINCH
630C-31 ELECTRICAL SCHEMATIC
635C-32
FREESPOOL MANIFOLD

The differential lock/winch freespool manifold

controls the front differential lock, rear differential
lock and winch freespool (if equipped) functions.
This manifold contains an non-adjustable
pressure relief valve, a solenoid operated free
reverse flow valve, and three 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.
The solenoid operated free reverse flow valve is
activated by the computer control system in
tandem with the solenoid operated pilot valves.
When open (normal position) this valve allows oil
to flow freely through the manifold to the front
axle. When closed (activated in tandem with one
or more of the manifold functions) oil is forced to
flow over the pressure relief valve to provide pilot
oil to the manifold function(s). This valve provides
pilot oil only when it is needed, thus reducing the
heat produced in the axle circuit by oil flowing
over the pressure relief valve.
Each solenoid operated pilot valve is operated in
tandem with the reverse flow valve by electrical
control signals via the computer control system.
When activated pilot oil from the manifold flows to
operate the function.
This manifold has two tank ports T and T1.
Coil resistance for all four solenoids is 8 ohms.
For information about the differential lock
functions refer to SECTION 15.

13.6
Tigercat 635C Skidder Winch
MANIFOLD DIFFERENTIAL LOCK/
WINCH FREESPOOL
(6350531 TO 6351000)

REAR
DIFFERENTIAL
LOCK SOLENOID

••
WINCH
FREESPOOL •• ••
SOLENOID

FRONT
DIFFERENTIAL
LOCK SOLENOID
MANIFOLD WINCH FREESPOOL
DIFFERENTIAL LOCK/WINCH
FREESPOOL MANIFOLD AND DIFFERENTIAL LOCKS
630C-255 (6350531 TO 6351000) 625C-18A ELECTRICAL SCHEMATIC
The differential lock/winch freespool manifold This manifold has two tank ports T and T1.
controls the front differential lock, rear differential
Coil resistance for all four solenoids is 33.8 ohms.
lock and winch freespool (if equipped) functions.
For information about the differential lock functions
This manifold contains an non-adjustable
refer to SECTION 15.
pressure relief valve, a solenoid operated free
reverse flow valve, a pressure reducing valve
used for the winch freespool function and three
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.
The solenoid operated free reverse flow valve is
activated by the computer control system in
tandem with the solenoid operated pilot valves.
When open (normal position) this valve allows oil
to flow freely through the manifold to the front
axle. When closed (activated in tandem with one
or more of the manifold functions) oil is forced to
flow over the pressure relief valve to provide pilot
oil to the manifold function(s). This valve provides
pilot oil only when it is needed, thus reducing the
heat produced in the axle circuit by oil flowing
over the pressure relief valve.
Each solenoid operated pilot valve is operated in
tandem with the reverse flow valve by electrical
control signals via the computer control system.
When activated pilot oil from the manifold flows to
operate the function.
This manifold is also equipped with a built in
winch pressure reducing valve. This pressure -
reducing valve is not adjustable and is factory set
to 250 psi (17 Bar). The pressure reducing valve
reduces pressure for proper operation of the
winch freespool function.

13.7
Tigercat 635C Skidder Winch
CIRCUIT DESCRIPTION Winch freespool is controlled by the winch control
- ALLIED WINCH switch. When the winch control switch is placed in
(6350501 TO 6350530) the WINCH FREESPOOL position a signal
(DIGITAL IN - Winch Freespool) is sent to the
Oil is supplied by a variable displacement piston
computer control system and second signal is sent
pump (main pump) via the priority valve. The
directly to the winch freespool solenoid coil. The
priority valve directs oil to the control valve (winch,
computer control system generates a signal
arch, dozer, grapple, boom). The control valve is
(DIGITAL OUT - Axle Pressure Valve) which is
equipped with an inlet relief valve which acts as a
sent out to the pressure valve (free reverse flow)
main relief.
solenoid on the differential locks/winch freespool
Oil enters the inlet section of the control valve and manifold to provide pilot pressure for the winch
is allowed to pass through the closed center spool freespool function. The pilot signal from the
sections to the end section. Each electro- manifold passes through the pressure reducing
hydraulically controlled spool section has a closed valve and releases the freespool clutch, allowing
centered 3-position spool with spring centering. Oil the cable to unwind freely.
is prevented from returning to tank by plugs in the
Refer also to SECTION 6 of THIS MANUAL for
T1, T3 and TP ports. Internal pilot pressure supply,
complete electrical schematics and more detailed
which is used to operate the spool sections, is
information about the computer control system.
generated by a pressure reducing valve located at
the end section of the control valve.
A hydraulic motor is used to drive the winch during
the winding IN of the cable.
The hydraulic motor receives oil from the main
pump via the winch spool section in the control
valve. Each electro-hydraulically controlled spool
section has a closed centered 3-position spool with
spring centering.
When the operator presses the activation switch
(DIGITAL IN - Winch Lever Switch) and pulls the
winch control lever back a signal (VOLTAGE IN -
Winch In) is sent to the computer control system.
The computer control system generates a signal
(CURRENT OUT - Winch In) which is sent out to
the WINCH in solenoid on the winch section of the
control valve activating the WINCH IN function.
When the WINCH IN 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
allow the spool to be shifted by internal pilot
pressure applied to the end of the spool. Shifting
the spool directs oil from the pump to the motor
and from the motor back to tank the control valve.
The winch section of the control valve is equipped
with a cartridge style relief valve on the A side to
protect the winch circuit from over pressurizing.
Return oil is directed through the control valve to
the inlet section T2 port where it returns to tank.

13.8
Tigercat 635C Skidder Winch

WINCH CIRCUIT - ALLIED WINCH

630C-77 (6350501 TO 6350510)

13.9
Tigercat 635C Skidder Winch

WINCH CIRCUIT - ALLIED WINCH

630C-78
(6350511 TO 6350530)

13.10
Tigercat 635C Skidder Winch

WINCH HYDRAULIC CIRCUIT SCHEMATIC - ALLIED WINCH

635C-26 (6350501 TO 6350530)

13.11
Tigercat 635C Skidder Winch
CIRCUIT DESCRIPTION Winch freespool is controlled by the winch control
- ALLIED WINCH switch. When the winch control switch is placed in
(6350531 TO 6351000) the WINCH FREESPOOL position a signal
(DIGITAL IN - Winch Freespool) is sent to the
Oil is supplied by a variable displacement piston
computer control system and second signal is sent
pump (main pump) via the priority valve. The
directly to the winch freespool solenoid coil. The
priority valve directs oil to the control valve (winch,
computer control system generates a signal
arch, dozer, grapple, boom). The control valve is
(DIGITAL OUT - Axle Pressure Valve) which is
equipped with an inlet relief valve which acts as a
sent out to the pressure valve (free reverse flow)
main relief.
solenoid on the differential locks/winch freespool
Oil enters the inlet section of the control valve and manifold to provide pilot pressure for the winch
is allowed to pass through the closed center spool freespool function. The pilot signal from the
sections to the end section. Each electro- manifold passes through the internal pressure
hydraulically controlled spool section has a closed reducing valve and releases the freespool clutch,
centered 3-position spool with spring centering. Oil allowing the cable to unwind freely.
is prevented from returning to tank by plugs in the
Refer also to SECTION 6 of THIS MANUAL for
T1, T3 and TP ports. Internal pilot pressure supply,
complete electrical schematics and more detailed
which is used to operate the spool sections, is
information about the computer control system.
generated by a pressure reducing valve located at
the end section of the control valve.
A hydraulic motor is used to drive the winch during
the winding IN of the cable. The hydraulic motor
receives oil from the main pump via the winch
spool section in the control valve.
When the operator presses the activation switch
(DIGITAL IN - Winch Lever Switch) and pulls the
winch control lever back a signal (VOLTAGE IN -
Winch In) is sent to the computer control system.
The computer control system generates a signal
(CURRENT OUT - Winch In) which is sent out to
the WINCH in solenoid on the winch section of the
control valve activating the WINCH IN function.
When the WINCH IN 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 the A side to protect the winch circuit from over
pressurizing.

13.12
Tigercat 635C Skidder Winch

WINCH CIRCUIT - ALLIED WINCH

630C-109
(6350531 TO 6351000)

13.13
Tigercat 635C Skidder Winch

13.14
Tigercat 635C Skidder Winch

WINCH HYDRAULIC CIRCUIT SCHEMATIC - ALLIED WINCH

630C-107 (6350531 TO 6351000)

13.15
Tigercat 635C Skidder Winch
WINCH PRESSURE WINCH IN RELIEF PRESSURE CHECK
1. Park the machine on level ground, lower grapple
and dozer blade to the ground, engage parking
WARNING brake, and shut off the engine. Install
Do not stand above or below the arch articulation lock.
assembly, grapple or between the arch and BELOW RIGHT
HAND CAB DOOR
rear chassis during this procedure.
MAIN ACCU AXLE
Before performing work on the arch assembly,
lower it to the ground and/or use proper CHARGE
LM1 RM1
support devices. • • •

IMPORTANT • • •
Avoid blowing oil over the relief for longer TEST PORT COMPARTMENT
than 5 seconds, as this will cause excessive 635C-25X BELOW RIGHT CAB DOOR
heating of the hydraulic fluid and possible
damage to hydraulic components. 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.
WARNING
3. Ensure that the hydraulic oil is at operating
Use caution when working on top of the rear temperature. See HYDRAULIC OIL HEATING
chassis, as there are many pinch areas between PROCEDURE in SECTION 8 of THIS MANUAL.
the arch, arch cylinders and winch. DO NOT
move arch when workers are in this area. CONNECTORS
DRIVE
PUMP
WARNING
••
Do not work under the arch without properly
supporting the arch/grapple assembly. NEVER ••
move the arch/grapple assembly when
workers are in this area.
••
WARNING
Park machine on level ground, stop engine, DISCONNECT TWO CONNECTORS
engage parking brake, lower dozer and ON DRIVE PUMP PRIOR TO
grapple to the ground and block wheels. PERFORMING PROCEDURE
635C-11
(6350501 TO 6350510)

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.

CONNECTORS ARE
LOCATED ON THE
BOTTOM OF PUMP.
PUMP SHOWN WITH
HOSES REMOVED
FOR CLARITY CONNECTORS
(2 PLACES)

••
DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
(6350511 TO 6351000)

13.16
Tigercat 635C Skidder Winch

POR
ADJUSTMENT

•• STANDBY
PRESSURE

TEMPORARILY DISABLE
AUTO RPM FUNCTION

8. It is also necessary to temporarily disable the

Auto RPM function to check pressure
630C-157 MAIN PUMP readings. Using the IQAN MDM navigate to
SHOWN WITH the PROPERTIES MENU~OTHER~FUNC.
HOSES REMOVED PARAM ~Auto RPM~change value to 0.0.
FOR CLARITY
Refer to PROPERTIES MENU OPERATION in
SECTION 6 of THIS MANUAL for more
MAIN information.
INLET
RELIEF 9. Set engine speed to 750 rpm.
•• 10. Disconnect the main hoses from the winch
section of the grapple control valve. Cap the
ports on the winch section and plug the hose
ends.
625C-80 CONTROL VALVE MAIN RELIEF 11. With the aid of an assistant, operate the winch
IN control and hold pressure.
5. Start the engine. Set engine speed to 2200
rpm. 12. FOR ALLIED WINCHES
WINCH IN pressure reading should be 3045-
6. Disengage the parking brake. This
3345psi @ 750 rpm(210-230 Bar @ 750
deactivates the main pump unloading valve.
rpm).
The main pump must be fully loaded to set
main pump POR and accurately check 13. Reconnect main hoses to the winch section of
function pressure readings. the grapple control valve.

7. It is necessary to temporarily increase the 14. Set engine speed to 2200 rpm.
pressure of the main pump to 4250psi @ 2200 15. Reset the main relief to 4000-4200 psi @ 2200
rpm (300 Bar @ 2200 rpm). rpm (275-290 Bar @2200 rpm).
a. Turn the main relief (located in control 16. Reset the main pump POR to 3000-3100 psi
valve inlet) valve IN all the way until lightly @ 2200 rpm (207-214 Bar @ 2200 rpm).
seated. 17. Enable the Auto RPM function. Using the
IQAN MDM navigate to the PROPERTIES
b. Set the main pump POR to 4250psi @ MENU~OTHER~FUNC. PARAM ~Auto
2200 rpm (300 Bar @ 2200 rpm). RPM~change value to 1.0.
Note: The Eng % Torque gauge (on the 18. Turn off the engine, engage parking brake,
IQAN MDM computer display) should be remove gauge, reinstall plugs on test ports and
monitored while main pump POR is raised. replace the cover plates. Remove articulation
If Eng % Torque readings jump by 15-30 % lock.
oil is flowing over the main relief.. Main
pump POR will need to be turned back to a Note: All relief valves are cartridge style,
pressure below this jump point in order to nonadjustable and factory set for each function.
acurately set pressures. Care should be taken to ensure that the proper
relief valve cartridge is used for each function to
ensure proper operation and avoid damage to the
hydraulic circuit components due to pressure
spikes.

