Tigercat Axles SERVICE & REPAIR MANUAL - PDF DOWNLOAD

AXLES

SERVICE AND REPAIR MANUAL

ISSUE 2.0, DECEMBER 2018 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat Axles TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v NON-APPROVED FIELD PRODUCT / PARTS CHANGES............................................................................... vi AXLE, EXPLODED VIEW - IB15 REAR AXLE..........................................................................................................viii AXLE EXPLODED VIEW - OB20 REAR AXLE .......................................................................................................... x AXLE EXPLODED VIEW - WOB17 REAR AXLE ......................................................................................................xii AXLE EXPLODED VIEW - SERVICE AND SAHR BRAKE .........................................................................................xii

SAFETY...............................................................................................................................................................1 DISASSEMBLY....................................................................................................................................................2 ASSEMBLY..........................................................................................................................................................3

Service and Repair Manual (this manual).......................................................................................Part No. 47731AENG Service and Repair Manual (BOGIE ARM).....................................................................................Part No. 47732AENG Service and Repair Manual (PLANETARIES).................................................................................Part No. 47738AENG Service and Repair Manual (DIFFERENTIALS)..............................................................................Part No. 47574AENG iii

INTRODUCTION................................................................................................................................................. v

Tigercat Axles INTRODUCTION This service and repair manual is made available by Tigercat to assist service technicians with disassembly, servicing and re-assembly of Tigercat axles.

Section 1 contains safety information that must be followed. DANGER, WARNING, CAUTION and NOTICE indicators are displayed where necessary, drawing attention to possible workplace and procedural hazards.

Only competent, trained personnel should be allowed to operate or work on the machine and/or components.

The information contained in this manual is current at time of printing. Improvements to the machine components are on-going and may not be covered in this document release.

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

Every effort is made to update manuals on a regular basis. Report discrepancies between this manual and the components in question to the Tigercat service department. The release date of this document appears on the title page.

Tigercat Industries Inc.

v

NON-APPROVED FIELD PRODUCT / PARTS CHANGES............................................................................... vi

Introduction

Tigercat Axles

NON-APPROVED FIELD PRODUCT / PARTS CHANGES Unauthorized changes of any kind made to components or materials used in Tigercat products could seriously affect product integrity, safe operation and could place operators at serious risk.

It is Tigercat policy that, NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN TIGERCAT APPROVED COMPONENTS FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes to, or install components, is only to be undertaken as follows: 1. The relevant components for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, service bulletin, price list, parts manual, or product literature issued by Tigercat.

2. Approved changes must be authorized, in writing, by the responsible Tigercat Engineering Manager.

Authorization by any other person is unacceptable.

Unauthorized component changes or service activities made, or contributed to, by a person or organization without receiving authorization may result in creating a dangerous situation. Persons or organizations performing such unauthorized changes or activities will be considered to have assumed the risk involved or to be negligent in having created this situation.

Tigercat will not be held responsible for any situation that may arise resulting from non-approved component changes to its products.

Should Tigercat become involved in a dispute resulting from changes made without proper authorization by Tigercat as stated above, Tigercat will take whatever action is appropriate to protect its interests.

Tigercat product warranties and certifications will become NULL and VOID if the above policy is not adhered to as specified.

Warranties provided to Tigercat by component manufacturers and suppliers will become NULL and VOID if the above policy is not adhered to as specified.

Tigercat Industries Inc.

vi

Tigercat Axles

Introduction

TRADEMARKS All trademarks,logos, service marks and brand names used in this document are the respective properties of each company.

TIGERCAT FLUID ANALYSIS (TFA) The Tigercat Fluid Analysis Program is a valuable preventative maintenance tool that provides benefits such as: • Early problem detection and intervention • Determining service and scheduled downtime events and cost • Effective monitoring of maintenance schedules and practices for cost analysis and resale provenance • Machine productivity logistics

TIGERCAT FLUID SAMPLING PROGRAM Fluid sample kits are available from your Tigercat dealer parts department. Fluid sample kits include a prepaid sample bottle and sample information kit with pre-printed labels to ensure timely analysis of samples and results. If required, arrangements can be made with your Tigercat dealer to supply and perform follow-up sampling. Contact your Tigercat dealer, the Tigercat parts department, or visit www.tigercat.com for more information.

TIGERCAT AXLES Tigercat manufactures different configurations of axles and bogie axles. Despite the physical differences between the configurations, internal parts and assembly processes are similar for each axle type. This manual details the differences using exploded view drawings and parts lists. Where disassembly or assembly processes vary, detailed instructions are provided in the body of the text. Different housings may be shown throughout the manual.

Axles are designated using several alpha-numeric characters that describe the axle type, planetary, differential types and differential sizes as shown in the following chart: Descriptors

Descriptor Legend

I

Inboard planetary and/or standard duty wheel bearings

O

Outboard planetary and/or heavy duty wheel bearings

R

Standard bogie

W

Wide-spread bogie

H

High-clearance bogie

B

Barrel differential

F

Flange differential

15/17/20

Indicates differential size

vii

AXLE, EXPLODED VIEW - IB15 REAR AXLE........................................................................................................viii

Introduction

Tigercat Axles

19

32 31 30 29 28

23 24

21 14 34

25 33

26

16

18 10 20

2

11

12

13

9

8

3

1 22

27

4

35

2

15 17 20 5

6

7

34

C00438

Axle, Exploded View - IB15 Oscillating Axle Shown NOTE: This exploded view is representative of a typical Tigercat Inboard oscillating axle. Some parts may not appear exactly as shown.

viii

30

Tigercat Axles ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Introduction

PA RT DESCRI PTI O N GEAR, SUN HOUSING, BRAKE KIT, BRAKE O-RING O-RING BOLT WASHER SPACER PIN, SPRING SHIM SHIM SHIM SHIM TRUNNION, REAR TRUNNION, FRONT BUSHING, REAR BUSHING, FRONT PIN, STEEL, TRUNNION

ITEM 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

ix

PA R T D E S C R I P T I O N CAP SEAL, OIL WASHER, THRUST, REAR WASHER, THRUST, FRONT BOLT WASHER BOLT RING, RETAINING SEAL, URETHANE SHIM SHIM SHIM SHIM SHIM DIFFERENTIAL, OSCILLATING PLANETARY PLUG, MAGNETIC

AXLE EXPLODED VIEW - OB20 REAR AXLE ......................................................................................................... x

Introduction

Tigercat Axles

2

17

16

15

12

13

1 11

10 3 1

5 14

4 6

7

2

12 8

9

C00437

Axle, Exploded View - OB20 Fixed Axle Shown

NOTE: This exploded view is representative of a typical Tigercat Outboard axle. Some parts may not appear exactly as shown.

x

Tigercat Axles ITEM 1 2 3 4 5 6 7 8 9

Introduction

PART DESCRI PTI O N KIT, BRAKE, SAHR W/BUSHING HOUSING, BRAKE SHAFT, AXLE PLUG, MAGNETIC O-RING BOLT WASHER BOLT WASHER

ITEM 10 11 12 13 14 15 16 17

xi

PA R T D E S C R I P T I O N SPACER PIN, SPRING SHIM DIFFERENTIAL, OSCILLATING PLANETARY SHIM SHIM SHIM

AXLE EXPLODED VIEW - WOB17 REAR AXLE .....................................................................................................xii

Introduction

Tigercat Axles

17

18

19

20

2 21 12

4

16

5 14

7

6

1

10

26 15

13

9

23

1 14 5

4

3 11

10

12 2

27

6 8

7

28

22

C00379

Axle, Exploded View - WOB17 Bogie Axle Shown

NOTE: This exploded view is representative of a typical Tigercat bogie axle. Some parts may not appear exactly as shown.

xii

24

25

Tigercat Axles ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Introduction

PART DESCRI PTI O N HOUSING, BRAKE BEARING, SLEW SHAFT, AXLE RING, SCRAPER O-RING SEAL, OIL PIN O-RING BOLT BOLT BOLT BOLT WASHER PLUG, MAGNETIC

ITEM 15 16 17 18 19 20 21 22 23 24 25 26 27 28

C00377

xiii

PA R T D E S C R I P T I O N KIT, BRAKE SPACER, BRONZE SHIM SHIM SHIM SHIM PIN, SPRING SHAFT, BOGIE, OUTPUT O-RING WASHER BOLT DIFFERENTIAL PLANETARY BOGIE ARM

AXLE EXPLODED VIEW - SERVICE AND SAHR BRAKE .......................................................................................xii

Introduction

Tigercat Axles

2

3

5

8

1

4 10

25

26

11 7

9 6 18

12

14

15

16 19

2

3

5

1 25

27

8 4 10

13 22

23

24

20

26

11 7

17 27

9 6 18

12

21

14

15

16 19 27

13 22

24

23

20

17 27

C00378

Service and SAHR (Spring Applied Hydraulic Release) Brake, Exploded View

NOTE: This exploded view is representative of a typical Tigercat brake kit, with SAHR and Service brake components. Some parts may not appear exactly as shown.

xiv

21

Tigercat Axles ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Introduction

PART DESCRI PTI O N PLUG, STEEL SCREW, BLEED SEAT, INSERT, BLEED PISTON, BRAKE O-RING, SQUARE, INNER RING, BACKUP, OUTER SPRING, PISTON, RETURN O-RING, SQUARE, OUTER RING, BACKUP, INNER PLATE, REACTION, BRAKE PLATE, FRICTION, BRAKE RETAINER, SPRING, SAHR PISTON, BRAKE, SAHR WASHER, BELLEVILLE

ITEM 15 16 17 18 19 20 21 22 23 24 25 26 27

xv

PA R T D E S C R I P T I O N WASHER, THRUST, BRAKE, SAHR RING, BACKUP, INNER RING, BACKUP, OUTER BOLT O-RING, SQUARE, INNER O-RING, SQUARE, OUTER PLANETARY BUSHING, NYLON RING, RETAINING, INTERNAL HOUSING, BRAKE DIFFERENTIAL SERVICE BRAKE COMPONENTS SAHR BRAKE COMPONENTS

Introduction

Tigercat Axles

xvi

Tigercat Axles SECTION 1– SAFETY Read and understand this safety section prior to servicing any machine components.

