Cat® 564-574 Forwarder

Training
Cat® 564-74 Forwarder Training Agenda:
Accident / Incident Reporting
Safety
Maintenance
Oil Supply & Cooling
Hydraulic System
Brake System
Hydraulic Specifications & Test Procedures
Electrical System
Transmission
Torque Converter
Axles
IQAN Control System
 Cat® 564-74 Forwarder

• Insert picture
 Accident / Incident Reporting

Secure all preliminary information

Contact your immediate supervisor
Completely fill out Required Report
Prompt reporting of Accidents/Incidents in
a timely fashion is required
Safety
Safety
Safety
Safety
Safety
Safety
Safety
Safety
Safety
 Serial Number Locations

Most Major
Components
Have Their
Center Joint SN
Own Serial
Machine SN BOGIE Axle SN
Number
Machine SN

Machine SN
Front Axle SN
Scheduled Maintenance
 Scheduled Maintenance
When adding
hydraulic oil to
the hydraulic
system use the
electric fill
pump to pump
oil through the
hydraulic
filters.
New oil may be
cleaned only to
a particulate
size of 25
microns
 Scheduled Maintenance

Positioned for Maintenance or Service

 Scheduled Maintenance

LUBRICATION NOTICE
Listed maintenance intervals are for normal
operating conditions. When greasing fittings, if
grease is not forced out of bushing ends with
recommended shots, increase number of shots
used until grease is forced out.
If grease can not be forced out check for blocked
passageways.
 BATTERY DISCONNECT SWITCH

Caution
To prevent DAMAGE to the engine ECM,
wait 30 seconds after engine shut down
before turning off the

Master Disconnect Switch

 Component Terminology
Forwarder Right Side View
Oil Supply & Cooling
 Hydraulic Pump

Hydraulic pump is located to the right side of the torque converter.

Tilt Cab for access.
Hydraulic Cooling
Oil Cooler has
internal By-pass

• Make up check
valves prevent
reverse flow when
pump is at
Check Valves
65 - PSI minimum stroke.
• Provides make –up
back pressure for
the anti – cavitation
check valves.
Hydraulic Cooling

• The de-stroke solenoid

valve holds the main
hydraulic pump at
minimum displacement
when starting the engine
 Hydraulic Tank

Note: 25 psi
= 1.72 bar

Note: 250 deg F.

= 120 deg. C.
 Hydraulic Oil Reservoir

Any one of these issues will activate an alarm in

the cab
Low oil level
Oil Temperature above 190 deg. F. = 90.6 deg. C.
Oil Filter by-pass 25 PSI Differential pressure = 1.72 bar
Hydraulic Oil Fill Pump

• The hydraulic oil fill

pump is protected by
a 10 amp circuit
breaker.
• A 75 amp relay is
mounted between the
pump & switched
power circuit.
Hydraulic System
Main Hydraulic Pump
Main Hydraulic Pump

Pilot control valve – pump regulator

Load sense controller assembly - standby
Main Hydraulic Pump
Main Hydraulic Pump
Main Control Valve
Main Control Valve
Main Control Valve
Control Valve Pressure Settings
Pilot Supply
 Main Control Valve
Valve Section - Neutral Position Valve solenoids

Pressure Limiter Port reliefs – non adjustable

Pilot pressure from

valve solenoids

Compensator spring & spool

Inlet flow from hydraulic pump
 Main Control Valve
Valve Activated - Pressure to A port, B port return to hydraulic tank

A port function pressure

is also ported to the
pressurel limiter for A
port

Pilot pressure
from the valve
solenoid39shifts
the valve spool
 Main Control Valve
Valve Activated - Pressure to B port, A port return to hydraulic tank
 Control Valve Spool Configuration
PLUG PLUG

“X” Configuration – all spools except swing and stick

PLUG ORIFICE

“A” Configuration – stick spool

ORIFICE PLUG

“B” Configuration – not used on the forwarder

ORIFICE ORIFICE

“D” Configuration – swing spool

(filter 9127320043 is installed under the orifice plug)
Valve Compensator Spring Configuration

KL-85% K-100%

KH-125% KX-150%
Load Sense Shuttle Network

Main Jib/Stick A Swing ABlade A

A B B B B

Steering Extension Grapple A Grapple Rotate

A B A B B A B

L/S Signal to
Pump43
 Control Valve Solenoids

Machine valve Solenoids are all the

same; on-off or proportional

Solenoids can be activated by hand;