13.17
Tigercat 635C Skidder Winch

13.18
Tigercat 635C Skidder

SECTION 14 - DOZER BLADE

OCTOBER 2008

CONTENTS - SECTION 14
CIRCUIT DESCRIPTION ............................................................................. 14.6
CIRCUIT DIAGRAM
6350501 TO 6350510 ............................................................................... 14.7
6350511 TO 6351000 ............................................................................... 14.8
CONTROL VALVE CHARACTERISTICS .................................................... 14.3
CONTROL VALVE ELECTRICAL SCHEMATIC .......................................... 14.3
DOZER CONTROL LEVER ......................................................................... 14.5
HYDRAULIC SCHEMATIC, CIRCUIT .......................................................... 14.9
PRESSURE CHECKS
DOZER UP/DOWN RELIEFS ................................................................. 14.10
Tigercat 635C Skidder Dozer blade
CONTROL VALVE
The control valve is located on the rear chassis OIL IN
OIL OUT
above the rear axle and under the cover plate.
INLET
SECTION
This control valve consists of an inlet section;
• • •
four, five or six spool sections (depending on
machine options chosen); and an end section with
integrated pilot supply. IN A WINCH B

For detailed information and an operating

description of the control valve refer to CONTROL OUT A ARCH B IN

VALVE in SECTION 12.

UP A DOZER B DOWN
DOZER SECTION
Pressure relief ports in the dozer spool section OPEN A GRAPPLE B CLOSE
are equipped with pressure relief cartridges on
both the A and B sides. All relief valves are
CW A ROTATE B CCW
cartridge style, factory set for each function and
nonadjustable.
UP A BOOM B DOWN
Spool limiting set screws are factory set for all
spool sections. The factory setting for the dozer
END
section spool stop is 5mm from the end of the SECTION
screw to the tightened jam nut. (Decreasing •
spool stop setting slows down dozer blade
CONTROL VALVE
movement.) the Refer also to CONTROL VALVE 620C-27 (dual function arch)
in SECTION 12.
*NOTE: There two variations of the control valve
in use, depending on whether the machine has a
a winch included.
A winch will add a spool section to the grapple
control valve, making it a six spool section valve.

14.2
Tigercat 635C Skidder Dozer blade

CONTROL VALVE CHARACTERISTICS

(6350501 TO 6350530)
• 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)
• Coil Resistance : 5.4 ohms
50
45
40
35

Flow gpm
30
25
20
15
10
5
0
0 200 400 600 800 1000 1200 1400 160
(107) (164) (220) (277) (334) (39
Control Current mA
Control Presure (psi)
CONTROL VALVE ELECTRICAL SCHEMATIC
(6350501 TO 6350530)
625C-77

CONTROL VALVE CHARACTERISTICS

(6350531 TO 6351000)
• Control Pressure Relief : 500 psi (34 Bar)
(Non-Adjustable)
• Start of Control : 0 gpm / 300ma /102 psi
(0 L/min / 300mA / 7 Bar)
• End of Control : 46.5 gpm/ 780 mA / 348 psi
(176 L/min/ 780 mA /24 Bar)
• Coil Resistance : 21.7 ohms
Control Valve Characteristics

50
45
40
35
Flow gpm

30
25
20
15
10
5
0
0 200 400 600 800 1000
(153) (255) (358)

Control Current mA
CONTROL VALVE ELECTRICAL SCHEMATIC Control pressure (psi)
(6350531 TO 6351000)
625C-78

14.3
Tigercat 635C Skidder Dozer blade

14.4
Tigercat 635C Skidder Dozer blade
DOZER CONTROL LEVER
DOZER
CONTROL
LEVER

CONNECTOR C1
•• 1. GND
2. POWER (+5VDC)
3. OUT A (0.5 VDC-4.5 VDC)
4. OUT B (4.5 VDC-0.5 VDC)

635C-03
CONTROL PANEL

The dozer control lever is located on the control

panel in the operator’s cab. Pressing the activation
switch on top of lever and pulling the lever BACK
to RAISE the dozer blade. Pressing the activation
switch on top of lever and pushing the lever
FORWARD to LOWER the blade. The control
lever will return to the center neutral position when
the handle is released.
The dozer control lever is a single axis joystick
designed for controlling hydraulic functions using
two contactless hall effect sensors that provide
mirrored voltage outputs for controlling proportional 630C-01T CONTROL LEVER
valve drivers.
DOZER/WINCH LEVER CHARACTERISTICS
• Contactless Hall Effect Sensors
• Start of Control (ie Dozer Up) : 0 % Lever
Movement In / Blade Stationary / 2500 mV
• End of Control (ie Dozer Up) : 100 % Lever
Movement In / Blade Up Max Rate / 4500 mV
• Start of Control (ie Dozer Dn) : 0 % Lever
Movement Out / Blade Stationary / 2500 mV
• End of Control (ie Dozer Dn) : -100 % Lever
Movement Out/ Blade Dn Max Rate / 500 mV

Dozer/Winch Lever Characteristics

4500
4000
3500
3000
Milli-Volts

2500
2000
1500
1000
500
0
-100 -75 -50 -25 0 25 50 75 100

Lever Position %

14.5
Tigercat 635C Skidder Dozer blade
DOZER CIRCUIT DESCRIPTION Return oil is directed through the control valve to
the inlet section T2 port where it returns to tank.
Oil is supplied by a variable displacement piston
pump (main pump) via the priority valve. The Refer also to SECTION 6 of THIS MANUAL for
priority valve directs oil to the control valve (winch, complete electrical schematics and more detailed
arch, dozer, grapple, boom). The control valve is information about the computer control system.
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.
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 valve, therefore oil flow to the
dozer control valve will be regulated to zero as the
pressure compensated piston pump de-strokes to
a zero angle.
The electro-hydraulically controlled spool section
has a closed centered 3-position spool with spring
centering.
When the operator presses the activation switch
(DIGITAL IN - Dozer Lever Switch) and moves the
dozer control lever forward or back a signal
(VOLTAGE IN - Dozer) is sent to the computer
control system. The computer control system
generates a signal (6350501 TO 6350530 PWM
OUT - Dozer Up-/Dn+ or 6350531 to 6351000
CURRENT OUT - Dozer Up-/Dn+) which is sent
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.

14.6
Tigercat 635C Skidder Dozer blade

DOZER CIRCUIT
635C-12 (6350501 TO 6350510)
14.7
Tigercat 635C Skidder Dozer blade

DOZER CIRCUIT
630C-79 (6350511 TO 6351000)
14.8
Tigercat 635C Skidder Dozer blade

DOZER HYDRAULIC CIRCUIT SCHEMATIC

635C-27

14.9
Tigercat 635C Skidder Dozer blade
DOZER PRESSURE DOZER UP/DOWN RELIEF
PRESSURE CHECK
NOTE: Park the machine on level ground as
WARNING this procedure will lift the front wheels off the
Do not stand above or below the dozer blade ground when the dozer blade is operated in its
or between the blade and front chassis during down position.
this procedure. 1. Park the machine on level ground, lower
Before performing work on the dozer blade, grapple and dozer blade to the ground, engage
lower the blade to the ground, or use proper parking brake, and shut off the engine. Install
supporting devices. articulation lock.
BELOW RIGHT
HAND CAB DOOR
IMPORTANT MAIN ACCU AXLE

Avoid blowing oil over the relief for longer

CHARGE
than 5 seconds, as this will cause excessive LM1 RM1 • • •
heating of the hydraulic fluid and possible
damage to hydraulic components. • • •

WARNING TEST PORT COMPARTMENT

635C-25X BELOW RIGHT CAB DOOR
Use caution when working around the dozer
area, as there are many pinch areas between 2. Connect a 0-345 Bar (0-5000 psi) gauge to the
the dozer assembly, cylinders and front ‘MAIN’ test port. All pressure readings for this
chassis. DO NOT move the blade when procedure will be read from the 'MAIN' test port.
workers are in this area. 3. Ensure that the hydraulic oil is at operating
temperature. See HYDRAULIC OIL HEATING
WARNING PROCEDURE in SECTION 8 of THIS
MANUAL.
Do not work under the blade without
properly supporting the dozer assembly.
NEVER move the dozer assembly when DRIVE
workers are in this area. PUMP

WARNING
Park machine on level ground, stop engine,
CONNECTORS •
engage parking brake, lower dozer and
grapple to the ground and block wheels. ••

••

DISCONNECT TWO CONNECTORS

ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
635C-11
(6350501 TO 6350510)

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.

14.10
Tigercat 635C Skidder Dozer blade
monitored while main pump POR is raised.
CONNECTORS ARE If Eng % Torque readings jump by 15-30 %
LOCATED ON THE
BOTTOM OF PUMP. oil is flowing over the main relief.. Main
PUMP SHOWN WITH
HOSES REMOVED pump POR will need to be turned back to a
FOR CLARITY CONNECTORS
(2 PLACES) pressure below this jump point in order to
acurately set pressures.

••
DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
(6350511 TO 6351000)

POR
ADJUSTMENT TEMPORARILY DISABLE

••
AUTO RPM FUNCTION
STANDBY 8. It is also necessary to temporarily disable the
PRESSURE Auto RPM function to check pressure
readings. Using the IQAN MDM navigate to
the PROPERTIES MENU~OTHER~FUNC.
PARAM ~Auto RPM~change value to 0.0.
Refer to PROPERTIES MENU OPERATION in
SECTION 6 of THIS MANUAL for more
information.
9. Set engine speed to 750 rpm.
630C-157 MAIN PUMP
10. Make sure that the area is clear and the tilt
SHOWN WITH
HOSES REMOVED out hood is closed.
FOR CLARITY

MAIN
INLET
IMPORTANT
RELIEF
Dozer blade will damage the tilt out hood if
• operated with the front door open.

11. With the aid of an assistant operate the dozer

UP control and hold.
625C-80 CONTROL VALVE MAIN RELIEF 12. DOZER UP pressure reading should be 3480-
3780 psi @ 750 rpm (240-260 Bar @ 750
5. Start the engine. Set engine speed to 2200 rpm)..
rpm.
13. LOWER dozer blade completely and hold.
6. Disengage parking brake. This deactivates CAUTION - This will raise the front wheels
the main pump unloading valve. The main off the ground.
pump must be fully loaded to set main pump
POR and accurately check function pressure 14. DOZER DOWN pressure reading should be
readings. 3480-3780 psi @ 750 rpm (240-260 Bar @
750 rpm).
7. It is necessary to temporarily increase the
pressure of the main pump to 4250psi @ 2200 15. Set engine speed to 2200 rpm.
rpm (300 Bar @ 2200 rpm). 16. Reset the main relief to 4000-4200 psi @ 2200
a. Turn the main relief (located in control rpm (275-290 Bar @2200 rpm).
valve inlet) valve IN all the way until lightly 17. Reset the main pump POR to 3000-3100 psi
seated. @ 2200 rpm (207-214 Bar @ 2200 rpm).
b. Set the main pump POR to 4250psi @ Continued on page 12
2200 rpm (300 Bar @ 2200 rpm).
Note: The Eng % Torque gauge (on the
IQAN MDM computer display) should be
14.11
Tigercat 635C Skidder Dozer blade
18. Enable the Auto RPM function. Using the
IQAN MDM navigate to the PROPERTIES
MENU~OTHER~FUNC. PARAM ~Auto
RPM~change value to 1.0.
19. Turn off the engine, engage parking brake,
remove gauge, reinstall plugs on test ports and
replace the cover plates. Remove articulation
lock.
Note: All relief valves are cartridge style,
nonadjustable and factory set for each function.
Care should be taken to ensure that the proper
relief valve cartridge is used for each function to
ensure proper operation and avoid damage to the
hydraulic circuit components due to pressure
spikes.