CONTENTS – SECTION 1 A

ISSUE 2.0, DECEMBER 2018

APPLYING LOCTITE PRODUCTS....................................................................................................................... 1.12 GASKET FORMING/SEALANT PRODUCTS.................................................................................................... 1.12 THREAD LOCKER AND PRIMER PRODUCTS................................................................................................ 1.12 C

CALIBRATION......................................................................................................................................................... 1.8 CAUTION................................................................................................................................................................ 1.3 CLEAN AND INSPECT.......................................................................................................................................... 1.10 CLEAN AND INSPECT...........................................................................................................................................1.11 COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING................................................... 1.12 D

DANGER................................................................................................................................................................. 1.3 DISASSEMBLY AND ASSEMBLY TOOLS............................................................................................................ 1.10 G

GASKET FORMING/SEALANT PRODUCTS....................................................................................................... 1.12 GREASE INJECTION INJURY................................................................................................................................ 1.7 GUIDE PINS.......................................................................................................................................................... 1.10 H

HAZARDS COMPRESSED AIR............................................................................................................................................. 1.5 FLAMMABILITY................................................................................................................................................... 1.4 LIQUID NITROGEN............................................................................................................................................. 1.5 VENTILATION...................................................................................................................................................... 1.5 WORKING WITH OIL........................................................................................................................................... 1.5 L

LIQUID NITROGEN................................................................................................................................................. 1.5 M

MATERIAL LIFTING AND HANDLING.................................................................................................................... 1.8 PERSONAL SAFE LIFTING AND CARRYING.................................................................................................... 1.9 N

NOTICE................................................................................................................................................................... 1.3 P

PICTOGRAMS........................................................................................................................................................ 1.4 PNEUMATIC GREASE GUNS................................................................................................................................ 1.7 R

READ THIS MANUAL FIRST.................................................................................................................................. 1.3 REQUIRED TOOLS................................................................................................................................................ 1.9 S

SAFETY................................................................................................................................................................... 1.4 COMPETENT PERSON....................................................................................................................................... 1.4 GENERAL PRECAUTIONS................................................................................................................................. 1.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)................................................................................................. 1.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)................................................................................................. 1.4 SAFE SUPPORT OF COMPONENTS................................................................................................................. 1.9 VITON SEALS...................................................................................................................................................... 1.6 SHIPPING COMPONENTS..................................................................................................................................... 1.9 T

THREAD LOCKING COMPOUNDS AND SEALANTS...........................................................................................1.11 REMOVE 518 LOCTITE FLANGE SEALANT.....................................................................................................1.11 REMOVE FASTENERS SECURED WITH LOCTITE 243 THREAD LOCKER...................................................1.11 REMOVE FASTENERS SECURED WITH LOCTITE 263 HIGH STRENGTH THREAD LOCKER....................1.11

Safety

Tigercat Axles

W

WARNING............................................................................................................................................................... 1.3 WORK CONDITIONS AND TOOLS........................................................................................................................ 1.8

1.2

Tigercat Axles

Safety

READ THIS MANUAL FIRST

SAFETY SYMBOLS

Study these instructions carefully and use them as a reference when disassembling, inspecting, repairing or assembling this unit.

This safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

The information contained in this manual is current at the time of printing. Tigercat reserves the right to make changes to the axles or manuals at any time. Changes to the manuals will not be reflected until the next revision of the document or will be issued in the form of service bulletins. Every effort is made to deliver updates on a regular basis.

UNDERSTANDING SIGNAL WORDS

DANGER

Report discrepancies between the manual and actual parts and processes to the Tigercat service department.

The date of manufacture and the date of release of this document may differ.

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

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

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

NOTICE NOTICE indicates a potentially damaging situation which, if not avoided, may result in property damage and is not related to personal injury.

1.3

Safety

Tigercat Axles

SAFETY

HAZARDOUS MATERIALS

GENERAL PRECAUTIONS

WARNING

Remember, safety is a prime responsibility of all.

Hazardous solvents, oils, fuels and materials are present or are used to service axles. Read and understand MSDS/PSDS literature.

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

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

Keep safety labels in good condition. Repair or replace damaged labels.

Read and understand Material Safety Data Sheets (MSDS)/Product Safety Data Sheets (PSDS) literature regarding chemicals, fuels, solvents and noxious materials.

• Handle and dispose of materials in keeping with local, regional and national laws and regulations.

In lieu of such laws and regulations, dispose of materials as suggested in the MSDS/PSDS literature.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

• Store materials to be disposed of in appropriate vessels with the materials clearly identified.

Personal protective equipment is provided to eliminate or control the danger of personal injury or health risks.

Know what PPE is required and use it. If unsure of safety requirements or procedures, contact your supervisor or Health and Safety representative.

Do not pour fluids into a sewage system, on the ground, or in a stream, pond or lake.

As a minimum, workers must wear approved safety footwear, protective glasses and protective gloves.

Use proper storage and handling for flammable solvents, oils, fuels and materials as indicated by MSDS/PSDS literature.

HAZARDS FLAMMABILITY

An accessible first aid kit and fire extinguishers must be readily available.

Smoking, welding, poor electrical connections, hot equipment, open flames and static discharge are external ignition sources that represent a serious safety hazard.

COMPETENT PERSON A competent person is defined as a worker with adequate knowledge, training and experience who knows the laws and regulations, can recognize unsafe conditions, practices, equipment or situations and can competently organize the work in a safety minded environment.

1.4

Tigercat Axles

Safety

LIQUID NITROGEN

WORKING WITH OIL Direct contact with oil implies a risk of skin complaints such as eczema, for example. Strict hygiene should always be observed.

WARNING Only workers trained in handling liquid nitrogen may do so. See the MSDS or PSDS for proper handling and storage of liquid nitrogen. Do not attempt to use liquid nitrogen until you have received proper training.

Other safety advice includes: • Oil used in this machine may be hot enough to cause serious burns.

• Avoid contact with oil, particularly heated oil.

Liquid nitrogen is used to shrink-fit bearing races, bushings, pins, shafts etc. It is extremely dangerous if not handled properly.

• Wash off oil on the skin immediately with soap and water.

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

VENTILATION

WARNING

• • • •

Do not burn discarded items except in an approved incineration process. Burning such items creates hazardous fumes.

DO NOT put oily rags in your pockets.

Change oil soiled clothing as soon as possible.

Keep an extra change of work cloths nearby.

Attend to cuts and abrasions immediately. Clean them and apply first-aid.

• DO NOT breath in oil fumes.

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

COMPRESSED AIR Compressed air is a concentrated, high pressure, high speed stream of air that can seriously injure or kill. Air pressures of 5 – 10 psi can cause serious injury. Most pneumatic tools operate at 80 – 120 psi.

Hazardous gases, fumes and vapours are the byproducts of internal combustion engines, solvent and cleansers. Verify your work area is adequately ventilated and utilize appropriate PPE as required.

Follow acceptable Health and Safety protocols for using compressed air.

• DO NOT clean clothing or skin using compressed air.

• Work in a ventilated area. Provide sufficient ventilation to prevent the build-up of toxic exhaust fumes. If indoors, use exhaust extensions to the outdoors or open the shop doors. Run the engine only when it is necessary for testing or adjustments.

• Verify the air stream is not aimed at a fellow worker or positioned in a way to cause debris to strike someone or other equipment.

• Use a chip guard.

• Air pressure of 30 psi (at the nozzle) is permitted to dry objects.

1.5

Safety

Tigercat Axles HIGH PRESSURE INJECTION INJURIES

VITON SEAL

WARNING

WARNING

Hydraulic fluids or grease under pressure can penetrate the skin and could result in death or serious injury.

Viton Fluroelastomers contain constituents harmful to unprotected skin and respiratory tracts. Follow all MSDS recommendations for handling and disposing of Viton manufactured components.

O-rings and other seals manufactured of Viton Fluoroelastomer materials (fluorine rubber) produce fluorine gas and a highly corrosive hydrofluoric acid 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.

Workers must be trained in the use of high-pressure fluids and appropriate emergency first-aid. Seek medical attention immediately in the event of a high-pressure injection injury.

Follow these procedures when inspecting equipment that has been subjected to high temperatures such as fire:

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

• Visually inspect any seals or gaskets which have suffered from heat; they will appear black and sticky.

If these are found, DO NOT touch.

• Determine the material composition of any seals or gaskets. If fluro-elastomer seals (Viton, Fluorel, or Tecnoflon) have been used, the affected area must be decontaminated before undertaking further work.

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation. There is a danger that you will tend to ignore this, thinking it will get better with time. Most often, it does not! Within a very short time the wound may begin to throb painfully, indicating that tissue damage has already begun.

• Wear disposable, heavy duty gloves (neoprene) and decontaminate the affected area by washing it thoroughly with lime water (Calcium Hydroxide solution).

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.

• Discard any contaminated materials, rags and gloves in accordance with MSDS recommendations and industry best practice.

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

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

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

1.6

Tigercat Axles

Safety GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS

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

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.

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

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.

• 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:

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 search for leaks with your bare hands.

Wear thick protective gloves.

• Wear safety goggles.

• 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.

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

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

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

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

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

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

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

• Remove dirt and grease from lube fittings prior to greasing.

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

• Replace any defective lube fittings on equipment with new fittings immediately.

• Replace badly positioned fittings with angled or swivel fittings for easier access.

• DO NOT handle any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

• Verify hoses are rated for the pressures to which they will be subjected.

WARNING DO NOT use hydraulic equipment suspected of being defective.

1.7

Safety

Tigercat Axles

WORK CONDITIONS AND TOOLS

MATERIAL LIFTING AND HANDLING

Work in a clean, well lit workplace. Sufficient space to lay out and sort various parts and assemblies should be available.

DANGER Use recommended supports and stands. If other stands or supports are used they must be suited to the task. They must be robust and stable.

Failure to use proper supports and stands may lead to situations which, if not avoided, could result in death or serious injury.

A basic set of tools is required in addition to special tools and instruments available with the machine.

WARNING Use tools intended for the work performed. Use of inappropriate or makeshift tools may lead to serious injury or death. Do not use Imperial measured tools on Metric measured parts and vice versa.

WARNING Assemblies and components are heavy. Use appropriate lifting equipment or assisted lifting techniques only.