Press the copper color button on top of
solenoid

Solenoid pilot bleed screws

Silver color screw on top of solenoid

Solenoid top hats

Top hat orifice diameters are not all the

same for every valve section

44
Main Control Valve Hydraulic Circuit
Load Sense Control
Combination Valve
Combination Valve
 Combination Valve
Brake Unloading Valve
 Combination Valve
Differential Lock Applied
 Combination Valve
Frame Lock Applied
Brake System
 Brake System

LS main hyd. pump

Return to tank
 BRAKE SYSTEM

Load Sense Cycling

Causes:
Faulty Accumulator
PL 160235
Leak in system
Check by pumping pedal
 BRAKE SYSTEM

Accumulator
1 Qt pre charge-1000 PSI
Checking

55
 BRAKE SYSTEM

Low Break Pressure

Light on Dash at 1100 PSI
How to check switch

56
 BRAKE SYSTEM

Brake Pedal
Shuttle Valve (cab)
Pressure Reducing Valve
8 Wheel 1100psi
All Others 850psi

57
Steering Hydraulics

IQAN controls joystick steering direction

depending on location of the seat.
Blade Hydraulics

When the seat is in the load position

The blade is controlled with the rocker
switch. When the seat is in the drive
position the blade is controlled by the
right joystick.
Optional Blade Float Hydraulics
Optional Blade Float Hydraulics
GENERAL DESCRIPTION

FUNCTIONAL DESCRIPTION
Frame Lock Cylinder
FRAME LOCK
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Hydraulic Specifications & Test Procedures
Electrical System
 Electrical
Relay Box On Firewall
Power is feed to the relay board from the circuit breaker in
the relay box on the firewall via wire #39 red. Power is
always at the relay board ready to power up the relay board
when the relay is energized by the ignition switch. The
power from wire # 39 also is used to power up the real time
clock in the computer.

Door Switch Fuse #17

Allows power to go to the relay board and
then to the door switch when ignition is turned
on.

RELAY BOARD
Power goes out to door switch, through the green
plug,(Door Con) on (+) and comes back on (S).

+ S G
81
 Start Ladder For VOAC System
Door Switch Closes
Door closes, magnetic on the door closes the
door switch allowing power to go back to the
Door Con.

RELAY BOARD
Power goes from Door Con to the start relay in
the shifter box.

FOOT SHIFTER SWITCH

Shifter Box
When this relay is energized power will go to the Foot
shifter switch. This switch will either send power to the
Foot Shifter or the Bump Shifter
82
START RELAY
 Start Ladder For VOAC System
Shifter in Neutral
When the shifter is in neutral it will send a Neutral
Start signal to the Neutral Start relay on the fire
wall. “N” or “P” will appear on the Shifter
Display.

SHIFTER DISPLAY

Neutral Start Relay

Neutral start relay is located on the left hand START SOLENOID
side of the firewall in the engine
compartment. When this relay is energized,
by the Neutral signal, it will allow the signal
sent from the key switch in start, to energize
the start solenoid.

NEUTRAL START RELAY 83

 Start Ladder For VOAC System
Start Solenoid Closed
When the Start Solenoid is
energized it will send power
to the starter solenoid and
turn over the engine.

POWER TO
STARTER
SOLENOID

Starter Solenoid

84
 Electrical
Swing Proximity Switch Target
Is the Swing Gear Rack
Relay Board Assembly
 Electrical

Joystick wiring
set up
 Electrical
Sensor Assemblies
Current Set-up
 Electrical

Wiring from
valve bank to
relay panel
Electrical
Electrical
Electrical
Transmission
 TRANSMISSION

Service
100 hours- oil and filter
Type of oil- SAE 10W Sump screen

Amount of oil- 12 Gallons

Refill about 9 gallons
Clean sump screen
Check oil level daily. Oil
temperature 140 degrees dipstick
engine running.
Location of Dip stick
Measure and fill location
 TRANSMISSION
Display
Test pattern
TC DC ER
8 8 8

ER
1 0 6
software version
displays current gear
shows error codes
95
 TRANSMISSION

SHIFTER HANDLE
Bump shift up and down
Cannot downshift if engine speed
is to high
 TRANSMISSION