14.12
Tigercat 635C Skidder
SECTION 15 - AXLES AND DIFFERENTIAL LOCKS
CONTENTS - SECTION 15 NOVEMBER 2008

AXLE PUMP ....................................................................................................... 15.2

BRAKE CIRCUIT ........................................................................... SEE SECTION 9
BRAKE PEDAL .............................................................................. SEE SECTION 9
CIRCUIT DIAGRAM
6350501 TO 6350509 ................................................................................... 15.17
6350510 TO 6350530 ................................................................................... 15.19
6350531 TO 6350620 ................................................................................... 15.21
6350621 TO 6351000 ................................................................................... 15.23
DIFFERENTIAL LOCK CONTROL SOLENOID VALVE
6350510 TO 6351000 ..................................................................................... 15.3
FILTERS
AXLE PRESSURE FILTER ............................................................................. 15.3
FRONT AXLE ................................................................................................... 15.10
AXLE OIL FILL .............................................................................................. 15.25
AXLE OIL LEVEL CHECK ........................................................... SEE SECTION 3
AXLE OIL LEVEL TOP UP .......................................................... SEE SECTION 3
DIFFERENTIAL AND DIFFERENTIAL LOCKS ............................................. 15.11
OIL CAPACITIES .......................................................................................... 15.25
OSCILLATION SHIM CHECK AND ADJUSTMENT (FRONT AXLE) ............ 15.30
SERVICE BRAKES (FRONT AXLE ONLY)
BRAKE BLEEDING .................................................................................. 15.13
BRAKE LINING INSPECTION .................................................................. 15.11
SERVICING BRAKES ............................................................................... 15.11
HYDRAULIC SCHEMATIC, CIRCUIT ............................................ 15.5, 15.7, 15.9
MANIFOLD DIFFERENTIAL LOCK/ WINCH FREESPOOL
6350501 TO 6350530 ..................................................................................... 15.4
6350531 TO 6351000 ..................................................................................... 15.8
PRESSURE REDUCING VALVE ....................................................................... 15.3
PRESSURE SETTINGS
AXLE PILOT PRESSURE CHECK AND ADJUSTMENT .............................. 15.24
REAR (BOGIE) AXLE
BOGIE ASSEMBLY INSTALLATION
6350501 TO 6351000 .............................................................................. 15.38
BOGIE AXLE ASSEMBLY DIAGRAM
6350501 TO 6350534 ................................................................... 15.39, 15.41
6350535 TO 6351000 .............................................................................. 15.37
BOGIE AXLE SHAFT INSTALLATION
6350501 TO 6350534 .............................................................................. 15.40
6350535 TO 6351000 .............................................................................. 15.44
DIFFERENTIAL AND DIFFERENTIAL LOCK
6350501 TO 6350534 .............................................................................. 15.14
6350535 TO 6351000 .............................................................................. 15.15
DRAINING AND REFILLING ....................................................... SEE SECTION 3
DRAINING AND REFILLING BOGIE AXLE
6350501 TO 6350534 .............................................................................. 15.32
6350535 TO 6351000 .............................................................................. 15.34
INSPECTION OF BOGIE INPUT GEAR/SHAFT ASSEMBLIES
6350501 TO 6350534 .............................................................................. 15.33
SLEW BEARING INSTALLATION
6350501 TO 6351000 .............................................................................. 15.36
SLEW BEARING LUBRICATION .................................................................. 15.45
WHEEL INSTALLATION
TAPERED ASSEMBLY STUD ...................................................................... 15.46
Tigercat 635C Skidder Axles and Differential Locks
AXLE PUMP
COOLING
The axle pump is a fixed displacement gear FAN PUMP
PUMP
pump. It is part of the multisection gear pump, CHARGE OIL
PUMP COOLER
which includes the cooling, fan, charge (*if BY-PASS
AXLE
equipped) and axle pumps. This pump stack is PUMP
• •
driven off the power take off of the main 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.

OUTLET MULTISECTION GEAR PUMP

DRIVEN 630C-175
(6350501 TO 6350510)
DRIVE
(IDLER) GEAR
GEAR

COOLING
FAN PUMP
• • PUMP
OIL
COOLER
AXLE BY-PASS
PUMP
•• ••
••
••
INLET

GEAR1 TYPICAL GEAR PUMP MULTISECTION GEAR PUMP

630C-236 (6350511 TO 6351000)
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.
* Note: Later machines are equipped with a drive
pump which includes an integrated charge pump.

15.2
Tigercat 635C Skidder Axles and Differential Locks
AXLE PRESSURE FILTER REAR (BOGIE AXLE) DIFFERENTIAL
LOCK PRESSURE REDUCING VALVE
The hydraulic axle circuit is equipped with a full
flow pressure filter with a 50 psi (3.5 Bar) bypass This machine is equipped with a pressure
valve and a restriction indicator sending unit. reducing valve in the rear differential lock
When a restriction is encountered the bypass pressure line. This pressure reducing valve is
valve diverts oil back to the axle circuit reservoir adjustable and factory set to 250 psi for proper
in the front axle to prevent unfiltered oil from operation of the rear differential locks.
entering the axle circuit. Note: This pressure reducing valve should not
For additional information on this filter refer to require adjusting. However, if adjustment is
FILTERS and SERVICE AND LUBRICATION required always turn the adjusting screw out then
POINTS in SECTION 3. back in to a setting of 250 psi.

DIFFERENTIAL LOCK CONTROL

IMPORTANT SOLENOID VALVE
(6350510 TO 6351000)
Note that the 635C skidder has two separate
This machine is equipped with a solenoid
hydraulic systems (the main hydraulic
directional valve to aid in disengaging the rear
system and the axle circuit). These two
(bogie axle) differential locks. This solenoid valve
hydraulic systems require two different types
is controlled by the computer control system.
of hydraulic oil that MUST NOT BE
INTERCHANGED under any circumstances. When the differential lock on/off switch is
deactivated the differential lock control solenoid
Always use the correct type of hydraulic oil
directional valve will shift to the retract position.
for the circuit you are filling. Refer to
The rear differential lock pressure reducing valve
APPROVED HYDRAULIC OILS in SECTION 3
will continue to supply pressure and the rear
of THIS MANUAL.
differential locks on warning light will remain on
BLUE until the computer control system receives a
ELEMENT signal from the curvic coupling that the rear
WATER
TRIPLE ABSORBING differential locks are disengaged.
ELEMENT
FILTER SIGHT
GAUGE It may be necessary to articulate the machine or
perform a quick clutch reverse to completely
• disengage the rear differential locks.
Note: When the differential lock on/off switch is
• deactivated the front differential locks should
•
release immediately and the front differential
locks on warning light will go out.

•• MAIN
PRESSURE TEST
REDUCING PORT
HYDRAULIC
TANK
VALVE
•
•• •
•
•
CHARGE
AXLE PRESSURE
FILTER FILTER
SOLENOID
VALVE
HYDRAULIC TANK, FILTERS AND
635C-23 SIGHT GAUGE
PRESSURE REDUCING VALVE
625C-93 AND SOLENOID VALVE

15.3
Tigercat 635C Skidder Axles and Differential Locks
MANIFOLD DIFFERENTIAL LOCK/
WINCH FREESPOOL
(6350501 TO 6350530)

FRONT
DIFFERENTIAL
LOCK SOLENOID

••
•• •• REAR
DIFFERENTIAL
LOCK SOLENOID

WINCH
FREESPOOL
SOLENOID

DIFFERENTIAL LOCK/WINCH
635C-32
FREESPOOL MANIFOLD

The differential lock/winch freespool manifold

controls the front differential lock, rear differential
MANIFOLD WINCH FREESPOOL
lock and winch freespool (if equipped) functions.
AND DIFFERENTIAL LOCKS
This manifold contains an non-adjustable 630C-31A ELECTRICAL SCHEMATIC
pressure relief valve, a solenoid operated free
reverse flow valve, and three 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.
The solenoid operated free reverse flow valve is
activated by the computer control system in
tandem with the solenoid operated pilot valves.
When open (normal position) this valve allows oil
to flow freely through the manifold to the front
axle. When closed (activated in tandem with one
or more of the manifold functions) oil is forced to
flow over the pressure relief valve to provide pilot
oil to the manifold function(s). This valve provides
pilot oil only when it is needed, thus reducing the
heat produced in the axle circuit by oil flowing
over the pressure relief valve.
Each solenoid operated pilot valve is operated in
tandem with the reverse flow valve by electrical
control signals via the computer control system.
When activated pilot oil from the manifold flows to
operate the function.
This manifold has two tank ports T and T1.
Coil resistance for all four solenoids is 8 ohms.
For information about the winch freespool function
refer to SECTION 13.

15.4
Tigercat 635C Skidder Axles and Differential Locks

AXLE/DIFFERENTIAL LOCK CIRCUIT HYDRAULIC SCHEMATIC

635C-28
(6350501 TO 6350510)

15.5
Tigercat 635C Skidder Axles and Differential Locks

15.6
Tigercat 635C Skidder Axles and Differential Locks

AXLE/DIFFERENTIAL LOCK CIRCUIT HYDRAULIC SCHEMATIC

635C-28A
(6350511 TO 6350530)

15.7
Tigercat 635C Skidder Axles and Differential Locks
MANIFOLD DIFFERENTIAL LOCK/
WINCH FREESPOOL
(6350531 TO 6351000)

REAR
DIFFERENTIAL
LOCK SOLENOID

••
WINCH
FREESPOOL •• ••
SOLENOID

FRONT
DIFFERENTIAL
LOCK SOLENOID

DIFFERENTIAL LOCK/WINCH
FREESPOOL MANIFOLD MANIFOLD WINCH FREESPOOL
630C-255 (6350531 TO 6351000) AND DIFFERENTIAL LOCKS
The differential lock/winch freespool manifold 625C-18B ELECTRICAL SCHEMATIC
controls the front differential lock, rear differential
lock and winch freespool (if equipped) functions. This manifold has two tank ports T and T1.

This manifold contains an non-adjustable Coil resistance for all four solenoids is 33.8 ohms.
pressure relief valve, a solenoid operated free For information about the winch freespool
reverse flow valve, a pressure reducing valve function refer to SECTION 13.
used for the winch freespool function and three
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.
The solenoid operated free reverse flow valve is
activated by the computer control system in
tandem with the solenoid operated pilot valves.
When open (normal position) this valve allows oil
to flow freely through the manifold to the front
axle. When closed (activated in tandem with one
or more of the manifold functions) oil is forced to
flow over the pressure relief valve to provide pilot
oil to the manifold function(s). This valve provides
pilot oil only when it is needed, thus reducing the
heat produced in the axle circuit by oil flowing
over the pressure relief valve.
Each solenoid operated pilot valve is operated in
tandem with the reverse flow valve by electrical
control signals via the computer control system.
When activated pilot oil from the manifold flows to
operate the function.
This manifold is also equipped with a built in
winch pressure reducing valve. This pressure -
reducing valve is not adjustable and is factory set
to 250 psi (17 Bar). The pressure reducing valve
reduces pressure for proper operation of the
winch freespool function.

15.8
Tigercat 635C Skidder Axles and Differential Locks

AXLE/DIFFERENTIAL LOCK CIRCUIT HYDRAULIC SCHEMATIC

635C-47
(6350531 TO 6351000)

15.9
Tigercat 635C Skidder Axles and Differential Locks
FRONT AXLE with specific properties to ensure reduced chatter
Power from the two drive motors is transmitted to and ensure proper lubrication of mechanical
the front axle via a transmission and the front components. Refer to APPROVED HYDRAULIC
drive shaft. Refer also to DRIVE in SECTION 8. OILS in SECTION 3 of THIS MANUAL. Refer also
to FRONT AXLE LUBRICATION in THIS
The front axle assembly is pivot mounted to the SECTION.
front frame allowing it to oscillate.
The front axle assembly consists of: IMPORTANT
(1) Input yoke
Note that the 635C skidder has two separate
(2) Spiral bevel gear set
hydraulic systems (the main hydraulic
(3) Differential gear set
system and the axle circuit). These two
(4) Hydraulic differential lock
hydraulic systems require two different types
(5) Inboard multiple wet disk brakes, (1-each side
of hydraulic oil that MUST NOT BE
in front axle only)
INTERCHANGED under any circumstances.
(6) Inboard planetary final drives, 1-each side
(7) axle housings and shafts, 1- each side Always use the correct type of hydraulic oil
for the circuit you are filling. Refer to
The final drive (6) is an inboard mounted
APPROVED HYDRAULIC OILS in SECTION 3
planetary gear arrangement, which further
of THIS MANUAL.
reduces speed and increases torque to the axles.
The input side receives drive power from the
differential via a sun gear shaft. The output side
(planetary carrier) is splined on to the axle.
The lubricant in the front axle assembly is axle
hydraulic oil. The axle hydraulic circuit is
separate from the main hydraulic system. The
front axle acts as a reservoir for the axle hydraulic
circuit. The axle circuit is powered by the axle
pump. Refer to CIRCUIT DESCRIPTION in THIS
SECTION.
The axle circuit uses a different type of hydraulic
oil than that used in the main hydraulic system.
Wet disk brakes and gears in the axles require oil