Dealer constructed tools may create a safety hazard if not constructed using the correct materials, design and workmanship. Only trained, competent personnel should design and weld fabricated equipment.

WARNING

CALIBRATION

Only competent personnel are permitted to operate cranes or hoists.

NOTICE

Operators must test and carefully inspect all lifting device controls, chains, straps, hooks, cables and other lifting devices prior to use. Do not use damaged equipment.

Mechanical and electrical instruments and tools used to measure values, weigh, or torque must be calibrated annually, as a minimum requirement.

• Operator's must observe appropriate safety practices for safe equipment use.

Only trained personnel may calibrate instruments and tools. Calibration records ( date, values and calibrator) must be available for review for a period of three years.

• Do not exceed working load limits.

• Ensure that the hoist is directly above the centre of the load and that the load is properly balanced and secured.

Tools must be calibrated when: • New

• Use appropriately rated straps, chains and slings in good condition.

• Repaired or changed

• Do not shock, jerk or bounce a load when lowering or lifting.

• When the scheduled calibration period has passed • Conditions other than normal operating conditions occur. For example, a device is dropped or exposed to extreme temperature.

• Clearly communicate with fellow workers when raising, moving and lowering loads.

• Observations indicate incorrect readings.

1.8

Tigercat Axles

Safety

PERSONAL SAFE LIFTING AND CARRYING

SHIPPING COMPONENTS

Proper methods for lifting and handling material protect workers against injury and makes the job easier. When equipment is available and conditions make it practical, mechanical devices should be used for lifting and carrying.

Depending upon the location of the machine site, repair site, or delivery/warehouse site an axle may or may not be filled with oil prior to shipping/delivery. Be aware of supply, shipping and storage constraints as legislated by local, regional, state or federal agencies.

When manually lifting components:

Mark axles that contain oil to clearly show that the axle contains oil.

• Wear appropriate PPE

Mark axles that do not contain oil to clearly show that the axle does not contain oil.

• Determine if the load is lifted, pushed, pulled or carried • Consider if a lifting device can be used

REQUIRED TOOLS

• Determine if the load weight is within your safe lifting capacity

To disassemble an axle requires the following tools, equipment and materials:

• Verify the route and destination used to move and place the load is clear of obstructions

A basic set of tools is required in addition to various special tools and measuring instruments. Additional tools and fixtures used include:

To safely lift a load,

• Bearing Puller

• Assume a stable lifting stance

• Isopropyl alcohol or equivalent solvent

• Keep feet hip width apart with one foot slightly ahead of the other for stability

• Clean rags

• Get a good grip on load. If the grip needs to be adjusted, put the load down, then adjust the grip.

• Marking pen or other marking method

• Keep your back straight

• Support Stands

• Lift with legs

• Wooden support blocks

• Keep load close to waist

• Torque wrench up to 600 ft/lbs

• Do not twist your torso. Move your feet.

• Snap ring installation tool

• Keep your head up and watch your route.

• Lead solder 0.120

• PPE

SAFE SUPPORT OF COMPONENTS

• Electrical Tape

Axles are very heavy and represent a significant crush hazard if not adequately supported and braced during shipping, service and repair. Use robust stands or wooden blocks to support and brace major components so they do not fall or roll. Use adequate chains and strapping to secure components. When separating one major component from another ensure that both components are adequately supported and level.

• Loctite solvent or equivalent • Loctite 243 - SSA194 • Loctite 263 - SSA250 • Spring Guide Tool B7506000 • Ball Lock Pins B7506001 • Brake Piston Installation Tool 80090B

Use lifting straps or chains to support components during the separation of components. Do not allow components to remain suspended on a lifting device.

• Compressed oil supply pump capable of 35 bar (500 psi)

For larger components it is safer to work with them on the ground/floor supported sufficiently to allow personnel to work safely.

• Guide Pins (as required) See, GUIDE PINS.

1.9

Safety

Tigercat Axles

DISASSEMBLY AND ASSEMBLY TOOLS

GUIDE PINS Guide pins are modified fasteners, made by technicians, used to assist with parts assembly. Alignment pins are hardened dowels assigned by engineering for precise component alignment.

C00440

A 30mm-14mm Air Leak Test, Brake Test Adapter B8590000

When a guide pin is referenced in the procedures, evaluate which fastener of sufficient length and thread pitch is required for the components being assembled and modify the fastener to create a guide pin.

B

A

A

C00440

A Spring Guide Tool B7506000

C00498

A Guide Pin B Grind Head From Fastener

To modify a fastener:

C00669

A Brake Piston MountingTool 80090B

A

1. Grind the head of the fastener to a diameter equal to or marginally less than the shank. DO NOT CUT THE HEAD OF THE FASTENER OFF. Cutting the head off may make the fastener too short.

2. Grind a moderate chamfer or taper to ease alignment of parts on the ground end of the guide pin.

3. Grind or cut a slot in the top of the ground end of the guide pin to permit a slot screwdriver to be used to insert and remove the pin.

4. Use fasteners that are compatible with the tapped hole in the component into which it is being threaded.

5. Mark and retain guide pins for future use.

When using guide pins: 1. Insert the guide pins finger tight, then an additional half turn.

2. When the assembly parts are secure, remove the guide pins and complete fastener installation. DO NOT torque assembly fasteners with the guide pins in place.

1.10

Tigercat Axles

Safety

CLEAN AND INSPECT

THREAD LOCKING COMPOUNDS AND SEALANTS

WARNING

REMOVE FASTENERS SECURED WITH LOCTITE 243 THREAD LOCKER

Be aware of hazardous solvents, oils, fuels and materials. Wear PPE, avoid breathing fumes and work safely. Read and understand MSDS/PSDS literature.

Fasteners secured with Loctite 243 Thread Locker compound are removable using hand tools.

1. Remove the fastener.

Before servicing or repairing the Tigercat axles, clean and inspect the unit carefully. Observe and record findings while disassembling the unit:

2. Clean threads with a wire brush.

1. Have required tools, solvents, lint free cloths, rags, tools and other items at hand.

4. Use a die to clear threads or a tap to clear threaded holes as an alternative method of cleaning the fastener.

3. Wipe excess material from screw.

2. Read accompanying reports.

3. Clean all surfaces of grease, oil and dirt. a. Use appropriate cleaning solutions or solvents to remove contaminants. b. Rinse components after cleaning. c.

Use cleaning methods in keeping with materials used and surface finishes.

4. Read procedures to determine critical component positioning and alignments before disassembly.

5. Mark critical component positions and alignments using a scribe or other method to assist in reassembly.

6. Clean and inspect each component as it is removed from the unit.

7. Place the unit on a clean, secure workbench or level surface.

8. Handle the parts carefully. Protect machined surfaces from nicks and burrs. Inspect gears, thrust washers and other wear components for roughness, damaged edges, wear patterns and foreign material.

Worn components must be replaced.

REMOVE FASTENERS SECURED WITH LOCTITE 263 HIGH STRENGTH THREAD LOCKER If screws treated with Loctite 263 threadlocker resist removal, heat the screw to approximately 121°C (250°F) and remove the screw while still hot. Adding a breaker bar or extension to the spanner/wrench provides additional leverage. Exercise caution, fasteners may snap off unless heated sufficiently.

To clean the screw: 1. Apply Bonderite C-SO Paint 200 Solvent Paint Line Cleaner or equivalent.

2. Clean threads with a wire brush.

3. Wipe excess material from screw.

REMOVE 518 LOCTITE FLANGE SEALANT Components mounted with Loctite 518 Flange Sealant leave residue on the component and mounting surface when removed. To clean the sealant: 1. Apply Bonderite C-SO Paint 200 Solvent Paint Line Cleaner or equivalent using a brush for thicker applications, or a solvent soaked rag for films.

2. Wipe excess material from the surface. If thicker material is present, allow the solvent to remain on the material for several minutes, then scrape with a plastic or wooden scraper.

3. Wipe parts with cleaning solvent to remove residual Bonderite.

1.11

Safety

Tigercat Axles

APPLYING LOCTITE PRODUCTS

GASKET FORMING/SEALANT PRODUCTS

CAUTION

CAUTION

Loctite products present conditions for eye, skin and lung irritation. Product vapours may be harmful and are highly flammable. Products may adhere skin and objects together. Follow MSDS conditions and recommendations for handling and using Loctite products.

Loctite gasket and sealant products are known eye, skin and lung irritants. Use in well ventilated conditions in conjunction with appropriate PPE as specified in the MSDS.

Wait for a period of one hour before filling components or assemblies with oil after applying Loctite thread locking compounds to fasteners.

THREAD LOCKER AND PRIMER PRODUCTS

1. Remove oil and grease from the parts to be assembled.

2. Apply a bead of the gasket forming compound around the features of the part, leaving margin for the material to spread as the part parts are assembled.

3. Apply the mating part.

1. The use of Threadlocker and Primer products requires a primer application to both parts being joined. Where primers are used with Threadlocker products follow these directions and conditions.

4. Thread fasteners to secure the mating part and apply specified torque within the alloted working time.

2. Parts must be degreased and washed with suitable cleaning solutions prior to priming.

5. Wipe excess gasket forming product from the site.

COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING

3. Use of Threadlocker and Primer requires a well ventilated work area.

Information provided from the field is used in the warranty process and is an important source of information for Tigercat customer services and product engineers.

4. Spray or brush both parts to be joined with primer and allow to dry for a minimum of 70 seconds. Parts should be used within one month of priming. Parts that are primed for future use must be kept free of contamination.

5. Apply several drops of Threadlocker product to both contact surfaces.

Provide the requested information. Insufficient or incomplete information may negatively impact or delay warranty decisions and service actions.

6. Thread the fastener into the hole or nut to distribute the threadlocker evenly prior to tightening and apply specified torque values.

Service reporting sheets are available on-line at http//:www.Tigercat.com, or from the nearest Tigercat dealer.

7. Wipe excess Loctite from the site.

Warranty coverage of power train components is contingent on performance of regular oil sampling at the owner’s expense during the warranty period. Refer to TIGERCAT FLUID ANALYSIS (TFA) on page vii for details.

8. Secure the assembled parts and allow to cure for a minimum of 70 seconds.

1.12

Tigercat Axles SECTION 2 – DISASSEMBLY Read and understand the safety SECTION in this manual prior to servicing any machine components.