SHIFTER HANDLE
Gear selector
Shifter Pattern
 TRANSMISSION

Troubleshooting
Shifter Handle
J4 Connector Pin
Located on bottom of
Shifter handle box
 TRANSMISSION

Shift Control Box

Interior View
Relays
Park
Frame lock
Neutral start
Foot / treadle pedal
shifter switch
 TRANSMISSION
TVP – (transient voltage
protection)

Has relay that is closed

when switch is turned on

TCU – (transmission control

unit)
 TRANSMISSION

Foot Shifter /
treadle pedal
Switches
Forwarder
Reverse
Diodes
First gear only
 TRANSMISSION

Foot Shifter
 TRANSMISSION

Sensors Input
Temperature Sensor
 TRANSMISSION
Sensors Input
Park Brake Pressure
Switch
normally closed
Brake Pressure switch

104
 TRANSMISSION

Sensors Input
Cylinder Speed MPU sensor

Output Speed MPU sensor

 TRANSMISSION
Sensors Input
Not Park vs Park
Park brake solenoid - nominally
closed, drains oil to tank
Park brake pressure switch -
sends oil pressure to
release park brake
 TRANSMISSION

CALIBRATING
Purpose of calibration
Clutch fill time - hold time
When you must calibrate the transmission
a) When solenoid valve assemblies are
changed
b) After repairs involving Transmission
clutches
c) When the TCU is replaced
d) If shift quality deteriorates
e) Every 500 hours of operation
 TRANSMISSION

CALIBRATING
Fitting in dash

Warming up machine

Stall transmission in 4th gear to

warm transmission oil to operating
temperature. (minimum 120 deg. F. =
49 deg. C
 TRANSMISSION

Calibration error codes which may appear

100- oil is too cold
101- engine speed to high
102- engine speed to low
127-calibrating without park brake set

Engine speed to properly calibrate- 1600 rpm

Forward gear only- program does everything
on its own
 TRANSMISSION

CAH on Display
C = calibrating
A = calibrating clutch “A”
H = Pressure needed to keep
clutch full
CAF on Display
C = calibrating
A = calibrating clutch “A”
F = Testing filling time (300 ms)
 Connecting Computer To TCU

Locate triple weather pack connector inside of dash on the left side.
Plug computer cord into dash fitting and computer. Open transmission
diagnostics program.
 Transmission Diagnostics Software
Version 1.3c

FG Series TCU Spec: YZ103963 Revision Level: G

TCU Serial Number: 209524

TCU connected to COM1 EXIT

Transmission Diagnostics Software

Version 1.3c

FG Series TCU Spec: YZ103963 Revision Level: G

TCU Serial Number: 209524

TCU connected to COM1 EXIT

 Stored TCU Errors
Errors received from ECU memory in chronological
Order from the most recent (#1) to the earliest (#8)

Error #1 44 DETAILS

Error #2 58 DETAILS

Error #3 44 DETAILS

Error #4 41 DETAILS

Error #5 52 DETAILS

Error #6 171 DETAILS

Error #7 41 DETAILS

Error #8 43 DETAILS

Click on the associated Details button to view the description of the error.

TCU connected CLOSE EXIT

114
 Stored TCU Errors
Errors received from ECU memory in chronological
Order from the most recent (#1) to the earliest (#8)

Error #1 44 DETAILS
TCU Error Description
58 DETAILS
Error #2

11 Error 44 DETAILS
NOT PARK#3
(input pin J1-K1) and NEUTRAL (input pin J2-A1) are both passive at ECU.
Legal conditions are: 41
1) NOT PARK DETAILS
active and NEUTRAL passive or 2) NOT PARK
Error #4
Passive and NEUTRAL active.
Error #5 52 DETAILS

Error #6 171 DETAILS

Error #7 41 DETAILS

Error #8 43 DETAILS

Click on the associated Details button to view the description of the error.