1 2
4 6 7
3

AXL-4X FRONT AXLE ASSEMBLY CROSS SECTION

15.10
Tigercat 635C Skidder Axles and Differential Locks
SERVICE BRAKES (FRONT AXLE ONLY)
The "wet" disk type service brakes (5) consist of
an annular piston, a brake disk with brake facing
material, and a brake backing plate. One brake
assembly is located on each side of the

BRAKE DISK

FRONT AXLE BACKING PLATE

630C-59 HYDRAULIC CONNECTIONS
DIFFERENTIAL AND DIFFERENTIAL LOCKS
The differential (3) distributes the power to each
side of the axle while allowing the wheels to turn
ANNULAR
at different speeds. Engaging the differential lock PISTON
function provides positive drive to both wheels of
the axle when tractive conditions might otherwise
allow one wheel to spin. The differential lock (4), AXL-BRK ANNULAR BRAKE
in the front axle assembly, is hydraulically
controlled and can be turned ON or OFF by differential case and before the final drive.
controls in the cab. The piston and the backing plate are attached to
Using the differential lock selector switch the the case and the brake disk is splined on to the
operator chooses to activate the front differential sun gear of the planetary final drive.
lock only or both the front and rear differential When the brake foot control in the cab is
locks. Pressing differential lock ON/OFF switch depressed, brake pressure oil moves the piston
to activates the differential lock(s) by energizing up against the brake disk and traps it between
the differential lock control valve solenoid(s) the piston and the backing plate to apply the
(located on the differential lock manifold) and brakes. Maximum operating pressure for the
directing pilot oil to the corresponding differential brakes is 1000 psi. For information on the brake
clutch pack assembly pistons, locking the hydraulic circuit refer to SECTION 9 of THIS
differential(s). MANUAL.
Note: This machine is equipped with a momentary BRAKE LINING INSPECTION
differential locks ON/OFF switch.
Inspection ports are provided in the differential
Refer also to DIFFERENTIAL LOCK in SECTION case on the front axle and are located on each
2 of the OPERATOR'S MANUAL for complete side of the pivot boss when viewed from the side
operating instructions. opposite the input shaft. Before inspecting the
brakes the axle must be drained.
IMPORTANT
• Remove brake inspection port plugs
Use differential locks sparingly and for brief
• Inspect brake linings on both sides of the
periods of time and only when additional
disk.
traction is needed or serious damage may
occur. • If brake lining material is worn down to the
bottom of the oil grooves, brake backing plate
and annular piston pressure plate assemblies
must be replaced.

15.11
Tigercat 635C Skidder Axles and Differential Locks

15.12
Tigercat 635C Skidder Axles and Differential Locks
BRAKE BLEEDING 2. Prior to bleeding brakes disconnect the two
connectors on the drive pump. This is a
The front axle assembly is equipped with two
safety precaution to prevent the machine from
brake bleed screws, one for each side. Brakes
travelling while brake bleeding is being
must be bled whenever there has been potential
performed.
for air to enter the system, such as removal of
hydraulic line. Both passages must be bled one at 3. Place a clear plastic tube over bleed screw
a time. with other end in a container.
BLEED 4. Start engine and run at IDLE
SCREWS
SINGLE BRAKE LINE 5. Loosen bleed screw
ACTUATES BOTH BRAKES
SINGLE BRAKE 6. With the aid of an assistant push and hold
PEDAL 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.

FRONT AXLE ASSEMBLY 9. Repeat above procedure for each bleed

screw.
AXL-BRK1 DUAL BRAKES (FRONT AXLE) 10. Reconnect the two connectors on the drive
PROCEDURE pump.

1. Park machine on level ground, lower dozer

and engage parking brake. Install articulation
lock pin and stop engine.

DRIVE
PUMP

CONNECTORS ••
•

•
DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
635C-11 (6350501 TO 6350510)

CONNECTORS ARE
LOCATED ON THE
BOTTOM OF PUMP.
PUMP SHOWN WITH
HOSES REMOVED
FOR CLARITY CONNECTORS
(2 PLACES)

••
DISCONNECT TWO CONNECTORS
ON DRIVE PUMP PRIOR TO
PERFORMING PROCEDURE
(6350511 TO 6351000)

15.13
Tigercat 635C Skidder Axles and Differential Locks
REAR (BOGIE) AXLE DIFFERENTIAL AND DIFFERENTIAL LOCKS
(6350501 TO 6350534)
The differential distributes the power to each side
Power from the two drive motors is transmitted to of the axle while allowing the wheels to turn at
the rear (bogie) axle via a transmission and the different speeds. The differential lock , in the rear
rear drive shafts. (bogie) axle assembly, is hydraulically controlled
The rear (bogie) axle is an assembly bolted directly and can be turned ON or OFF by controls in the
to the rear frame. cab. Engaging the differential lock function
provides positive drive to all four wheels of the
REAR ( BOGIE) AXLE axle when tractive conditions might otherwise
Each axle assembly consists of a differential allow one or more wheels to spin
housing (part of the chassis), input yoke, Using the differential lock selector switch the
differential gear set complete with hydraulic operator chooses to activate the front differential
differential lock, outer planetary final drives (2-each lock only or both the front and rear differential
side), bogie housing (1- each side) and shaft (1- locks. Pressing differential lock ON/OFF switch
each side). to activates the differential lock(s) by energizing
The gear oil in the planetary final drives, differential the differential lock control valve solenoid(s)
and bogie housings are partially separated within (located on the differential lock manifold) and
the axle by internal seals and partitions, which vary directing pilot oil to the corresponding differential
depending on bogie configuration. clutch pack assembly pistons, locking the
differential(s).
For machines 6350501 to 6350534 this means 9
different drain points and 5 fill points when the Refer also to DIFFERENTIAL LOCK in SECTION
bogie housings are filled indirectly through the 2 of the OPERATOR'S MANUAL for complete
differential housing. operating instructions.

The bogie housings can be filled directly if desired, Note: When differential lock selector switch is in
adding one extra fill point on each bogie housing. the FRONT AND REAR position the differential
locks switch acts as a momentary switch.
Refer to SERVICE AND LUBRICATION POINTS
CHART in SECTION 3 of THIS MANUAL for
differential oil capacity and recommended gear
oils.

•
DIFFERENTIAL AND
BOGIE HOUSINGS
FILL/LEVEL PLUG
•• (1 PLACE)

PLANETARY
FILL PLUG
(4 PLACES)
BOGIE HOUSING
DRAIN PLUG
(4 PLACES - LOWER) •
PLANETARY
LEVEL/DRAIN
PLUG
(4 PLACES) •• WHEEL HUB IN
PLANETARY
FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

635C-18
(6350501 TO 6350534)
15.14
Tigercat 635C Skidder Axles and Differential Locks
REAR (BOGIE) AXLE DIFFERENTIAL AND DIFFERENTIAL LOCKS
(6350535 TO 6351000) The differential distributes the power to each side
Power from the two drive motors is transmitted to of the axle while allowing the wheels to turn at
the rear (bogie) axle via a transmission and the different speeds. The differential lock , in the rear
rear drive shafts. (bogie) axle assembly, is hydraulically controlled
and can be turned ON or OFF by controls in the
The rear (bogie) axle is an assembly bolted directly
cab. Engaging the differential lock function
to the rear frame.
provides positive drive to all four wheels of the
REAR ( BOGIE) AXLE axle when tractive conditions might otherwise
Each axle assembly consists of a differential allow one or more wheels to spin
housing (part of the chassis), input yoke, Using the differential lock selector switch the
differential gear set complete with hydraulic operator chooses to activate the front differential
differential lock, outer planetary final drives (2-each lock only or both the front and rear differential
side), bogie housing (1- each side) and shaft (1- locks. Pressing differential lock ON/OFF switch
each side). to activates the differential lock(s) by energizing
The gear oil in the planetary final drives, differential the differential lock control valve solenoid(s)
and bogie housings are partially separated within (located on the differential lock manifold) and
the axle by internal seals and partitions, which vary directing pilot oil to the corresponding differential
depending on bogie configuration. clutch pack assembly pistons, locking the
differential(s).
For machines 6350535 to 6351000 this means 5
different drain points and 1 fill point when the bogie Refer also to DIFFERENTIAL LOCK in SECTION
housings are filled indirectly through the differential 2 of the OPERATOR'S MANUAL for complete
housing. operating instructions.

The bogie housings can be filled directly if desired, Note: When differential lock selector switch is in
adding one extra fill point on each bogie housing. the FRONT AND REAR position the differential
locks switch acts as a momentary switch.
Refer to SERVICE AND LUBRICATION POINTS
CHART in SECTION 3 of THIS MANUAL for
differential oil capacity and recommended gear
oils.

•
DIFFERENTIAL
•
FILL/LEVEL PLUG
(1 PLACE)

• BOGIE HOUSINGS
FILL/LEVEL PLUG
(2 PLACES)

BOGIE HOUSING
DRAIN PLUG
(4 PLACES )

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

625C-94
(6350535 TO 6351000)

15.15
Tigercat 635C Skidder Axles and Differential Locks
CIRCUIT DESCRIPTION position, the computer control system also sends
(6350501 TO 6350509) a signal (DIGITAL OUT - Rear Diff Lock) to the
rear differential lock solenoid. Note that program
The axle circuit is a separate hydraulic system,
logic contains safeguards to prevent the rear
which uses a different type of hydraulic oil than
differential lock from engaging while the machine
that used in the main hydraulic system. Wet disk
is in motion.
brakes and gears in the front axle require oil with
specific properties to ensure reduced chatter and Whenever the rear (bogie) axle differential lock is
ensure proper lubrication of mechanical engaged a signal (VOLTAGE IN - Curvic
components. Refer to APPROVED HYDRAULIC Coupling) is sent from the rear axle to the
OILS AXLE CIRCUIT in SECTION 3 of THIS computer control system for use in differential
MANUAL. lock operation. The program logic contains
safeguards to prevent the rear differential lock
The axle pump draws oil from the axle circuit
from engaging while the machine is in motion.
reservoir (front axle) and sends it through the axle
The curvic coupling signal is also sent
pressure filter to the differential lock/winch
independently to the rear differential light to
freespool manifold. Note that the axle pressure
indicate to the operator that the rear differential
filter is equipped with a filter bypass. When the
lock is engaged.
filter is bypassed (due to a clogged filter or cold
temperatures) the differential locks will not Refer also to SECTION 6 of THIS MANUAL for
function and error message appears.. complete electrical schematics and more detailed
information about the computer control system.
When no manifold operated functions are in use
oil flows freely through the manifold and out port FRONT DIFFERENTIAL LOCK ACTIVATION
T1 to the axle circuit reservoir (front axle). NOTES:
When one or more manifold functions are in use When the differential lock selector switch is in the
the reverse flow valve is closed (activated in FRONT position this machine is equipped with a
tandem with one or more of the manifold 10 minute AUTO-OFF feature which automatically
functions) oil is forced to flow over the pressure deactivates the front differential locks after 10
relief valve to provide pilot oil to the manifold minutes have passed.
function(s). When a manifold function is
The front differential locks can be engaged while
activated pilot oil from the manifold flows to
the machine is in motion. It is important to note
operate the function.
that the front differential light is controlled by the
Each solenoid operated pilot valve in the electrical system and not by the hydraulic system.
differential locks/winch freespool manifold is The light will illuminate when the joystick
operated in tandem with the reverse flow valve by differential switch depressed and not when the
electrical control signals via the computer control differential lock is hydraulically engaged.
system. When activated pilot oil from the
FRONT AND REAR DIFFERENTIAL LOCK
manifold flows to operate the function.
ACTIVATION NOTES:
The position of the differential lock selector switch
When differential lock selector switch is in the
(FRONT/FRONT AND REAR) sends a signal
FRONT AND REAR position the differential locks
(VOLTAGE IN - Front Diff Only) to the computer
switch acts as a momentary switch.
control system for use in determining whether the
only front differential locks or both the front and Engaging the rear differential curvic coupling
rear differential locks will be activated by the while the machine is in motion could cause
differential locks ON/OFF switch. serious damage. Program logic contains
safeguards to prevent the rear differential lock
When the operator presses the differential locks
from engaging while the machine is in motion.
ON/OFF switch on the joystick a signal (DIGITAL
Whenever the rear (bogie) axle differential lock is
IN - Diff Lock) is sent to the computer control
engaged a signal (VOLTAGE IN - Curvic
system. The computer control system sends a
Coupling) is sent from the rear axle to the
signal (DIGITAL OUT-Axle Pressure Valve) to the
computer control system for use in differential
reverse flow solenoid to provide pressure to the
lock operation. The curvic coupling signal is also
manifold via the axle pressure relay. At the same
sent independently to the rear differential light to
time a signal (DIGITAL OUT- Front Diff Lock) is
indicate to the operator that the rear differential
sent to the front differential lock solenoid via the
lock is engaged.
differential lock relay. If the differential lock
selector switch is in the FRONT AND REAR
15.16
Tigercat 635C Skidder Axles and Differential Locks