CONTENTS – SECTION 17

ISSUE 2.0, DECEMBER 2018

A

AXLE/BRAKE HOUSING, REMOVE........................................................................................................................... 2.15 AXLE, PREPARING TO DISASSEMBLE THE.............................................................................................................. 2.3 B

BOGIE ARM, REMOVE BOGIE ARM ORIENTATION.................................................................................................................................... 2.11 DISCONNECT BOGIE ARM FROM SLEW BEARING............................................................................................ 2.13 BRAKES, REMOVE SAHR BRAKE COMPONENTS............................................................................................................................... 2.17 SERVICE BRAKE COMPONENTS.......................................................................................................................... 2.16 H

HYDRAULIC TUBING, REMOVE.................................................................................................................................. 2.7 M

MACHINE ORIENTATION............................................................................................................................................. 2.3 MOVING AXLES/AXLE COMPONENTS ALL AXLES................................................................................................................................................................. 2.4 AXLES........................................................................................................................................................................ 2.4 BOGIE AXLES........................................................................................................................................................... 2.4 O

OIL, REMOVE BEFORE DRAINING OIL........................................................................................................................................... 2.5 FROM AN AXLE......................................................................................................................................................... 2.5 FROM AN AXLE WITH SERVICE AND SAHR BRAKES........................................................................................... 2.5 FROM AXLES WITHOUT BRAKES OR WITH SERVICE BRAKES ONLY................................................................ 2.6 FROM AXLES WITH SAHR BRAKES....................................................................................................................... 2.6 P

PLANETARIES, REMOVE FROM AXLES.................................................................................................................... 2.9 S

SAFETY......................................................................................................................................................................... 2.3 T

TRUNNIONS DISASSEMBLE REAR TRUNNION........................................................................................................................... 2.8 REMOVE TRUNNION PIN......................................................................................................................................... 2.8 REMOVE TRUNNIONS (AXLE)................................................................................................................................. 2.7

Disassembly

Tigercat Axles

2.2

Tigercat Axles

Disassembly

SAFETY

PREPARING TO DISASSEMBLE THE AXLE

See, SAFETY on page 1.4 for references to safety warnings and messages.

WARNING Axles and axle components are heavy. Use appropriate lifting devices. Support and brace major components so they DO NOT fall or roll.

When removing one major component from another ensure that both components are adequately supported and level.

MACHINE ORIENTATION A

B

C

B

A

See, MATERIAL LIFTING AND HANDLING on page 1.8 See, PERSONAL SAFE LIFTING AND CARRYING on page 1.9.

D

See,SAFE SUPPORT OF COMPONENTS on page 1.9.

C00376

A B C D

Planetary Brake (optional) Differential Yoke

See,CLEAN AND INSPECT on page 1.11.

Service the axle or components on a clean, robust work surface or on a floor or section of ground. The work area: A

B

• Must be level

C

• Must be clean • Have a barrier (tarpaulin or sheets of plywood) on the ground if not in a workshop.

F

• Must have components blocked to eliminate movement

MOVING AXLES/AXLE COMPONENTS Axles may be shipped as complete units or partially disassembled.

A E

D

C00377

A B C D E F

Bogie Arm Brake Housing Differential Planetary Yoke Slew Bearing

References to left or right of the axle or bogie axle are based on viewing the axle with the differential yoke facing the observer.

C00382

A B C D

2.3

Lifting Strap Planetary Brake Housing Differential

B

C

D

Disassembly

Tigercat Axles

Axles

All Axles

Place axles directly on the work surface (suitable stands or floor with blocks).

Separate the units as required.

1. Lift components using correctly rated lifting straps or chains and specified lift points.

Use lifting straps or chains and lifting rings.

A

B

D

C

J

H

E

G

F C00380

A B C D E

Lifting Strap Bogie Arm Bolts Lifting Chain Lifting Ring

F G H J

BOGIE AXLES

Planetary Bogie Slew Bearing Differential Brake Housing

2. Block each section of the axle so that adjacent segments are supported independently of the others.

DO NOT leave loads suspended.

Bogie axle units may be received as complete assemblies or in sections.

NOTICE

Move units or sections using lifting straps, chains and lifting rings.

Illustrations DO NOT show blocking or bracing of components. Refer to SAFE SUPPORT OF COMPONENTS on page 1.9.

For balanced lift on the bogie arms, use the lifting rings and chain wrapped in the locations illustrated.

2.4

Tigercat Axles

Disassembly

REMOVE OIL

2. Place a container of suitable size beneath the differential magnetic drain plug.

WARNING

3. Capture oil samples for Tigercat Fluid Analysis, if required. See, TIGERCAT FLUID ANALYSIS (TFA) on page vii.

Handle and dispose of materials in keeping with local, regional and national laws and regulations. In lieu of such laws and regulations, dispose of materials as suggested in the MSDS/ PSDS literature. See, WORKING WITH OIL on page 1.5.

4. Remove a fill plug nearest the magnetic drain plug.

5. Remove the magnetic drain plug from the differential. Inspect for metal particles.

6. Loosen the magnetic drain plugs from each planetary housing. Oil will drain from the planetaries and differential through the differential.

NOTICE

7. Remove gear oil remaining inside the axle during disassembly using clean rags. Absorb excess gear oil, then dispose of rags in a fireproof container.

An axle may contain up to 63 US litres (16.6 US gallons) of oil.

A bogie axle may contain up to 250 US litres (66.2 US gallons)of oil.

8. Clean all plugs of oil and debris.

9. Reinstall fill and drain plugs once clean.

Verify that containers are of sufficient size and quantity to safely contain and store drained oil.

FROM AN AXLE WITH SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES

Drain plugs vary in number and location depending upon axle model.

B

A

C

BEFORE DRAINING OIL Before draining oil from an axle, consider that: • The axle must be level • Drains must be facing down • Warm oil drains faster than cold.

FROM AN AXLE

F

A

B

A

C C00470

A B C D E F

E

D

Planetary Fill Plug Differential Approximate Fill Line Magnetic Drain Plug Brake/Axle Housing

Gear oil in axles with SAHR (Spring Applied Hydraulic Release) brakes may be segregated by a nylon bushing positioned between the SAHR brake and the differential.

Oil must be added separately to the differential and brake housings/planetaries.

D

C00384

A B C D E

E

Axle Housing Differential Fill Plug Magnetic Drain Plug Approximate Fill Line

Follow steps 1 to 9 of FROM AN AXLE on page 2.5.

Use multiple containers and remove the drain plugs from the differential and each brake/axle housing to empty the axle.

1. Orient the axle with the magnetic drain plug of the differential facing the ground.

2.5

Disassembly

Tigercat Axles From Axles With SAHR (Spring Applied Hydraulic Release) Brakes:

Samples for the Tigercat Fluid Analysis program must be taken separately from the differential and each brake housing/planetary.

5. Axles with SAHR brakes may be equipped with a nylon bushing that segregates differential/brake oil from planetary/bogie arm oil.

FROM A BOGIE AXLE A

B

A

6. Remove the magnetic drain plug from the differential. Oil will drain from the differential side of the nylon bushing in the brake housing, and the differential.

C

7. Remove magnetic drain plugs for the bogie arms, planetaries, and brake housings.

8. Collect separate oil samples from each bogie arm and the differential. See TIGERCAT FLUID ANALYSIS (TFA) on page vii.

E

9. Remove gear oil remaining inside the bogie housing during disassembly, using clean rags. Absorb excess gear oil, then dispose of rags in a fireproof container.

C B

D

BOGIE AXLES AND AXLES WITH SAHR BRAKES, BUSHING REMOVED

C00383

A B C D E

Bogie Arm Magnetic Drain Plug Fill Plug Approximate Fill Line Differential

Bogie axles and straight axles constructed after the listed serial numbers/date, or after SAHR brakes have been serviced no longer utilize the nylon bushing and retaining ring. With the bushing and retaining ring no longer used, oil is free to flow between major axle components.

1. Place containers of suitable size beneath each magnetic drain plug.

Fill axle assemblies using the fill ports on the brake housings. Allow time for oil to flow between components.

Axles with 15 inch and 17 inch differentials require up to 10 minutes to disperse oil evenly.

2. Loosen fill plugs.

From Axles Without Brakes Or With Service Brakes Only:

Machine Model

3. Remove magnetic drain plugs from the bogie arms and differential. Oil will drain from the planetaries into the bogie arms. Oil from the brake housings and differential will drain through the differential.

4. Capture oil samples for Tigercat Fluid Analysis, if required. See TIGERCAT FLUID ANALYSIS (TFA) on page vii.

Serial Number/Date

1085B

10850536

2160

216000103

1075C

10751071

632E

6320221

615E

6151028

625E

6250524

635G

6353073

1185

after 05/15/2018

See, BOGIE AXLES AND AXLES WITH SAHR BRAKES, BUSHING REMOVED on page 2.6.

2.6

Tigercat Axles

Disassembly

AXLE DISASSEMBLY

Trunnions may or may not be attached to the differential as received. There is a front trunnion (input side) and a rear trunnion. The front trunnion is open at both ends and fits over the yoke. The rear trunnion has a plate on one end.

MARK CRITICAL COMPONENT POSITIONS AND ALIGNMENTS WITH A SCRIBE OR OTHER METHOD TO ASSIST IN REASSEMBLY.

REMOVE HYDRAULIC TUBING

Assess trunnion wear while trunnions are attached to the differential.

Remove hydraulic tubing from the differential and inspect for damage. DO NOT re-use bent, creased or crushed tubing or fittings.

DO NOT turn fittings using the tubing. Use the correct tools to loosen and tighten fittings.

1. Place pry bars through the mounting tabs and attempt to move the trunnion on the differential. If there is a notable amount of play, the trunnion must be removed and components evaluated.

Note and record the location and arrangement of any tubes found on the differential.