TCU connected CLOSE EXIT

115
 Gear Information
Selector Position

Neutral

Selector Inputs
0 1 0 0 0

Forward Neutral Reverse Up shift Down shift

Transmission Gear Range

Neutral

CLOSE
 Transmission Controller Information
Transmission DF150 TCU Controlled No Calibration Speed 1600 RPM
Diff Lock
Gear Train 4x4 Shift Mode Manual Shuttle Shift Speed 490 RPM

Inching None Maximum Speeds 4 Downshift Inhibit 1850 RPM

Forward Speed

Drive Type Converter without lockup Maximum Speeds 4 Engine Pulses 43

Reverse Per Revolution
Disconnect None
Minimum Forward 1 Output Pulses 98
Gear Per Revolution
Handle Type Bump
Default Forward 1 Cylinder Pulses 71
Gear Per Revolution
System Voltage 12 Volts
Default Reverse 1 Software Spec YZ103963
No Gear Number
Brake Cutoff
Max Preselect 1 TCU Serial Number 209524
Funk Forward Gear
Display Type
Date Programmed 07/10/03
Max Preselect 1
Park Brake Type Wet Brake Reverse Gear
 Digital Input States
BINARY J1-h1 N/A J1-h2 OFF J1-h3 OFF
J1-j1 OFF J1-j2 ON J1-j3 OFF
J1-k1 ON J1-k2 ON J1-k3 OFF

OFF
J2-a1 OFF J2-a2 J2-a3 ON
OFF
J2-b1 OFF J2-b2 J2-b3 OFF
OFF
J2-c1 OFF J2-c2 J2-c3 OFF

DF150 Output Driver Currents

Battery Voltage 13.9 VDC Solenoid C 0 mA
Solenoid 1 53mA Solenoid D 0 mA
Solenoid 2 53mA Driver 9 10 mA
Solenoid 3 667mA Driver 10 0 mA
Solenoid 4 53mA Driver 11 0 mA
Solenoid A 667 mA Driver 12 0 mA
Solenoid B 53mA Driver 13 0 mA
 Digital Input States
J1-h1 N/A J1-h2 OFF J1-h3 OFF
J1-j1 OFF J1-j2 OFF J1-j3 OFF
J1-k1 ON J1-k2 ON J1-k3 OFF

J2-a1 ON J2-a2 OFF J2-a3 ON

J2-b1 OFF J2-b2 OFF J2-b3 OFF
J2-c1 OFF J2-c2 OFF J2-c3 OFF

DF150 Output Driver Currents

Battery Voltage 13.9 VDC Solenoid C 0 mA
Solenoid 1 0 mA Solenoid D 0 mA
Solenoid 2 0 mA Driver 9 0 mA
Solenoid 3 0 mA Driver 10 0 mA
Solenoid 4 0 mA Driver 11 0 mA
Solenoid A 0 mA Driver 12 0 mA
Solenoid B 0 mA Driver 13 0 mA

CLOSE
 Transmission Diagnostics Software
Clutch Calibration Values x

Directional Clutches Speed Clutches

Clutch Fill Hold Clutch Fill Hold
1 19 139 A 21 140

2 19 147 B 16 164

20 138 0 0
3 C
20 139 0 0
4 D

CLOSE

TCU connected to COM1 EXIT

 Speeds and Temperature

Engine Speed 802 RPM

Output Speed 0 RPM

Cylinder Speed 0 RPM

Sump Temp 66° F / 19° C

CLOSE
Transmission Troubleshooting
Transmission Troubleshooting
 Transmission Troubleshooting
Troubleshooting Transmission
Over Heating

1. Verify that the temperature gauge is working properly before proceeding

2. Converter stalling-Shift to a lower gear

3. Oil level too high-Establish proper oil level

4. Heat Exchanger dirty- Clean Heat Exchanger

5. Clutch Slipping- Check clutch pressure: fitting of the test port is a #4 Boss o-ring
Check on the transmission by the solenoid. If you have pressure, the solenoid
is functioning correctly. Pressure reading should be 240-260 PSI at 1800-
2000 RPM’s
If the pressure reads below this level the clutch piston seal is probably worn.

6. Charge Pump- Check to see if it is pumping enough oil

To do this locate the lube in test port on the Transmission face, reading
should be no less than 25 PSI

7. Transmission Filter- Make sure the hose from the Charge Pump to the
Transmission oil filter is going into the filter on the inlet side and the hose on the
outlet side is on the side going to the Transmission.