AXLE/DIFFERENTIAL LOCK CIRCUIT

635C-22A (6350501 TO 6350509)
15.17
Tigercat 635C Skidder Axles and Differential Locks
CIRCUIT DESCRIPTION lock selector switch is in the FRONT AND REAR
(6350510 TO 635620) position, the computer control system also sends a
signal (DIGITAL OUT - Rear Diff Lock) to the
The axle circuit is a separate hydraulic system,
differential lock control solendoid. Note that
which uses a different type of hydraulic oil than
program logic contains safeguards to prevent the
that used in the main hydraulic system. Wet disk
rear differential lock from engaging while the
brakes and gears in the front axle require oil with
machine is in motion.
specific properties to ensure reduced chatter and
ensure proper lubrication of mechanical Whenever the rear (bogie) axle differential lock is
components. Refer to APPROVED HYDRAULIC engaged a signal (VOLTAGE IN - Curvic Coupling)
OILS AXLE CIRCUIT in SECTION 3 of THIS is sent from the rear axle to the computer control
MANUAL. system for use in differential lock operation. The
program logic contains safeguards to prevent the
The axle pump draws oil from the axle circuit
rear differential lock from engaging while the
reservoir (front axle) and sends it through the axle
machine is in motion. The curvic coupling signal is
pressure filter to the differential lock/winch
also sent independently to the rear differential light
freespool manifold. Note that the axle pressure
to indicate to the operator that the rear differential
filter is equipped with a filter bypass. When the
lock is engaged.
filter is bypassed (due to a clogged filter or cold
temperatures) the differential locks will not function Refer also to SECTION 6 of THIS MANUAL for
and error message appears. complete electrical schematics and more detailed
information about the computer control system.
When no manifold operated functions are in use
oil flows freely through the manifold and out port FRONT DIFFERENTIAL LOCK ACTIVATION
T1 to the axle circuit reservoir (front axle). NOTES:
When one or more manifold functions are in use When the differential lock selector switch is in the
the reverse flow valve is closed (activated in FRONT position this machine is equipped with a
tandem with one or more of the manifold 10 minute AUTO-OFF feature which automatically
functions) oil is forced to flow over the pressure deactivates the front differential locks after 10
relief valve to provide pilot oil to the manifold minutes have passed.
function(s). When a manifold function is activated The front differential locks can be engaged while
pilot oil from the manifold flows to operate the the machine is in motion. It is important to note that
function. the front differential light is controlled by the
Each solenoid operated pilot valve in the electrical system and not by the hydraulic system.
differential locks/winch freespool manifold is The light will illuminate when the joystick
operated in tandem with the reverse flow valve by differential switch depressed and not when the
electrical control signals via the computer control differential lock is hydraulically engaged.
system. When activated pilot oil from the manifold FRONT AND REAR DIFFERENTIAL LOCK
flows to operate the function. ACTIVATION NOTES:
The position of the differential lock selector switch When differential lock selector switch is in the
(FRONT/FRONT AND REAR) sends a signal FRONT AND REAR position the differential locks
(VOLTAGE IN - Front Diff Only) to the computer switch acts as a momentary switch.
control system for use in determining whether the
only front differential locks or both the front and Engaging the rear differential curvic coupling while
rear differential locks will be activated by the the machine is in motion could cause serious
differential locks ON/OFF switch. damage. Program logic contains safeguards to
prevent the rear differential lock from engaging
When the operator presses the differential locks while the machine is in motion. Whenever the rear
ON/OFF switch on the joystick a signal (DIGITAL (bogie) axle differential lock is engaged a signal
IN - Diff Lock) is sent to the computer control (VOLTAGE IN - Curvic Coupling) is sent from the
system. The computer control system sends a rear axle to the computer control system for use in
signal (DIGITAL OUT-Axle Pressure Valve) to the differential lock operation. The curvic coupling
reverse flow solenoid to provide pressure to the signal is also sent independently to the rear
manifold via the axle pressure relay and to the rear differential light to indicate to the operator that the
differential lock solenoid on the manifold. At the rear differential lock is engaged.
same time a signal (DIGITAL OUT- Front Diff
Lock) is sent to the front differential lock solenoid
via the differential lock relay. If the differential
15.18
Tigercat 635C Skidder Axles and Differential Locks

AXLE/DIFFERENTIAL LOCK CIRCUIT

635C-48 (6350510 TO 6350530)
15.19
Tigercat 635C Skidder Axles and Differential Locks

15.20
Tigercat 635C Skidder Axles and Differential Locks

AXLE/DIFFERENTIAL LOCK CIRCUIT

635C-49 (6350531 TO 6350620)
15.21
Tigercat 635C Skidder Axles and Differential Locks
CIRCUIT DESCRIPTION a signal (DIGITAL OUT - Rear Diff Lock) to the
(6350621 AND UP) differential lock control solenoid. Note that program
logic contains safeguards to prevent the rear
The axle circuit is a separate hydraulic system,
differential lock from engaging while the machine is
which uses a different type of hydraulic oil than that
in motion.
used in the main hydraulic system. Wet disk
brakes and gears in the front axle require oil with Whenever the rear (bogie) axle differential lock is
specific properties to ensure reduced chatter and engaged a signal (VOLTAGE IN - Curvic Coupling)
ensure proper lubrication of mechanical is sent from the rear axle to the computer control
components. Refer to APPROVED HYDRAULIC system for use in differential lock operation. The
OILS AXLE CIRCUIT in SECTION 3 of THIS program logic contains safeguards to prevent the
MANUAL. rear differential lock from engaging while the
machine is in motion. The curvic coupling signal is
The axle pump draws oil from the axle circuit
also sent independently to the rear differential light
reservoir (front axle) and sends it through the axle
to indicate to the operator that the rear differential
pressure filter to the differential lock/winch
lock is engaged.
freespool manifold. Note that the axle pressure
filter is equipped with a filter bypass. When the Refer also to SECTION 6 of THIS MANUAL for
filter is bypassed (due to a clogged filter or cold complete electrical schematics and more detailed
temperatures) the differential locks will not function information about the computer control system.
and error message appears. Note: This machine is equipped with a 10 minute
When no manifold operated functions are in use oil AUTO-OFF feature which automatically
flows freely through the manifold and out port T1 to deactivates the differential locks after 10 minutes
the axle circuit reservoir (front axle). have passed.
When one or more manifold functions are in use FRONT DIFFERENTIAL LOCK ACTIVATION
the reverse flow valve is closed (activated in NOTES:
tandem with one or more of the manifold functions) The front differential locks can be engaged while
oil is forced to flow over the pressure relief valve to the machine is in motion. It is important to note that
provide pilot oil to the manifold function(s). When the front differential light is controlled by the
a manifold function is activated pilot oil from the electrical system and not by the hydraulic system.
manifold flows to operate the function. The light will illuminate when the joystick
Each solenoid operated pilot valve in the differential switch depressed and not when the
differential locks/winch freespool manifold is differential lock is hydraulically engaged.
operated in tandem with the reverse flow valve by REAR DIFFERENTIAL LOCK ACTIVATION
electrical control signals via the computer control NOTES:
system. When activated pilot oil from the manifold
flows to operate the function. Engaging the rear differential curvic coupling while
the machine is in motion could cause serious
The position of the differential lock selector switch damage. Program logic contains safeguards to
(FRONT/FRONT AND REAR/REAR) sends a prevent the rear differential lock from engaging
signal (VOLTAGE IN - Front Diff Only) to the while the machine is in motion. Whenever the rear
computer control system for use in determining (bogie) axle differential lock is engaged a signal
which differential lock(s) will be activated by the (VOLTAGE IN - Curvic Coupling) is sent from the
differential locks ON/OFF switch. rear axle to the computer control system for use in
When the operator presses the differential locks differential lock operation. The curvic coupling
ON/OFF switch on the joystick a signal (DIGITAL signal is also sent independently to the rear
IN - Diff Lock) is sent to the computer control differential light to indicate to the operator that the
system. The computer control system sends a rear differential lock is engaged.
signal (DIGITAL OUT-Axle Pressure Valve) to the
reverse flow solenoid to provide pressure to the
manifold via the axle pressure relay and to the rear
differential lock solenoid on the manifold. At the
same time a signal (DIGITAL OUT- Front Diff Lock)
is sent to the front differential lock solenoid via the
differential lock relay. If the differential lock
selector switch is in the FRONT AND REAR or
REAR position, the computer control system sends
15.22
Tigercat 635C Skidder Axles and Differential Locks

AXLE/DIFFERENTIAL LOCK CIRCUIT

635C-50 (6350621 TO 6351000)
15.23
Tigercat 635C Skidder Axles and Differential Locks
PRESSURE SETTINGS 4. Start engine.
AXLE PILOT PRESSURE CHECK AND
5. Set engine speed to 2200 rpm.
ADJUSTMENT
6. Activate one of the manifold functions (front
NOTE: Ensure hydraulic oil is at operating
or rear differential locks, winch freespool),
temperature. Refer to HYDRAULIC OIL
pressure reading should be 635 psi (44 Bar)
HEATING PROCEDURE in SECTION 8.
at the 'AXLE' test port.
1. Park machine on level ground, lower grapple
7. Set engine speed to 750 rpm.
and dozer and engage parking brake. Install
articulation lock pin and stop engine. 8. Activate one of the manifold functions,
BELOW RIGHT
pressure reading should be no lower than 600
HAND CAB DOOR psi (41 Bar) at the 'AXLE' test port.
MAIN ACCU AXLE 9. If pressure readings are correct proceed to
step 13.
CHARGE
LM1 RM1 • • • 10. Set engine speed to 2200 rpm.

• • • 11. Replace the relief valve cartridge (non-

adjustable).
TEST PORT COMPARTMENT 12. Repeat steps 5 to 9.
635C-25X BELOW RIGHT CAB DOOR
13. Stop engine.
2. Connect a 0-70 Bar (0-1000 psi) gauge to the 14. Reconnect the front differential lock, rear
'AXLE' test port. differential lock and winch freespool coil
connectors.
15. Remove gauge.
FRONT
DIFFERENTIAL
LOCK SOLENOID

• ••
•• •
REAR
DIFFERENTIAL
LOCK SOLENOID

WINCH
FREESPOOL
SOLENOID

DIFFERENTIAL LOCK/WINCH
FREESPOOL MANIFOLD
635C-32
(6350501 TO 6350530)

REAR
DIFFERENTIAL
LOCK SOLENOID

••
WINCH
FREESPOOL •• ••
SOLENOID

FRONT
DIFFERENTIAL
LOCK SOLENOID

DIFFERENTIAL LOCK/WINCH
FREESPOOL MANIFOLD
630C-255 (6350531 TO 6351000)
3. Disconnect the front differential lock, rear
differential lock and winch freespool (if
equipped) coil connectors from the differential
lock/winch freespool manifold.

15.24
Tigercat 635C Skidder Axles and Differential Locks
FRONT AXLE OIL FILL FRONT AXLE OIL LEVEL CHECK
The 635C is equipped with an axle hydraulic circuit Refer to FRONT AXLE OIL LEVEL CHECK AND AXLE
which is completely separate from all other CIRCUIT FILL in SECTION 3.
hydraulic circuits. The front axle acts as a
AXLE OIL LEVEL FILL (TOP UP
reservoir for the axle hydraulic circuit.
PROCEDURE)
Note: For machines equipped with rear bogie axles
This filling procedure should be used only to top up the
the axle circuit includes the front axle only. Refer
axle hydraulic oil level. Refer to AXLE OIL LEVEL
to REAR (BOGIE) AXLE in this section for
CHECK AND AXLE CIRCUIT FILL in SECTION 3 for
information regarding the rear axles.
complete top up procedure.
Always keep the axle hydraulic circuit filled to the
If front axle has been drained or differential lock
correct level. A low axle hydraulic oil level can
function has been affected by extremely low axle
result in severe damage to the axle pump.
hydraulic oil levels refer to AXLE OIL FILL in THIS
Refer also AXLE CIRCUIT RESERVOIR - FRONT SECTION for a more detailed filling procedure.
AXLE in SECTION 2 of THE OPERATOR'S
AXLE OIL FILL PROCEDURE
MANUAL.
This procedure should be used only if the front axle
Before starting work, read and follow all “servicing
has been drained or if differential lock function has
safety precautions” as listed in SECTION 1 of
been affected by extremely low axle hydraulic oil
THIS MANUAL.
levels.
Refer to APPROVED HYDRAULIC OILS ~ AXLE
If only a top up of the front axle hydraulic oil level is
CIRCUIT in THIS SECTION for a list of approved
required refer to AXLE OIL LEVEL CHECK AND AXLE
hydraulic oils.
CIRCUIT FILL in SECTION 3.
CAPACITIES
CAUTION
For front and rear axle oil fill capacities, refer to the
Note that the 635C skidder has two separate
table: SERVICE AND LUBRICATION in SECTION 3 of
hydraulic systems (the main hydraulic
THIS MANUAL.
system and the axle circuit). These two
hydraulic systems require two different types OIL FILL - AXLES INSTALLED
of hydraulic oil that MUST NOT BE Use one of the following procedures for machines with
INTERCHANGED under any circumstances. front axle in place on the machine.
Always use the correct type of hydraulic oil A) Filling without an oil fill pump.
for the circuit you are filling. Refer to
APPROVED HYDRAULIC OILS in THIS B) Filling with an oil fill pump (external).
SECTION. C) Filling with the machine's axle oil pump.