2. Inspect each trunnion carefully for seal condition and bushing wear.

REMOVE TRUNNIONS (IB17, OB17, IB15 OSCILLATING DIFFERENTIALS)

3. Pull each trunnion straight off the differential.

DISASSEMBLE FRONT TRUNNIONS

REMOVE TRUNNIONS (AXLE) A

A

B

C

B

D

E

C00396

A B C D E

Urethane Seal Thrust Washer Front Trunnion Front Bushing Oil Seal

1. Remove the oil seal from the front of the trunnion.

2. Remove the front trunnion bushing. a. Place the trunnion on support blocks.

C C00395

b. Tap the bushing incrementally in a rotating star pattern from the trunnion using a punch and hammer.

A Rear Trunnion B Axle C Front Trunnion

3. Remove the urethane seal from the rear of the trunnion. Discard the seal.

4. Remove the thrust washer.

2.7

Disassembly

Tigercat Axles

DISASSEMBLE REAR TRUNNIONS A

B

REMOVE TRUNNION PIN

C

A

B

D E

J H

C00398

A B C D E F G H J

G

F

C00397

C

A Differential B Trunnion Pin C Bolts

Trunnion Cap Shims Thrust Washer Rear Trunnion Oil Seal Retaining Ring Rear Trunnion Bushing Washer Bolt

1. Remove the rear trunnion pin from the differential. a. Remove bolts holding the trunnion pin to the differential. b. Remove the trunnion pin.

1. Remove the oil seal.

2. Remove the retaining ring.

3. Remove the rear trunnion bushing: a. Place the trunnion on support blocks. b. Tap the bushing incrementally in a rotating star pattern from the trunnion, using a punch and hammer.

2.8

Tigercat Axles

Disassembly

REMOVE PLANETARIES FROM AXLES A

L

K

B

C

D

E

J

F

G H

C00385

A B C D E F

Inboard Planetary Axle

Differential Brake Housing O-ring Sun Gear Ring Gear Axle Housing

G H J K L

A

L

K

B

C

Washers Bolts Spring Pin Shims Spacer

D

J

Differential Axle Housing O-ring Axle Shaft Ring Gear Planetary

Outboard Planetary Axle G H J K L M

2.9

F

G H

M

C00386

A B C D E F

E

Washers Bolts Spring Pin Shims Spacer Sun Gear

Disassembly

Tigercat Axles A B C

D

E

F

G H

C00387

A B C D

Bogie Arm Output Gear Support O-ring Bogie Output Shaft

Bogie Axle Planetary E F G H

For information regarding service and repair of Tigercat planetaries, see 47738AENG, PLANETARIES, SERVICE AND REPAIR MANUAL.

Ring Gear Planetary Washers Bolts

WARNING The bogie axle bearing support is held in place by the planetary. Once the bolts are removed the bearing support may fall. Secure the bearing support.

1. Position the axle in a clean work area so that all axle components are adequately supported on stands or wooden blocks (not shown).

Planetaries are attached to a brake housing/axle housing on axles.

Planetaries are attached to the outside of each bogie arm.

5. Remove the two remaining bolts from the planetary, then remove the planetary.

2. Remove the bolts: a. Leave two bolts horizontally opposed to secure the planetary from binding on the dowels.

a. Pull the planetary perpendicular to the differential/brake housing/axle housing/bogie arm.

Bogie Axle Planetaries b. Secure the bearing support to the bogie arm using two bolts with washers.

b. Remove bolts from the top half of the planetary.

3. Remove the bolts from the bottom half of the planetary.

c.

4. Cinch lifting straps to the planetary and tension them in preparation to support and move the planetary See, MOVING AXLES/AXLE COMPONENTS on page 2.3.

2.10

Remove the output shaft.

Tigercat Axles

Disassembly WARNING

NOTICE

The IB15 axle brake housing is held in place by the planetary. Once the bolts are removed the brake housing may fall. Secure the brake housing.

If axles, spacers, shims, input gears or input bearings are replaced, recalculate the axle shaft end play. The spacer, shims and spring pin are attached to the long spline end of the left axle shaft. Verify that these parts DO NOT remain in the bogie housing/differential.

Planetaries IB15 ONLY d. Secure the axle brake housing to the differential using two bolts with washers.

NOTICE

e. Remove the axle shaft/sun gear. A shaft spacer and shims are attached to the end of the left axle shaft. Verify that they are present when the left shaft is removed.

Bogie axles with parking (SAHR) brakes require that the parking brake be released before removing or installing the axle. Retraction pressure is 32-34 bar (470-500 psi). See, REMOVE BOGIE AXLE SHAFT on page 2.12 , step 9.

6. Set the sun gear aside for cleaning and inspection.

SAFETY on page 1.4

REMOVE BOGIE ARM

BOGIE ARM ORIENTATION

WARNING

A

Bogie arm components are heavy. Use appropriate lifting devices. Support and brace major components so they DO NOT fall or roll.

When removing one major component from another ensure that both components are adequately supported and level.

C

F

D

See, SAFETY on page 1.4.

See, PERSONAL SAFE LIFTING AND CARRYING on page 1.9.

E

See, SAFE SUPPORT OF COMPONENTS on page 1.9.

G

Service the bogie arm on a clean, robust work surface or on a floor or section of ground. The work area:

F

C00421

A B C D E F G

• Must be level • Must be clean • Have a barrier (tarpaulin or sheets of plywood) on the ground if not in a workshop • Must have components blocked to eliminate movement.

B

Left Bogie Arm Differential Right Bogie Arm Planetary Yoke Planetary Side of Bogie Arm Differential Side of Bogie Arms

References to a left or right bogie arm are based on viewing the bogie axle with the differential yoke facing the observer.

WARNING When removing the input cover on the bogie arms, the input gear and bearing may slide out of the bogie arm.

2.11

Disassembly

Tigercat Axles

REMOVE BOGIE AXLE SHAFT

M

N

P

Q

A

G

H L

K

J

E

D

C

B

F C00484

C00391

A B C D E F G H

Bogie Arm Axle Shaft Input Gear Shaft Support Spacer Retaining Ring Punch Mark (on Input Gear Cover) Inner Race Outer Race

J K L M N P Q

O-ring Input Gear Cover Bolts Spring Pin Shims Spacer Output Bearing Support

Locate the brake housing/slew bearings between the bogie arms and differential.

1. Remove the retaining ring securing the shaft support spacer in the input gear.

1. Brace components with stands or wooden blocks so that the central axle components DO NOT drop when disconnected from the bogie arms.

2. Remove the shaft support spacer.

NOTICE

2. Place a heavy piece of cardboard or plywood beneath the input gear cover.

3. Remove the bolts securing the input gear cover, then remove the cover. The input gear and bearing may fall from the bogie arm when the cover is removed.

4. Remove the input gear and bearing outer race.

5. Remove the o-ring from the input gear cover.

6. Remove the bead of sealant from the cover and the cover seat. See,THREAD LOCKING COMPOUNDS AND SEALANTS on page 1.11 2.12

Replacing a damaged axle shaft or worn spacer requires recalculation of the shim stack height.

See, INSTALL BRAKES on page 3.5

Tigercat Axles

Disassembly DISCONNECT BOGIE ARM FROM SLEW BEARING E

D

C00463

F

A

C

B

A Use indicated ports for SAHR brake retraction C00392

1. Release the parking brakes if SAHR (Spring Applied Hydraulic Release) brakes are present. This activity may require two persons; one to activate oil pressure, the other to remove the axle. If there are no brakes, or service brakes only, proceed to step 10.

A B C D E F

Differential Bolts Slew Bearing Bogie Arm (with axle shaft removed) Slew Bearing Mounting Surface Oil Seal

a. Refer to the associated machine service manual to determine which ports on the axle must be energized to release the brakes.

MARK THE ALIGNMENT OF THE SLEW BEARING BALL PORTS RELATIVE TO THE BRAKE HOUSING AND THE BOGIE HOUSING.

b. Install an M14 input fitting suitable for use with the available oil supply system into the port indicated in the machine service manual.

1. Brace components with stands or wooden blocks or cinch lifting straps to the bogie mounting housing and tension them in preparation to support and move the housing. See, MOVING AXLES/AXLE

c.

Connect the oil supply to the fitting and activate the oil pressure to retract the SAHR brake.

COMPONENTS on page 2.3.

2. Attach lifting rings to the lifting plates on the bogie arm if using a lifting device.

2. Remove the axle shaft from the differential.

Left and right axle shaft a. Pull the shaft straight out, perpendicular to the differential.

3. Verify that the bogie axle shaft for the side of the bogie being serviced has been removed. See, AXLE DISASSEMBLY on page 2.7

Left axle shaft only

4. Remove the bolts from the slew bearing: a. Remove bolts from the top half of the slew bearing that secure it to the bogie arm.

b. Verify that a shaft spacer, shims and spring pin are secured to the long spline end of the left axle shaft. These components must be accounted for during disassembly. If they remain in the differential they will cause severe damage to the differential.

3. Repeat steps 1 to step 10 for the right side bogie axle shaft.

4. Cinch lifting straps and tension them in preparation to support and move the bogie housing. See, MOVING AXLES/AXLE COMPONENTS on page 2.3 .

b. Leave two bolts horizontally opposed in the slew bearing. c.

Remove the bolts from the bottom half of the slew bearing.

5. Remove the two remaining bolts from the slew bearing.

6. Move the bogie arm perpendicular to the differential using a lift or pry bars. The bogie mounting plate must clear the end of the slew bearing. DO NOT tip the bogie arm over.

7. Follow step 1 to step 6 to remove the other bogie arm.

2.13

Disassembly

Tigercat Axles

REMOVE SLEW BEARINGS A

B

C

D

E

F C00393

A B C D E F

Brake Housing O-ring Scraper Ring Slew Bearing Bolts Differential

1. Brace components with stands or wooden blocks.

2. Mark the orientation of the slew bearings. Place a mark on the outer race of the slew bearing and a mark adjacent, on the brake housing.

3. Remove the bolts securing the slew bearing to the bogie mounting housing. a. Remove bolts from the top half of the housing. b. Leave two bolts horizontally opposed in the housing. c.

Remove the bolts from the bottom half of the housing.