8. As a last resort check the Axle ratios of the machine

 Transmission Troubleshooting

Common Error Codes

41-Door not closed, Engine not running
44-Door not closed, Engine running, Park Brake on
52-Door not closed, Engine running, Park Brake off

ERROR CODES

Digital and Analog transmissions have different error codes

Troubleshooting using the codes
Histogram
Understanding Passive and Active
Solving Error Code 48
 Transmission Troubleshooting

11265 sheet 1
Torque Converter
 Torque Converter
Charge Pump
Implement Pump
mpu
Drive Ratio 1:0.837

Charge Pump
 Torque Converter
Converter Pressure
Low RPM High RPM Stall
Converter In 30 psi 105 psi 42 psi
Range (60-115)
Converter Out 25 psi 94 psi 39psi
Range (40-90)
Cold Oil 100-110

The lower the engine RPM at stall the lower the converter pressure
The higher the engine RPM at stall the higher the converter pressure
Example - Driving in 1st gear at 2500 rpm Converter In 118 psi & Converter Out 92
psi
When the oil temperature is high the converter pressures will be lower.
Converter pressure will be in low if the converter relief is faulty or the filter is in
by-pass
RPMs low at stall could be a Rolled Sprag Clutch
RPMs low on stall can be caused by the engine not producing required HP
Axles
 AXLES

1200 Series Front 564

Ratios
28.667-28L-26 Tires
33.426-30.5-32 Tires
7/8” mounting bolts
 AXLES
1200 Series Front Axles
Service
Oil Level
250 hours Ports

Type of oil-TDH
Straight hydraulic oil may
Drain Plug
make the brakes and
differential lock chatter
Amount of oil-5 Gallons
Drain
Plug
132
 AXLES
NAF Bogies

06- Front Frame on the 574

Ratio- 24.37

08- Rear Frame on the 574

Ratio- 24.87
 AXLES
574 Shown With Bogie Lift

TK458
 AXLES - 06

Type of oil-80W90
11 Locations:
Differential 11.0 Ltr.
Planetary 3.5 Ltr. Ea
Walking Beam 42.0 Ltr. Ea
Trans Axle 1.0 Ltr. Ea
Amount of Oil 111.0 Ltr
29.3 Gal
Change oil in Differential, Planetary,
Walking Beam, and Trans Axle after first
250 hrs. Then every 2000 hrs after that.
 AXLES - 06
Oil Level Important
Parking On Hill Differential- Trans Axle
Appling Diff Lock
Fill plug location
Differential for Differential
Dip Stick and Transverse
Axle

Breather Drain Plug

Cap
 AXLES - 06
Fill planetary first, drain last
Planetary

Plug position for

draining oil

Plug position for filling

and checking oil
 Axles - Differential
Oil Level Important
Parking on hills
Appling Diff Lock
Breather

Drain Plug
Dip Stick Fill Plug
 Axles - Planetary
Fill planetary first, drain last

Plug position for

draining oil

Plug position for filling

and checking oil
Axles - Walking Beam (Gear Driven)
Checking Oil:
Remove fill plug, oil level
should be no lower then 3/8”
from bottom of hole.
Note: Four places.

Changing Oil:
Fill Port

First 250 Hrs. Drain all.

There after. Save Port

Note: Four places. Drain Pug

 Axles - Slewing Bearing

Service
250 hours
Grease- Brand EP
until clean grease exits
7 locations on each bearing
grease points -remove and
replace plastic plugs
plastic plugs for bearing pucks
leave in
 Axles - Service Brake

Service brake may stick when new because of the wedge

Service Brake

wedge
 Axles – Service Brake

Brake Inspection & Bleeding

Inspect Brakes Ever 2000 Hrs. Brake
Inspection

Bleed Port
IQAN control system

Iqan Develop G4 Edition

 Iqan Control System

What is IQAN?
Machine Control System
Engine
Joysticks
Interprets electrical inputs and changes them to
intelligent information
What makes up the system?
Display-MDM unit
XP unit
Joysticks
Sensors
 Iqan Control System

What IQAN controls

Joystick outputs
High reference voltage error
low reference voltage error

What IQAN does not control

Horsepower of the engine
Fuel efficiency of the engine
Horsepower of the Hydraulic pump
Loader
LOADERS
 LOADERS

Link Assembly
Inner and Outer
Links from Main
Boom to Jib Boom
 LOADERS

Squirt Boom
Adjusting
Brass pucks
Make a tool
 Loaders – Swing Box
Cast box
Racks
Piston with seals
Shoe
Shoe adjusting bolt
Barrel O-ring
Tie Rods
End Caps with Seals
Pinion Gear
Hub 151
 Loaders – Swing box

Location for the

Swing proximity
switch inserted
into the Swing Box