Perform this procedure only when the axle is cold. If the front axle is being replaced or reinstalled after
removal from the machine in the refer to OIL FILL -
PRIOR TO AXLE REPLACEMENT in THIS SECTION.
An axle fill kit is available for use in performing the
following procedures (Tigercat part number 25300B -
details below).

AXLE FILL KIT Tigercat P/N 25300B

ITEM # QTY DESCRIPTION
MANUAL FILL HOSE
1 1 5/8" ID RUBBER HOSE X 36"
2 1 NIPPLE, 10JIC(F)-5/8"ID BARB BRASS
11 1 HOSE CLAMP
Dispose of all fluids properly. EXTERNAL SUCTION HOSE
8 1 HOSE 16LP 16JIC(45)-16JIC(STR)
9 1 COUPLING REDUCER 12NPT-16NPT BLK IRON
10 1 NIPPLE 12NPT(M)-12 NPT(M) SCH40 16.5" LG
OTHER ITEMS
3 1 UNION 10JIC(M)-08JIC(M)
4 1 CONNECTOR STR 10JIC(M)-06ORB(M)
5 1 UNION 08JIC(M) - 08JIC(M)
6 2 08JIC HEX CAP PLUG
7 1 UNION 16JIC(M)-16JIC(M)
15.25
Tigercat 635C Skidder Axles and Differential Locks
A) FILLING WITHOUT AN OIL FILL PUMP 4. Place a suitable container under the front axle
to catch any oil that overflows during filling.
FRONT AXLE - MANUAL FILL
5. Disconnect the drain line (between front axle
For this part of the procedure you will need a
and bulkhead) at the bulkhead. Cap the
manual fill hose (items 1,2,11) and union (item 3).
bulkhead fitting to avoid contamination of the
1. Park machine on level ground, lower dozer. axle hydraulic circuit.
Engage parking brake. Install articulation lock
6. Connect the manual fill hose to the drain line
pin and stop engine.
and insert the spout of a clean funnel into the
2. Remove any debris and clean the area end.
around any port plugs removed during this
7. Fill the front axle until the oil level reaches the
operation to prevent contamination of the axle
oil fill level plug (1/2).
hydraulic circuit.
8. Replace the oil fill level plug.
9. Reconnect all hoses disconnected during this
procedure. Care should be taken to ensure
all hoses and fittings are kept clean to avoid
contamination of the hydraulic circuit.

• ••
NORMAL FILL
LEVEL CHECK
PLUGS (1/2)

630C-221
FRONT AXLE FILL LEVEL
3. Remove the front axle oil fill level plug (1/2).

NOTE 630C
SHOWN SOME
HOSES SHOWN
ARE NOT USED
ON 635C
MODEL

DRAIN LINE
(TO FRONT
AXLE DRAIN
PORT)

630C-235 AXLE HOSE BULKHEAD

15.26
Tigercat 635C Skidder Axles and Differential Locks
B) FILLING WITH AN OIL FILL PUMP
(EXTERNAL)
It is recommended that the rating of the
external mechanical pump not exceed 5
gallons/minute. Adjustable flow is also
recommended.
Additional fittings will be required to adapt to the
hose size of the pump.
•• •
FRONT AXLE - OIL FILL PUMP NORMAL FILL
LEVEL CHECK
1. Park machine on level ground, lower dozer. PLUGS (1/2)
Engage parking brake. Install articulation lock
pin and stop engine. FRONT AXLE FILL LEVEL
630C-221

2. Remove any debris and clean the area 7. Pump oil into the front axle until the oil level
around any port plugs removed during this reaches the oil fill level plug (1/2).
operation to prevent contamination of the axle
hydraulic circuit. 8. Replace the oil fill level plug.

3. Remove the front axle oil fill level plug (1/2). 9. Reconnect all hoses disconnected during this
procedure. Care should be taken to ensure
4. Place a suitable container under the front axle all hoses and fittings are kept clean to avoid
to catch any oil that overflows during filling. contamination of the hydraulic circuit.
5. Disconnect the drain line (between front axle
and bulkhead) at the bulkhead as shown.
Cap the bulkhead fitting to avoid
contamination of the axle hydraulic circuit.
6. Connect the line from the oil fill pump to the
drain line.

NOTE 630C
SHOWN SOME
HOSES SHOWN
ARE NOT USED
ON 635C
MODEL

DRAIN LINE
(TO FRONT
AXLE DRAIN
PORT)

••

630C-235 AXLE HOSE BULKHEAD

15.27
Tigercat 635C Skidder Axles and Differential Locks
C) FILLING WITH THE MACHINE'S AXLE
OIL PUMP

FRONT AXLE
SUCTION HOSE
CONNECTION

NOTE 630C
SHOWN SOME
HOSES SHOWN
••
ARE NOT USED
ON 635C
MODEL

630C-220 FRONT AXLE SUCTION LINE

FRONT AXLE - AXLE OIL PUMP

For this part of the procedure you will need a
external suction hose (items 8,9,10), two unions
(item 5 & 7) and two caps (item 6).
1. Park machine on level ground, lower dozer.
Engage parking brake. Install articulation lock
pin and stop engine.
2. Remove any debris and clean the area
around any port plugs and hoses removed
during this operation to prevent contamination
of the axle hydraulic circuit. Care should be
taken to ensure that all hoses and connectors
remain clean throughout the procedure.
3. Remove the front axle oil fill level plug (1/2).
4. Place a suitable container under the front axle
to catch any oil that overflows during filling.
5. Disconnect the suction line at the bulkhead
fitting. Cap the fitting at the bulkhead.
Connect the external suction hose to the
suction line.
6. Place the free end of the external suction
hose into a container of clean axle hydraulic
oil. This container should contain more than
enough oil to fill front axle to avoid cavitation
damage to the axle pump.
7. With the aid of an assistant, start and run the
engine until the oil level reaches the oil fill
level plug (1/2).
8. Stop the engine.
9. Replace the oil fill level plug.

15.28
Tigercat 635C Skidder Axles and Differential Locks
OIL FILL - PRIOR TO AXLE REPLACEMENT 6. Reconnect the suction line.
1. Prior to installation of front: 7. Verify that the machine is sitting level.
8. Start the engine and run for 1 1/2 minutes to
FRONT AXLE 3/4 FILL charge the system.
LEVEL PLUGS,
PRIOR TO
INSTALLATION ONLY 9. Engage the front differential locks.
•• •• 10. Check the differential lock manifold pilot
pressure at the 'AXLE' test port, verifying that
full pressure (635 psi) is present. Refer also
to PRESSURE SETTINGS~ AXLE PILOT
• •• PRESSURE CHECK AND ADJUSTMENT in
THIS SECTION. Troubleshoot if pressure is
NORMAL FILL
LEVEL CHECK not correct.
PLUGS (1/2)
11. Run the machine with both front and rear
differential locks for 5 more minutes.
630C-221
FRONT AXLE FILL LEVEL
12. Shut off the front differential lock and run for
Prefill the front axle is filled to the 3/4 level another 10 minutes only the rear differential
plug, as shown. lock engaged.

2. Allow front axle to sit for 2 hours. Recheck fill 13. Disengage the rear differential lock and stop
levels and top up as required. the engine.

3. Install the front axle.

FRONT AXLE
SUCTION HOSE
CONNECTION

NOTE 630C
SHOWN SOME
HOSES SHOWN
•
ARE NOT USED
ON 635C
MODEL

630C-220 FRONT AXLE SUCTION LINE

4. Disconnect the axle suction line as shown.

FILL SUCTION
LINE WITH AS
MUCH OIL AS
POSSIBLE

••

630C-179 FILL SUCTION LINE

5. Using a funnel fill the suction line with as much

oil as possible.

15.29
Tigercat 635C Skidder Axles and Differential Locks
FRONT AXLE OSCILLATION SHIM 3. Set a dial indicator against the spiral bevel
CHECK AND ADJUSTMENT input pinion shaft on the input end of the axle.
1. The axle must be securely bolted to the
chassis through the axle supports (front and
back). Torque all axle mounting bolts. Refer
to TORQUE CHART in SECTION 3 of THIS
MANUAL.
2. Temporarily remove the two grease hoses
from the axle pivot to prevent grease
pressure from affecting the set-up. Plug hose
ends to avoid contamination.

AXLE-05 SET DIAL INDICATOR

4. Using a long pry bar between the chassis and

the axle housing pry the axle backward. It
may be necessary to tip the axle from side to
side to position the axle fully back for a proper
reading.

AXLE-13 REMOVE GREASE HOSE

AXLE-06 USE LONG PRY BAR

AXLE-17 REMOVE GREASE HOSE

BETWEEN CHASSIS AND

AXLE-07 AXLE HOUSING

15.30
Tigercat 635C Skidder Axles and Differential Locks
10. Remove the outer cover plate. Carefully
remove the center pivot cover plate from the
axle (6 bolts). Care must be taken to ensure
that the thrust washer (a round perforated disk)
and shims do not fall.

AXLE-10 TIP AXLE SIDE TO SIDE

AXLE-12 REMOVE CENTER PIVOT COVER

SHIMS

•• THRUST
WASHER
AXLE-11 TIP AXLE SIDE TO SIDE

5. Zero the dial indicator.

••
6. Using a long pry bar between the chassis and
the axle housing pry the axle forward. It may
be necessary to tip the axle from side to side
AXLE-16 THRUST WASHER AND SHIMS
to position the axle fully forward for a proper
reading. 11. If the measurement was below .004” ADD
shims to get the required range. A 0.010” shim
7. Read the dial indicator. Axle movement
will change the reading by 0.010”. Stock shims
should be .004” to .014”. Check the reading
are 0.010” and 0.040” thick.
twice by repeating steps 4 through 7.
12. If the measurement was above .014” REMOVE
8. If the reading is within the required range go
SHIMS to correct the reading. A 0.010” shim
to step 16.
will change the reading by 0.010”. Stock shims
9. If the reading is not within the required range are 0.010” and 0.040” thick.
follow steps 10 through 15 to adjust.
13. Replace the thrust washer.
14. Replace the center pivot front cover plate.
Make sure that the thrust washer and shims do
not slide out of place and become damaged.
Torque cover bolts (6) to 80 lbf-ft.
15. Repeat steps 4 to 7 to check the adjustment
again. This reading should be checked twice.
16. Reinstall grease hoses in the axle pivot and
add grease until back pressure is felt.

15.31
Tigercat 635C Skidder Axles and Differential Locks
REAR (BOGIE) AXLE DIFFERENTIAL AND BOGIE HOUSINGS
(6350501 TO 6350534) (1 FILLING POINT)
The bogie axle has 5 separate oil reservoirs. 1. Note that the bogie housings must be level to
Each reservoir must be filled separately to get drain and refill them properly.
the proper level of lubrication in the bogie axle.
2. Before draining the oil from the bogie
Refer to SERVICE AND LUBRICATION POINTS housings, the axle should sit for at least 30
CHART in SECTION 3 for differential oil capacity minutes so that contaminants in the oil can
and recommended gear oils. settle in the oil pan.
DRAINING AND REFILLING 3. Remove the DIFFERENTIAL AND BOGIE
BOGIE AXLE HOUSINGS FILL/LEVEL PLUG.
• Park the machine on level ground. 4. Remove the BOGIE HOUSING DRAIN
• Stop the engine and engage parking brake.. PLUGS (2 per housing – lower plugs) and
drain the oil into a suitable container for
• The bogie axle must be level in order to drain disposal.
and refill it properly.
5. Remove the DIFFERENTIAL DRAIN PLUG
• Note that it will be necessary to reposition the and drain the oil into a suitable container for
wheel hubs when draining and refilling the disposal.
planetary drives.
6. Clean any fillings from the five drain plugs.
• The oil must be warm before draining and
refilling. 7. Replace the DIFFERENTIAL DRAIN PLUG
and the BOGIE HOUSING DRAIN PLUGS (2
• Clean around all fill, level and drain plugs per housing – lower plugs)
before removing them.