4. Remove the two remaining bolts, then remove the slew bearing.

5. Remove the scraper ring from the slew bearing.

6. Remove the O-ring from the brake housing.

2.14

Tigercat Axles

Disassembly

REMOVE AXLE/BRAKE HOUSINGS

A

B

C

D

E

F

G

H

J

U T S

R

P

Q

N M

K

L

C00394

A B C D E

Differential Inner Backup Ring Inner Square O-ring Outer Square O-ring Outer Backup Ring

K L M N P

SAHR Brake Rod Seal SAHR Brake Piston Bolt Washer Brake Housing

Service Brakes

F G H J

Brake Piston Reaction Plate Friction Plate Piston Return Spring

SAHR (Spring Applied Hydraulic Release) Brakes Q R S T U

SAHR Brake Piston Seal SAHR Brake Thrust Washer Belleville Washers SAHR Spring Retainer Bolts

1. Brace components with stands or wooden blocks.

4. Verify straps are positioned and tensioned correctly.

2. Cinch lifting straps to the axle/brake housing and tension them in preparation to support and move the housing. See, MOVING AXLES/AXLE

NOTICE Service brake components are loose in the brake housing and may fall out when the brake housing is removed.

COMPONENTS on page 2.3

3. Remove the bolts from the axle/bearing housing. a. Remove bolts from the top half of the axle/ bearing housing. b. Leave two bolts horizontally opposed in the axle/ bearing housing. c.

5. Loosen the two bolts securing the brake housing to the differential. Turn each bolt, incrementally, to equally diminish the pressure exerted by the Belleville washers on the housing.

Remove the bolts from the bottom half of the axle/brake housing.

2.15

Disassembly

Tigercat Axles

6. Remove the two remaining bolts, then remove the axle/brake housing.

A

NOTICE Wipe the plates clean using a clean cloth, then inspect for wear. DO NOT clean the friction plates with alcohol or solvents.

B

7. Remove the loose reaction and friction plates from the axle/brake housing.

8. Remove the piston return springs from the brake housing.

9. Remove and discard the o-ring from between the brake housing and differential.

C C00390

REMOVE BRAKES

A Differential B Pry Bars C Brake Piston

SERVICE BRAKE COMPONENTS

CAUTION Wear appropriate PPE and follow instructions for using compressed air, see COMPRESSED AIR on page 1.5. Wear eye protection.

3. If compressed air is unavailable, use lady slipper pry tools to carefully remove the brake piston. DO NOT mar the machined surfaces.

A B

A

C

B

C00389

C00459

C

A B C D E F

A Air Pressure Device B Differential C Brake Piston

1. Insert an air nozzle into the input port.

2. Apply a rag (not shown) against the brake piston.

Hold it firmly in place and apply air pressure.

The brake piston is expelled from the housing as pressure is applied.

D

Differential O-ring Inner Backup Ring Inner Square O-ring Outer Square O-ring Outer Backup Ring

4. Remove the inner and outer backup rings and O-rings from the differential . Discard them.

5. Remove and discard the O-ring found between the differential and brake housing.

2.16

Tigercat Axles

Disassembly

SAHR (SPRING ASSISTED HYDRAULIC RELEASE) BRAKE COMPONENTS

b. Remove the bolts when pressure is fully relieved from the Belleville washers.

3. Remove the SAHR spring retainer.

WARNING DO NOT service SAHR brakes without reading THIS SECTION thoroughly. Internal components are compressed and possess high potential energy. Follow instructions in the manual carefully to avoid injury. Wear appropriate PPE.

4. Remove the Belleville washers.

5. Remove the SAHR brake thrust washer.

A B

Tigercat axles are manufactured without brakes, with service brakes only, or with service brakes and SAHR brakes.

The SAHR spring retainer, Belleville washers, inner and outer O-rings, SAHR brake thrust washer and SAHR brake piston remain with the brake housing when removed from the differential.

C

1. Position the brake housing on a work surface with the planetary end down.

A

A

B C D C00458

A B C D E F

E

F

E

D

SAHR Brake Piston Dowel Axle/Brake Housing SAHR Brake Rod Seal SAHR Brake Piston Seal Protective Barrier

6. Orient the brake/axle housing horizontally. Block the housing so it does not move.

7. Tap the SAHR brake piston from the brake/axle housing.

C00457

A B C D E

a. Place a protective barrier in the planetary side of the housing to protect the SAHR brake piston if it falls.

Bolts SAHR Spring Retainer Belleville Washers SAHR Brake Thrust Washer Brake Housing

2. Loosen the bolts securing the SAHR spring retainer to the SAHR brake piston slowly. a. Turn each bolt, incrementally in a rotating star pattern to equally diminish the pressure exerted on the retainer by the Belleville washers.

b. Tap around the circumference of the piston in an incremental star pattern using a wooden dowel and a hammer.

8. Remove the inner backup ring and inner square O-ring from the housing.

9. Remove and discard the outer backup ring and outer square O-ring from the SAHR brake piston.

2.17

Disassembly

Tigercat Axles

10. Remove remove and discard the the retaining ring and nylon bushing from the SAHR brake piston.

DIFFERENTIAL For information regarding service and repair of Tigercat differentials, see 47574AENG, DIFFERENTIALS, SERVICE AND REPAIR MANUAL.

2.18

Tigercat Axles SECTION 3 – ASSEMBLY Read and understand the safety section in this manual prior to servicing any machine components.

CONTENTS – SECTION 3

ISSUE 2.0, DECEMBER 2018

A

AIR PRESSURE TESTING AXLE LEAK TEST.................................................................................................................................................... 3.29 SERVICE BRAKE TEST.......................................................................................................................................... 3.30 AXLE INSTALLATION INSTALL BOGIE INPUT/AXLE SHAFT.................................................................................................................... 3.19 INSTALL SUN GEAR, AXLE SHAFT AND PLANETARY......................................................................................... 3.22 LEFT AXLE SUN GEAR/AXLE SHAFT.................................................................................................................... 3.21 RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES..................................................... 3.20 RIGHT AXLE SUN GEAR/AXLE SHAFT FOR SERVICE AND SAHR BRAKES..................................................... 3.20 RIGHT SUN GEAR/AXLE SHAFT AND PLANETARY............................................................................................. 3.22 B

BEARING INSTALLATION COOLING BEARINGS AND SLEEVES FOR INSTALLATION................................................................................... 3.3 HEATING BEARINGS FOR INSTALLATION............................................................................................................. 3.4 BLEED SCREWS, FITTINGS AND PLUGS, INSTALL.................................................................................................. 3.4 BOGIE ARMS.............................................................................................................................................................. 3.13 INSTALL BOGIE ARM.............................................................................................................................................. 3.18 C

CLEANING AND INSPECTION..................................................................................................................................... 3.3 COOLING BEARINGS FOR INSTALLATION................................................................................................................ 3.3 D

DIFFERENTIAL............................................................................................................................................................. 3.4 F

FILL THE AXLE WITH OIL.......................................................................................................................................... 3.31 BOGIE AXLE............................................................................................................................................................ 3.32 STRAIGHT AXLE..................................................................................................................................................... 3.32 G

GUIDE PINS.................................................................................................................................................................. 3.4 I

INSTALL BRAKE HOUSING/AXLE HOUSING........................................................................................................... 3.13 BRAKE/AXLE HOUSING OB17, IB17, OB20 AXLE................................................................................................ 3.13 BRAKE HOUSING IB15 AXLE................................................................................................................................. 3.13 INSTALL BRAKES SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES................................................................................. 3.8 SERVICE BRAKE O-RINGS/BACKUP RINGS.......................................................................................................... 3.6 SERVICE BRAKE PISTON........................................................................................................................................ 3.6 SERVICE BRAKES.................................................................................................................................................. 3.12 INSTALL SUN GEAR, AXLE SHAFT AND PLANETARY............................................................................................ 3.22 LEFT SUN GEAR/AXLE AND PLANETARY............................................................................................................ 3.23 PLANETARIES TO BOGIE ARM.............................................................................................................................. 3.24 RIGHT SUN GEAR/AXLE SHAFT AND PLANETARY............................................................................................. 3.22 M

MACHINE ORIENTATION............................................................................................................................................. 3.3 MOVING AXLE COMPONENTS................................................................................................................................... 3.3 O

OIL, FILL THE AXLE AXLES WITH NO BRAKES/SERVICE BRAKES ONLY........................................................................................... 3.31

Assembly

Tigercat Axles

AXLES WITH SAHR BRAKES................................................................................................................................. 3.32 P

PRESSURE TESTING, AIR AXLE LEAK TEST.................................................................................................................................................... 3.29 S

SLEW BEARINGS GREASE A BOGIE SLEW BEARING...................................................................................................................... 3.17 GREASE A LUBED FOR LIFE SLEW BEARING..................................................................................................... 3.16 INSTALL SLEW BEARINGS.................................................................................................................................... 3.14 SLEW BEARING ORIENTATION............................................................................................................................. 3.14 TYPES OF SLEW BEARINGS................................................................................................................................. 3.16 T

TRUNNIONS, INSTALL ALTERNATE TRUNNION BUSHING INSTALLATION............................................................................................. 3.28 FRONT TRUNNION................................................................................................................................................. 3.27 REAR TRUNNION................................................................................................................................................... 3.26 TRUNNION BUSHINGS.......................................................................................................................................... 3.26 TRUNNION PIN....................................................................................................................................................... 3.25

3.2

Tigercat Axles

Assembly

SAFETY

BEARING INSTALLATION

See SAFETY on page 1.4 of this manual for references to safety warnings and messages.

COOLING BEARINGS AND SLEEVES FOR INSTALLATION

MACHINE ORIENTATION

WARNING

See MACHINE ORIENTATION on page 2.3 for pictorial references to left or right sides of the axle or bogie axle.

These are based on viewing the axle with the differential yoke facing the observer.

Chilled components are extremely cold and may damage exposed tissues. Use appropriate PPE when handling chilled parts.

MOVING AXLE COMPONENTS

Cooling shrinks bearings and sleeves to allow them to be inserted with machine features to ensure the tightest fit possible between surfaces.

See, MOVING AXLES/AXLE COMPONENTS on page 2.3 for pictorial references for moving axles and axle components. Axles and axle components may be shipped in a variety of states of assembly or disassembly. Review this manual to determine which procedures fit the task at hand.

Cooling may take place in a freezer unit where the part is left for a period of time and allowed to reach a minimum temperature. In other instances, use liquid nitrogen to cool the parts.

CLEANING AND INSPECTION See CLEAN AND INSPECT on page 1.11 of this manual for references to cleaning and inspecting the unit.