••
DIFFERENTIAL AND
BOGIE HOUSINGS
FILL/LEVEL PLUG
• (1 PLACE)

PLANETARY
FILL PLUG
(4 PLACES)
BOGIE HOUSING
DRAIN PLUG
(4 PLACES - LOWER) ••
PLANETARY
LEVEL/DRAIN
PLUG
(4 PLACES) • WHEEL HUB IN
PLANETARY
FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

635C-18 (6350501 TO 6350534)

15.32
Tigercat 635C Skidder Axles and Differential Locks
8. Refill the differential and bogie housings with INSPECTION OF BOGIE INPUT
new oil until the level reaches the bottom of GEAR/SHAFT ASSEMBLIES
the DIFFERENTIAL AND BOGIE HOUSINGS (6350501 TO 6350534)
FILL/LEVEL PLUG.
Complete information not available at time of
Refer to SERVICE AND LUBRICATION printing.
POINTS CHART in SECTION 3 for
differential oil capacity and recommended For service interval, materials and procedures
gear oils. refer to PSB 1594 or contact Tigercat Customer
Service.
9. Replace the DIFFERENTIAL AND BOGIE
HOUSINGS FILL/LEVEL PLUG.
PLANETARY DRIVES (4 FILLING POINTS)
10. Position the wheel hub for draining the
planetary, with the drain plug in the lowest
possible position as shown.
11. Remove the PLANETARY FILL PLUG.
12. Remove the PLANETARY DRAIN/LEVEL
PLUG and drain the oil into a suitable
container for disposal.
13. Reposition the wheel hub for filling the
planetary, with the PLANETARY DRAIN/
LEVEL PLUG at 9 o’clock and the fill plug at 1
o’clock as shown.
14. Refill the planetary with new oil until the level
reaches the bottom of the PLANETARY
DRAIN/LEVEL PLUG. (Note: To get a correct
filling level the wheel hub must be in the
planetary fill position as shown.)
Refer to SERVICE AND LUBRICATION
POINTS CHART in SECTION 3 for
differential oil capacity and recommended
gear oils.
15. Repeat steps 10 to 14 for each of the four
planetary drives.
AFTER DRAINING AND REFILLING
16. Check all drain, fill and level plugs for leaks.

15.33
Tigercat 635C Skidder Axles and Differential Locks
REAR (BOGIE) AXLE DRAINING AND REFILLING
(6350535 TO 6351000) BOGIE AXLE
The bogie axle oil reservoirs (differential, bogie • Park the machine on level ground.
housings and planetaries are all connected and • Stop the engine and engage parking brake.
can be are at 3 locations to get the proper level
of lubrication in the bogie axle. • The bogie axle must be level in order to drain
and refill it properly.
Refer to SERVICE AND LUBRICATION POINTS
CHART in SECTION 3 for differential oil capacity • Note that it will be necessary to reposition the
and recommended gear oils. wheel hubs when draining and refilling the
planetary drives.
• The oil must be warm before draining and
refilling.
• Clean around all fill, level and drain plugs
before removing them.

•
DIFFERENTIAL
••
FILL/LEVEL PLUG
(1 PLACE)

•• BOGIE HOUSINGS
FILL/LEVEL PLUG
(2 PLACES)

BOGIE HOUSING
DRAIN PLUG
(4 PLACES )

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

625C-94 (6350535 TO 6351000)

15.34
Tigercat 635C Skidder Axles and Differential Locks
BOGIE AXLE FILL (3 FILLING POINTS)
1. Note that the bogie housings must be level to
drain and refill them properly.
2. Before draining the oil from the bogie
housings, the axle should sit for at least 30
minutes so that contaminants in the oil can
settle in the oil pan.
3. Remove the DIFFERENTIAL FILL/LEVEL
PLUG and the BOGIE HOUSINGS FILL/
LEVEL PLUGS (1 per housing).
4. Remove the BOGIE HOUSING DRAIN
PLUGS (2 per housing) and drain the oil into
a suitable container for disposal.
5. Remove the DIFFERENTIAL DRAIN PLUG
and drain the oil into a suitable container for
disposal.
6. Clean any fillings from the five drain plugs.
7. Replace the DIFFERENTIAL DRAIN PLUG
and the BOGIE HOUSING DRAIN PLUGS (2
per housing – lower plugs)
8. Refill the differential and bogie housings with
new oil until the level reaches the bottom of
the FILL/LEVEL PLUGS.
Refer to SERVICE AND LUBRICATION
POINTS CHART in SECTION 3 for
differential oil capacity and recommended
gear oils.
9. Replace the DIFFERENTIAL FILL/LEVEL
PLUG and the BOGIE HOUSINGS FILL/
LEVEL PLUGS.
10. Check all drain, fill and level plugs for leaks.
11. Run axle for at least 10 minutes to remove
trapped air in confined spaces.
12. Recheck oil level and top up as necessary.

15.35
Tigercat 635C Skidder Axles and Differential Locks
BOGIE SLEW BEARING INSTALLATION OK RED PAINT
STAMP MARK
(6350501 TO 6351000) ••••
1. Ensure the mating surfaces on the chassis •
•
and the slew bearing are free of debris and
handling damage.
2. Gather the necessary seals – 1 large o-ring
and 1 large green wiper.
STAR/CROSSING
PATTERN •• •
3. Apply a light coat of grease on the mounting
spigot on the chassis.
4. Install the o-ring over the spigot. Be careful to
eliminate any twist in the o-ring, as this may
•
cause the o-ring to move out of position. 635C-42 BOLT TIGHTENING PATTERN
7. Mount the slew bearing on the spigot of the
chassis with the markings (red paint mark and
OK
STAMP
• RED PAINT MARK
(THIS SIDE FACING AWAY OK stamps) in the uppermost position.
FROM THE CHASSIS.
NOTE: Because of the bolt pattern, the
markings may need be positioned slightly to
the front or rear instead of perfectly vertical.
•• This is acceptable, but it is important to mount
both the left and right bearings with the
•• markings shifted in the same direction (both
to the front of the chassis, or both to the rear).
8. Using Blue Loctite 242, insert the bolts
(M20x2 - QTY 24) in a star/crossing pattern.
Care should be taken to keep the bearing
635C-43 BEARING ORIENTATION INDICATOR positioned straight on the spigot to eliminate
misalignment before torquing.
5. Identify the face of the bearing inner race 9. Torque bolts in a star/crossing pattern to
which has been marked by the manufacturer 560 N-m (415 lbf-ft).
with a large red paint mark at one point and
two OK stamps (on later machines). 10. Locate the two opposing grease points and
the two threaded plugs on the outside
The slew bearing will be installed with marked diameter of the bearing.
face of the inner race facing out (away from
the chassis). NOTE: The grease points and plugs may be
covered by plastic caps. If so, carefully
remove the caps and keep them for
reinstallation.
11. Remove the threaded plugs.
12. Pump grease into the two grease ports until
fresh grease exits the opened ports.
13. Re-plug the ports.
14. Rotate the bearing to ensure smooth turning.
635C-44 WIIPER SEAL ORIENTATION 15. If applicable, replace or re-install the plastic
caps to prevent the grease nipples and purge
6. The green wiper seal is installed on the
ports from being packed with dirt.
unmarked face of the slews bearing (the side
that will be against the chassis when 16. Repeat steps 1 to 15 for the opposite side.
installed).
17. Wait at least 1 hour to allow the Loctite to
With a light coat of grease, install the green cure before filling the bogie axle with oil.
wiper seal in its channel. The large lip of the
seal faces outward to allow outward purging
of barrier grease as shown.
15.36
Tigercat 635C Skidder Axles and Differential Locks

BRONZE
SPACER

•• SHIMS

SPRING
• PIN

COVER •
O-RING

SOCKET HEAD
CAPSCREW
RETAINING RING
(* SPACER NOT SHOWN)
••
(M10X1.5) LEFT AXLE SHAFT
BEARING RIGHT AXLE
• INPUT
SHAFT

•• • GEAR
BEARING SEAL RING
•• •• ••
•
•• SOCKET HEAD

DOWEL PIN • CAPSCREW

(M18X2)

•• ••
•• ••
••
•
RIGHT HAND
BOGIE BOLT
ASSEMBLY (M20X2)

SLEWING
BEARING

GREEN
WIPER SEAL
O-RING

LEFT HAND
BOGIE
ASSEMBLY

BOGIE AXLE ASSEMBLY (6350535 TO 6351000)

15.37
Tigercat 635C Skidder Axles and Differential Locks
BOGIE ASSEMBLY INSTALLATION 5. EARLIER DESIGN (6350501 TO 6350534)
(6350501 TO 6351000) Using Blue Loctite 242, insert the socket cap
1. Ensure the mounting surfaces on both the screws (M18x2 -14mm hex key to tighten)
slew bearing and bogie assembly are clean into the 20 through holes to the inside of the
and free of damage. slew bearing.
If cleaning is necessary, prevent debris from Using Blue Loctite 242, insert the socket cap
falling into either the bogie assembly or screws (M18x2) and washers into the 4 holes
bearing. In addition ensure threads in on the outside of the bogie assembly.
housing (both for the slew bearing and the 6. LATER DESIGN (6350535 TO 6351000)
bearing cap on the opposite side) are clean
and free of grease, oil or other debris. Using Loctite 242, insert the socket head cap
screws (M18x2 - 14mm hex key to tighten)
into the 24 through holes to the inside of the
BALL BEARING slew bearing.
INSERTION CAP
TO THE TOP 7. Torque the cap screws evenly in a star/
crossing pattern to 420 N-m (310 lbf-ft). Use
a torque bar and a ¾” drive socket with a
•• shortened M14 stub.
8. If the shafts are not being installed
immediately, cover the opening in the bogie
assembly to prevent accumulation of debris
inside the housing.
9. Repeat steps 1 to 8 for the opposite side.
635C-47 SLEW BEARING RACE ORIENTATION
10. Wait at least 1 hour to allow the Loctite to
Also ensure that the outer slew bearing race cure before filling the bogie axle with oil.
is positioned in the correct orientation, with
the ball bearing insertion cap to the top as
shown.

635C-45 SEAL ORIENTATION

2. Insert the oil seal in the cavity of bogie CHAIN LOCATION FOR BALANCED LIFT
635C-46 EARLIER DESIGN (6350501 TO 6350534)
assembly as shown with a light coat of
grease in the cavity and on the lip of the seal.
3. Install the two straight dowel pins into the
bogie housing, tapping lightly on the end to
ensure full seating in the hole.
4. Use chains positioned as shown for a
balanced lift of the bogie assembly.
Mount the bogie assembly using the dowel
pins as a guide. Position the assembly tight
to the slew bearing, ensuring that the oil seal
does not move out of the correct position. CHAIN LOCATION FOR BALANCED LIFT
635C-48 LATER DESIGN (6350535 TO 6351000)
15.38
Tigercat 635C Skidder Axles and Differential Locks

BRONZE
SPACER

• SHIMS
SPRING
PIN
••
RIGHT AXLE
COVER
SHAFT ••
••
SOCKET HEAD LEFT AXLE SHAFT
CAPSCREW (M8)
SOCKET HEAD
CAPSCREW
•• (M18)

• •
••
SOCKET HEAD
CAPSCREW
BOLT (M18)
(M20)
•
•• •• •• •

RIGHT HAND
BOGIE
ASSEMBLY SLEWING
BEARING

GREEN
WIPER SEAL

O-RING

LEFT HAND
BOGIE
ASSEMBLY

BOGIE AXLE ASSEMBLY (EARLIER DESIGN 6350501 TO 6350534)

15.39
Tigercat 635C Skidder Axles and Differential Locks
BOGIE AXLE SHAFT INSTALLATION VIEW OF OIL
(EARLIER DESIGN 6350501 TO 6350534) CHANNEL
WITHOUT SHAFT
INSTALLING THE RH SIDE (LONG) SHAFT
ASSEMBLY.
••

635C-49

4. Apply grease to the sealing surface and

spline on the shaft.
5. Apply a small bead of flange sealant (Loctite
635C-51 RH SHAFT ASSEMBLY 518 or equivalent) to the bearing cap flange to
1. Identify the correct vertical alignment of the seal it against the bogie housing.
bearing cap of the RH shaft assembly. There
6. Install the RH shaft assembly into the bogie in
should be a machined flat and stamped
the orientation identified in step 1. Be careful
dimple indicating which way is up, as shown
not to damage the shaft seal lips if present.
above.
7. Install bolts (M10x1.5) with blue Loctite 242
If the stamped dimple is not visible, examine
and torque bolts evenly to 67 N-m (49.5 lbf-ft).
the inside of the bearing cap to find the oil
channel (shown in figures 635C-49 and 635C- DETERMINE SHAFT SPACER STACK LENGTH
50 below) which needs to be in the “up” 8. Stack the bronze spacer and selected shims
position and mark the outer face for to measure a total length of 2.375 in(60 mm)
installation. for use as a setup spacer. Note that it may
2. Ensure the inside of the bearing cap flange be necessary to use some shims from shaft
and mating face on the bogie housing are being replaced or suitable washers to acheive
clean and free of any contaminant. a total length of 2.375 in(60 mm)
Insert the spring pin into the hole on the end
of LH (short) shaft and slide the selected
shims over the spring pin.
Install the bronze spacer on the spring pin
and seat firmly against the shim stack. Use a
soft material against the bronze spacer to
avoid damage to it during installation.
NOTE: Remove any burs on spacers so that
the shim stack sits squarely against the axle.
9. Apply grease to the sealing surface and
spline on the shaft. Insert the LH shaft
assembly into the bogie. Be careful not to
635C-50 damage the shaft seal lips if present.

3. Liberally lubricate the shaft bearings with gear 10. Using two of the bearing cap bolts (M10) in
oil through the oil channel and rotate the cap opposing locations, take up the slack in the
to spread the oil around. Repeat to ensure shaft bearings by turning the bolts in snug but
proper lubrication and prevent damage to not fully torqued, ensuring there is no
components. looseness between the cap and the shaft.

15.40
Tigercat 635C Skidder Axles and Differential Locks
SOCKET HEAD COVER
CAPSCREW
(M10X1.5)

•• RIGHT AXLE
SHAFT
•• RING SEAL

BEARINGS

••
••
••
••

•
••
SEAL RING

DOWEL PIN

BOGIE AXLE ASSEMBLY (EARLIER DESIGN 6350501 TO 6350534)

15.41
Tigercat 635C Skidder Axles and Differential Locks
11. Using the 2 jacking holes, turn two bearing 20. Insert the left hand shaft with spacer stack
cap bolts through the bearing cap flange until and solder into the bogie. Be careful not to
they just touch the mating surface on the damage the shaft seal lips if present or to
bogie housing. These bolts are used to crush the solder against anything except the
measure the gap. end of the other shaft.
12. Remove the LH shaft from the bogie. NOTE: The bearing cap flange should almost,
13. Remove the bronze spacer and shims. but not quite meet the mating surface on the
bogie housing before inserting and tightening
14. Measure the distance that was between the caps screws.
bearing cap flange and the mating surface by
measuring the protrusion of the bolts through 21. Using 4 evenly spaced bolts, tighten down the
the jacking holes. Record the gap bearing cap evenly in an X pattern so that the
measurement. solder is compressed to indicate the end play
between the spacer and the RH shaft when
15. Calculate the stack length required using the the solder is removed.
gap measurement recorded in step 14.
22. Remove the 4 bolts and then the LH shaft
LSTACK = 2.375 in - gap in - .02 in from the bogie.
(LSTACK = 60 mm - gap mm - 0.5 mm) 23. Remove the solder wire from the spacer block
16. Stack the bronze spacer and selected shims and measure the thickness at each of the four
to measure a total length of LSTACK as points of where it was compressed.
calculated in step 15. Note the largest measurement, Pmax.
17. Install the bronze spacer on the spring pin Note the smallest measurement, Pmin.
and seat firmly against the shim stack. Use a
soft material against the bronze spacer to 24. If Pmax - Pmin > 0.010 in (0.2mm)
avoid damage to it during installation. Ensure Adjust the straightness of the spacer stack
the face of the spacer is as parallel as and proceed to step 19 to repeat the testing.
possible to the end face of the shaft.
25. If Pmax >0.050 in (1.25mm)
TESTING THE SHAFT SPACER STACK
Adjust the spacer stack by adding shims as
18. Ensure the inside of the bearing cap flange required and proceed to step 19 to repeat the
and mating face on the bogie housing are testing.
clean, free of any contaminant.
26. If Pmin < 0.030 in (0.75 mm)
ROSIN CORE SOLDER Adjust the spacer stack by removing shims as
DIAMETER 1/16 IN (1.5 mm)
required stack and proceed to step 19 to
repeat the testing.
27. Both Pmin and Pmax measurements should
be 0.030 - 0.050 in (0.75-1.25 mm).
This is the correct end play reading.
If not correct proceed to step 19 to repeat the
testing until the measurements are correct.

635C-52 TESTING THE SHAFT SPACER STACK

19. Attach 2 short lengths of rosin core solder

with wire diameter ~ 1/16 in (1.5 mm) to the
end of the spacer block, securing with
electrical tape as shown.

15.42
Tigercat 635C Skidder Axles and Differential Locks
INSTALLING THE LH SIDE (SHORT) SHAFT
ASSEMBLY.
28. As previously done for the RH shaft, identify
the correct vertical alignment of the bearing
cap of the LH shaft assembly and mark it on
the outer face if not already marked.
29. Ensure the inside of the bearing cap flange
and mating face on the bogie housing are
clean, free of any contaminant.

635C-50

30. Liberally lubricate the shaft bearings with gear

oil through the oil channel and rotate the cap
to spread the oil around. Repeat to ensure
proper lubrication and prevent damage to
components.
31. Apply grease to the sealing surface and
spline on the shaft.
32. Apply a small bead of flange sealant (Loctite
518 or equivalent) to the bearing cap flange to
seal it against the bogie housing.
33. Install the LH shaft assembly into the bogie in
the orientation identified in step 28. Be
careful not to damage the shaft seal lips if
present.
34. Install bolts (M10x1.5) with blue Loctite 242
and torque bolts evenly to 67 N-m (49.5 lbf-ft).

15.43
Tigercat 635C Skidder Axles and Differential Locks
BOGIE AXLE SHAFT INSTALLATION Record the measured value.
(LATER DESIGN 6350535 TO 6351000) 13. The final end play reading should be
1. Remove the input gear covers and the the input .050-.080 in (1.25-2.03 mm).
gears on left and right the bogie assemblies. Calculate the stack length of additional shims
2. Install the right axle shaft in the right bogie needed to obtain this reading.
assembly. Ensure correct shaft orientation with For example:
the longest spline length into the differential.
If the measured value is .100 in (2.54 mm)
3. Install the right input gear. If required, install the
shaft spacer and retaining ring in the input gear. Additional shims required should measure
.020 - .050 in (.51 - 1.29 mm) to achieve
4. Apply a small bead of flange sealant (Loctite the correct final end play reading of
518 or equivalent) around the outermost .050-.080 in (1.25-2.03 mm).
perimeter of the input gear cover recess in the
right bogie housing. 14. Select the appropriate shims to obtain a shim
stack length equal to the value determined in
5. Install the o-ring on the right input gear cover. step 13.
Wet the entire o-ring surface with gear oil.
15. Remove left input gear and the left axle shaft.
6. Re-install the right input gear cover. Apply Blue
Loctite 242 to the bolts (M10x1.5 - QTY 6) and Remove the bronze spacer and install the
torque bolts to 67 N-m (49.5 lbf-ft). additional shims on the spring pin.

7. Stack the bronze spacer and selected shims to 16. Install the bronze spacer on the spring pin
measure a total length of 2 in (51 mm) for use and seat firmly against the shim stack. Use a
as a setup spacer. soft material against the bronze spacer to
avoid damage to it during installation.
Insert the spring pin into the hole on the end of
left axle shaft and slide the selected shims over 17. Reinstall the left axle shaft with the bronze
the spring pin. spacer towards the right axle shaft.

Install the bronze spacer on the spring pin and 18. Reinstall the left input gear.
seat firmly against the shim stack. Use a soft 19. Using a pry bar or similar tool apply a slight
material against the bronze spacer to avoid axial force to the left input gear to ensure
damage to it during installation. accurate measurements are taken in the next
NOTE: Remove any burs on spacers so that step.
the shim stack sits squarely against the axle. 20. Place a dial indicator onto the end of the input
8. Insert the left axle shaft with the set-up spacer shaft to measure end play.
facing the right axle shaft. 21. Use the M12 bolt as a handle and move the
A reasonable amount of force should be applied left axle shaft back and forth axially to read
axially to the left shaft (for example a moderate the actual shaft endplay.
blow with a rubber mallet) to ensure all The final end play reading should be .050-
components are seated firmly. .080 in (1.25-2.03 mm).
9. Install the left input gear. If required, insert the If the reading is not correct record the
left shaft spacer and retaining ring in the left maximum measured value and repeat steps
input gear and install the gear. 13 to 21.
10. Insert a long M12 bolt into the threaded end of 22. Apply a small bead of flange sealant (Loctite
the left axle shaft. 518 or equivalent) around the outermost
11. Using a pry bar or similar tool apply a slight perimeter of the input gear cover recess in
axial force to the left input gear to ensure the left bogie housing..
accurate measurements are taken in the next 23. Install the o-ring on the left input gear cover.
step. Wet the entire o-ring surface with gear oil.
12. Place a dial indicator onto the end of the input 24. Re-install the left input gear cover. Apply Blue
shaft. Using the M12 bolt as a handle, pull the Loctite 242 to the bolts (M10x1.5 - QTY 6)
shaft until it contacts the retaining ring. Note the and torque bolts to 67 N-m (49.5 lbf-ft).
movement on the dial indicator this movement
is the end play reading.
15.44
Tigercat 635C Skidder Axles and Differential Locks
SLEW BEARING LUBRICATION -
BOGIE AXLES
The slew bearing has a lifetime lubrication in the
raceway grease chamber and needs no service.
The only service work is the replacement of soiled
grease in pre-chamber (buffer chamber).

BOGIE 2

buffer grease
chamber Then open the opposite outlet plug (also pos. 92
covered with white plastic cap).
Grease with a hand grease gun, at both grease
nipples per side, until grease squeezes out thumb
wide from the outlet opening (pos. 92). Then close
this outlet hole with plug and cap.
BOGIE 1 When grease squeezes out from the gap, the gap
Clean the area around the grease nipples and has sealed itself with grease all the way around the
outlet plugs (pos. 90/92). circumference. Leave the excess grease built up to
protect against dirt.
Cover the grease nipples with plastic caps.

BOGIE 3

Open outlet plug, first the one on side A (pos. 92;

covered with white plastic cap).
Fill at both grease nipples per side (pos. 90;
covered with white plastic caps) standard grease.
Lubricate with hand grease gun until grease
squeezes out with thumb wide from the outlet
opening (pos. 92). Then close this outlet hole with
plug and cap.

15.45
Tigercat 635C Skidder Axles and Differential Locks
WHEEL INSTALLATION REAR AXLE WHEEL INSTALLATION
Note: All wheel installation joints and surfaces Each planetary wheel has quantity 23 of M22
should be clean free of paint, grease and x 1.5 wheel bolts.
oil etc. Use grade 8 bolts, hardened
• Place wheel assemblies on the planetary
washers and standard torque practices.
wheel hubs.
FRONT AXLE WHEEL INSTALLATION
• Place clamping ring on the wheel studs.
• Use tapered assembly studs to help with
• Install nuts and washers by hand to ensure
wheel installation. Two or thee studs can be
nuts are not cross threaded.
used on each side.
• Torque the nuts to 800 Nm (590 lbf/ft).

2.17"
MIN. FULL
IMPORTANT
THREAD .79"
.406" DRILL If a power wrench is used, be sure that the
.06" X 45°
wheel bolts are first hand-engaged to prevent
7/8"-14 UNC
THREAD stripping. Operate the wrench slowly to
20°
prevent damage to the threads.

2.64"

3.41"

AXL-WHL TAPERED ASSEMBLY STUD 7/8"

The tapered assembly stud shown can be

fabricated to aid in wheel installation on an
axle flange.
• Place wheel on wheel installation studs.
• Place clamping ring on the wheel installation
studs.
• Install wheel bolts and washers by hand to
ensure bolts are not cross threaded. Use only
wheel bolts with thread size 7/8”-UNC for all
front axles.
• Remove assembly studs and install the
remaining bolts.
• Torque the 7/8” – UNC bolts to 500-550 lbf/ft
(680-745 Nm).

15.46