WARNING Only workers trained in handling liquid nitrogen may do so. See the MSDS or PSDS for proper handling and storage of liquid nitrogen. DO NOT attempt to use liquid nitrogen until properly trained.

PRIOR TO ASSEMBLY Prior to axle assembly: 1. Have all required parts readily available.

2. Clean and inspect each component before it is assembled.

Liquid nitrogen or vapours from liquid nitrogen can cause severe damage to exposed skin, eyes or lungs. Always wear protective equipment and use tongs to remove parts from the liquid nitrogen bath.

3. Verify dimensions of parts to be assembled or replaced.

• Ensure they are the right parts.

When cooling bearings:

• Verify orientation.

1. Refer to the bearing manufacturer's literature for bearing cooling specifics.

• Replace damaged or worn components as required.

2. Standard product bearings should not be cooled below -54°C (-65°F).

4. Prepare bearings for installation. Bearings must be thoroughly cleaned, then kept covered, free from dirt and damage.

3.3

Assembly

Tigercat Axles

HEATING BEARINGS FOR INSTALLATION

2. Insert the part in the correct orientation with the cone shape facing up to fit into the bottom of the bleed screw.

WARNING

3. Insert the bleed screw.

Heated bearings are extremely hot. Use appropriate PPE when handling hot parts. See, HEATING BEARINGS FOR INSTALLATION on page 3.4.

4. Tighten the bleed screw finger tight. The bleed screw must be snug in the threaded hole.

5. Tighten the bleed screw an additional one quarter turn using a wrench.

1. Always refer to the bearing manufacturer's literature for bearing heating specifications.

6. Apply step 1 to step 4 for other fittings and plugs unless otherwise indicated.

2. Direct flame or localized heat applied to a bearing may raise the bearing temperature unevenly, resulting in race hardness reduction.

GUIDE PINS NOTICE

3. Take extreme care that standard product bearings, gears, or steel sleeves are never heated above 120°C (250°F). If bearings, gears, or steel sleeves are heated above this temperature, the metallurgical structure may soften, rendering them unsuitable for use.

Fasteners used to make guide pins must match the thread size and pitch of the component into which they are inserted.

Guide pins are modified fasteners, made by assembly technicians, used to assist with parts assembly. Review the components to be assembled and make guide pins accordingly. For details, see, GUIDE PINS on page 1.10.

4. Heat and cool bearing components gradually.

5. Use feeler gauges to ensure the bearing components are fully seated after the parts are positioned and cooled.

DIFFERENTIAL

INSTALL BLEED SCREWS, FITTINGS AND PLUGS

For information regarding service and repair of Tigercat differentials, see 47574AENG, DIFFERENTIALS, SERVICE AND REPAIR MANUAL.

Bleed screw seats, bleed screws, fittings and plugs are made of materials more malleable than steel and are subject to deformation and compression if overtightened.

Finger tighten these parts so that they can be loosened as required during assembly, until final tightening is needed.

A

B

C00455 A Bleed Screw B Bleed Screw Seat

When completing final installation of bleed screw seats and bleed screws: 1. Apply a small amount of gear oil to the bleed screw seat.

3.4

Tigercat Axles

Assembly

INSTALL BRAKES A

B

C

D

E

U T S

R

Q

P

N M

K

L

C00394

A B C D E

Differential Inner Backup Ring Inner Square O-ring Outer Square O-ring Outer Backup Ring

K L M N P

SAHR Brake Rod Seal SAHR Brake Piston Bolt Washer Brake Housing

Service Brakes

F G H J

Brake Piston Reaction Plate Friction Plate Piston Return Spring

SAHR (Spring Applied Hydraulic Release) Brakes Q R S T U

Tigercat axles may be built without brakes, with service brakes, or with service brakes and SAHR brakes.

If the axle being serviced does not come equipped with brakes, proceed to INSTALL BRAKE HOUSING/AXLE HOUSING on page 3.13.

3.5

SAHR Brake Piston Seal SAHR Brake Thrust Washer Belleville Washers SAHR Spring Retainer Bolts

F

G

H

J

Assembly

Tigercat Axles

SERVICE BRAKE O-RINGS/BACKUP RINGS

SERVICE BRAKE PISTON

NOTICE

A

G

B

F

C

DO NOT damage the inner and outer square O-rings or backup rings. Verify they are seated correctly. Pinched or damaged rings must be replaced.

5. Apply the brake piston into the differential housing. a. Lubricate the brake piston with gear oil. b. Insert the brake piston into the differential housing. Maintain the face of the brake piston parallel to the face of the differential retainer.

D B C

E

A B

E C

D

C00399 A B C D E F G

D

Differential Inner Backup Ring Inner Square O-ring Outer Square O-ring Outer Backup Ring Service Brake Port Bleed Port

E

F

1. Position the differential on a clean work surface with blocks or wedges (not shown) so that axle components are adequately supported.

2. Loosen the service brake port and bleed port fittings.

3. Install inner and outer O-rings into the differential retainer.

C00486 A B C D E F

a. Apply a coat of thick assembly grease to each O-ring. b. Insert the inner and outer square O-rings. Note the orientation of each ring, relative to the other.

4. Install inner and outer backup rings into the differential.

Bolt Washer Jack Bolt Brake Piston Installation Tool 80090B Service Brake Piston Differential

a. Apply a coat of thick assembly grease to each backup ring.

6. Apply the brake piston installation tool 80090B on the differential retainer per kit instructions. Secure each end using a bolt with washer torqued to 27Nm (20 lbf-ft).

b. Insert the inner and outer backup ring. Note the orientation of each ring, relative to the brake piston.

7. Thread a jack bolt into each of the weld nuts until each bolt makes contact with the surface of the brake piston.

3.6

Tigercat Axles

Assembly

8. Incrementally tighten the jack bolts one turn at a time in an alternating pattern, using a hand tool, to seat the brake piston into the retainer as far as it will go. Tap the perimeter of the brake piston while tightening the jack bolts.

13. Repeat step 1 to step 13 for the opposite side of the differential.

A

B C

DO NOT force the brake piston.

DO NOT pinch the square O-rings or backup rings. If the rings are damaged, they must be replaced.

A

B D

A

C00445 A B C D E

E

D

C

Differential Air Supply in Brake Inlet Port Jack Bolt Brake Piston Installation Tool 80090B Service Brake Piston

D C

9. Loosen the brake piston instillation tool 12.75mm (0.25 inch) so that there is a gap between the bottom surface of the tool and the brake piston.

A B C D

10. Insert an air supply coupler to the brake inlet port opening.

11. Test the brake piston seals. a. Apply air to deflect the brake piston against the bottom of the brake piston installation tool. b. Incrementally tighten the jack screws (see step 8) to press the service brake piston back in as far as it will go, then repeat step 11a to verify that the piston deflects properly. c.

B

C00402

If the piston does not move extract the piston and replace the inner and outer rings.

d. Repeat step 10 and step 11.

12. Remove the brake piston installation tools.

3.7

Left and Right IB15 Brake Piston Tabs

Brake Piston Differential Tab Alignment With Bolt Hole Yoke

B

Assembly

Tigercat Axles SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES

A D

NOTICE The brake housing must be parallel to a level work surface to install the SAHR brake piston.

A

C

B

C00401

Left and Right OB20/IB17/OB17/OB15 Brake Piston Tabs A B C D

Brake Piston Differential Tab Alignment With Bolt Hole Yoke

B

14. Tighten bleed screws and plugs finger tight, then tighten one quarter turn using a wrench.

C00446 A Brake Housing B SAHR Brake Piston

1. Lubricate the SAHR brake piston seal grooves with gear oil.

A

B

C

C00464 A SAHR Brake Piston Seal B Brake Housing C SAHR Brake Rod Seal

3.8

Tigercat Axles

Assembly

2. Lubricate the SAHR brake rod seal with gear oil, then install it in the groove in the axle/brake housing.

A

3. Lubricate the SAHR brake piston seal with gear oil, then install it on the piston.

NOTICE Step 4 may require an assistant to hold the piston in place while the SAHR spring retainer is applied. Increased tolerances require that the piston be installed using the retainer to evenly pull the piston into position.

B

C00652

A Spring Retainer B Bolts Set Equally Spaced

A

6. Align the holes in the spring retainer with those in the piston, then insert four lubricated bolts positioned 90° to one another, through the retainer, to engage the piston threads.

7. Tighten the bolts finger tight in a criss-cross patter, then continue to tighten the bolts incrementally, one turn at a time until the piston is flush with the spring retainer.

F

E

B

8. Remove the bolts, then remove the retainer.

9. Inspect both sides of the piston bore for seal shavings.

D

a. Hair-thin pieces of shaved seal are permissible as they will not effect seal performance.

C C00651

A B C D E F

b. Remove the piston and inspect the seals if larger portions of seal are evident.

Brake Housing Spring Retainer Bolts SAHR Brake Piston SAHR Brake Rod Seal SAHR Brake Piston Seal

c.

Repeat step 1 to step 7 if seal replacement is required.

10. Seat the piston using a rubber mallet from the piston side of the brake housing.

4. Insert the piston into the brake housing so that the lead edge of the piston shaft contacts the machined mating face of the brake housing evenly. An assistant may be required to hold the piston in place.

11. Orient the brake housing on a level surface with the SAHR brake piston facing up.

5. Insert the SAHR spring retainer from the other side of the brake housing.

3.9

Assembly

Tigercat Axles A

A B

B

C

D

E

C00447

A SAHR Brake Thrust Washer B Groove in Brake Housing

C00448 A B C D E

12. Apply white grease to the groove in the brake housing, then install the thrust washer in the groove.

13. Apply white grease to the surface of the SAHR thrust washer.

NOTICE

Bolt SAHR Spring Retainer Belleville Washers Spring Guide Tool B7506000 Brake Housing

14. Place Spring Guide Tool B7506000 on the end of the brake piston in the brake housing.

The brake housing must be perpendicular to a level work surface to align the Belleville washers.

A A

A

A

A-A

GAP

A

B

C

D

C00407 A B C D

Belleville Washers Spring Guide Tool B7506000 SAHR Brake Piston Brake Housing

15. Install the Belleville washers onto the spring guide tool with the convex sides contacting one another.

There must be a gap between the outer edges.

3.10

Tigercat Axles

Assembly A

B

A B C

C D

H D E G

F

F E C00449 A B C D E F

C00450

Spring Guide Tool B7506000 Bolt Ball Lock Pins B7506001 SAHR Spring Retainer Belleville Washers Brake Housing

16. Remove spring guide tool B7506000, carefully from the piston/Belleville washers. The washers must remain aligned with the piston.

17. Insert ball lock pins B7506001 into opposite holes into the top of the spring retainer to pick up the SAHR spring retainer.

18. Lower the SAHR spring retainer onto the piston/ Belleville washers, then disengage the ball lock pins.

19. Apply Loctite #263 to bolts, then install into the SAHR spring retainer. Torque bolts to 53 Nm (39Lbf-ft) in an incremental star pattern. Incremental tightening applies an even load to the Belleville washers beneath the SAHR spring retainer. See, APPLYING LOCTITE PRODUCTS on page 1.12.

A B C D E F G H

Dial Indicator Brake Housing SAHR Spring Retainer Hydraulic Supply Fitting Bleed Seat Bleed Screw Magnetic Plug Measuring Rod

20. Install a bleed seat insert and bleed screw into the bleed port. Finger tighten, then tool tighten one quarter turn.

21. Install magnetic plug(s) into the drain port(s).

22. Insert a hydraulic fitting into the input port. Finger tighten, then tool tighten one quarter turn.

23. Apply hydraulic pressure, slowly, to the hydraulic fitting and loosen the bleed screw until oil seeps from the bleed screw, then tighten the bleed screw.

24. Install a dial indicator on the end of the brake housing with the measuring rod set at a right angle to contact the SAHR spring retainer surface.

25. Apply and release hydraulic pressure to move the piston through the range of motion. Required pressure is 32bar (470 psi ) to 35bar (500 psi) Displacement must be 5.7mm – 6.2mm (0.225 in – 0.245 in).

3.11

Assembly

Tigercat Axles

SERVICE BRAKES A

NOTICE Reaction plate inspection tabs must align with the inspection port.

H

A E B

B C F

D

C

G

C00461 A B C D E

E

2. Install the service brake piston return springs into the brake housing.

D

C00404 A B C D E F G H

Reaction Plate Friction Plate O-ring Brake Housing SAHR Brake Service Brake Piston Return Spring Inspection Tabs Must Align Oil Passages Must Align

1. Install reaction plates and friction plates into the brake housing. a. Install a reaction plate into the housing. Ensure the inspection tabs align with the inspection port. b. Apply a light coat of clean gear oil to each friction plate. c.

Brake Housing Inspection Port Reaction Plate (Tabs Aligned With Inspection Port) Friction Plate Magnetic Plug

Install a friction plate in the housing.

d. Repeat step a to step c. The number of reaction plates and friction plates depends upon the axle configuration. The oil passages in the friction plates must align.

3.12

Tigercat Axles

Assembly

INSTALL BRAKE HOUSING/AXLE HOUSING The brake housing or axle housing may or may not contain brake components. If brake components are present, take steps to prevent the components from falling from the housings during installation.

3. Install temporary guide pins (see previous illustrations) in the brake housing to assist in brake housing alignment.

No Brake or Service Brake Only 4. Install the brake housing onto the differential.

BRAKE HOUSING IB15 AXLE

a. Hold brake components (if present) in position.

A

B

C

b. Align brake housing with the temporary dowel pins on the differential and engage the housing to the differential.

With SAHR (Spring Applied Hydraulic Release) Brakes Leave the hydraulic pressure in place to install the axle shaft.

5. Install the brake housing onto the differential. a. Align brake housing with differential.

D

b. Loosen the bleed screw on the brake housing.

C00406 A B C D

c.

Guide Pin O-ring Brake Housing Differential

d. Apply hydraulic pressure - 32bar (470 psi ) to 35 bar (500 psi) - to the input fitting on the brake housing to retract the brake.

BRAKE/AXLE HOUSING OB17, IB17, OB20 AXLE A

B

Apply minimal hydraulic pressure to purge air from the system. When hydraulic fluid flows from the bleed screw, reduce pressure and snug the bleed screw, finger tight.

C

6. Secure the brake housing to the differential using bolts with washers finger tightened. Hand torque each to 278Nm (205 lbf-ft) to ensure the service brake piston tabs are not bent. DO NOT use pneumatic tools to tighten the bolts.

7. Disengage hydraulic pressure, then slowly loosen the bleed screw to remove residual pressure. Place a rag over the bleed screw to avoid pressure spray.

F

C00405 A B C D E F

BOGIE ARMS E D

Guide Pin O-ring Axle Housing Bolt Washer Differential

For information regarding service and repair of Tigercat bogie arms, see 47732AENG, BOGIE ARM, SERVICE AND REPAIR MANUAL.

1. Apply a light coat of assembly grease to the O-ring and install it on the differential.

2. Clean the bolts and threaded bolt holes in the differential and apply Loctite Thread Locker 242 and Loctite 7649 Primer to each.

3.13

Assembly

Tigercat Axles

SLEW BEARINGS

INSTALL SLEW BEARINGS

Inspect slew bearings carefully for signs of wear and or damage. Damaged slew bearings must be replaced.

NOTICE

Bogie axles may be built with single row or double row slew bearings. Single and double row bearings requiring regular grease applications are essentially the same in construction. Single and double row slew bearings built to lube for life specifications are essentially the same in construction. The inner slew bearing race is mounted to the brake housing.

Mating surfaces must be clean and free of burrs.

DO NOT permit dirt or metal filings to fall into the bogie arm.

1. Align the slew bearing with the brake housing: a. Align the marks added prior to disassembly.

For A New, Lube For Life, Bearing

SLEW BEARING ORIENTATION

b. Align the manufacturer`s grease point and the red mark on the inner race at top centre of the bogie housing.

A

For A New, Greasable, Slew Bearing G

c.

B

Align the ball port and manufacturer`s red mark at the top centre of the bogie housing.

The alignment of either type of slew bearing may be skewed forwards or backward by several degrees depending upon bolt pattern machining. Whatever rotation is applied to one side MUST be applied to the other in the same direction and magnitude.

E

C A F

B

C

D

D

E

C00412 A B C D E F G

Brake Housing Single Row Slew Bearing Brake Housing Double Row Slew Bearing Bogie Arm Manufacturer`s Grease Point Ball Port

F C00452 A B C D E F

Install re-usable slew bearings using the alignment marks made at the time of disassembly.

For new slew bearings, align the manufacturer's marks (red) on the inner and outer races with the ball port openings on the larger outer race. Align the ball port with the markings made on the brake housing and bogie arm at the time of disassembly.

E

Scraper Ring O-ring Bolt Oil Seal Slew Bearing Brake Housing

2. Clean the bearing using isopropyl alcohol to remove any excess grease, then cover the bearing to protect from dirt and debris until ready for use.

3. Verify that the slew bearing mounting surfaces and matching surfaces on the brake housing are clean and free from burrs.

3.14

Tigercat Axles

Assembly

4. Apply a light coat of grease to the scraper ring, and scraper ring groove on the slew bearing, then insert the scraper ring in the groove of the slew bearing.

The large rib on the scraper ring faces out towards the brake housing.

5. Apply a light coat of oil to the O-ring then install the O-ring on the brake housing. The O-ring must not be twisted.

7. Clean bolts with isopropyl alcohol, then apply Loctite Thread Locker 242 and Loctite 7649 Primer to each bolt. See, APPLYING LOCTITE PRODUCTS on page 1.12.

8. Seat the slew bearing against the brake housing/ chassis. Verify the correct orientation, then thread bolts finger tight. Torque each to 560Nm (405 lbf-ft) in a star pattern.

NOTICE Align slew bearings on each side of the axle in the same direction and orientation.

G

A

B

F E C

C00466 A B C D E F G

D

Slew Bearing Bogie Arm Oil Seal (Grease is NOT permitted to seep from this oil seal) Brake Housing O-ring Scraper Ring Internal Seal

6. Align the slew bearing for mounting on the chassis or brake housing: a. Position the slew bearing with the scraper ring and O-ring facing the axle/brake housing. b. Align the marks made on the slew bearing and the brake housing at the time of removal. Align the slew bearing on the bogie arm: c.

Align the slew bearing as described in step 1.

The port may or may not align perfectly along the vertical axis. If the ball port on one slew bearing is slightly off centre with the ball port, ensure that the other ball port is off centre in the same direction and by the same amount.

3.15

Assembly

Tigercat Axles

TYPES OF SLEW BEARINGS Two types of slew bearings are utilized in Tigercat bogie axles.

A G B

The, lube for life, slew bearing is a sealed, self-lubricated bearing that requires minimal service. The outer ring is fitted with 4 grease fittings that require periodic lubrication to replace soiled grease in the grease buffer chamber. See the LUBRICATION AND MAINTENANCE section of the machine Operator and Service manuals.

The, greasable slew bearing requires lubrication during assembly and at regular service intervals as indicated in the machine Operator and Service manuals.

LUBRICATE SLEW BEARINGS

F

GREASE A LUBED FOR LIFE SLEW BEARING A

E

D

C

B

A

H

C

B F

E J

D

C

A

F

B

E

D

C00453 A B C D E F

F

Outer Race Low Pressure Grease Supply Input Port Slew Bearing Ball Fill Plugs (reference only) Outlet Port (remove plug)

1. Clean grease and debris from all fittings and outlet plugs.

E C00467 A B C D E F G H J

D

C

Grease Fitting Slew Bearing Grease Buffer Chamber O-ring Brake/Axle Housing Scraper Ring Single Row Slew Bearing - greasable Single Row Slew Bearing - lube for life Double Row Slew Bearing - lube for life

3.16

Tigercat Axles

Assembly GREASE A BOGIE SLEW BEARING

B

A

A

B

D

C00468 A B C D

B

C

C

Outlet Port Input Grease Fitting Slew Bearing Bogie Arm

2. Remove the outlet plug at the top of the slew bearing.

E

3. Apply a low pressure grease applicator to an input grease fitting on one side of the housing, then fill the grease buffer chamber until grease flows freely from the outlet port at the top of the slew bearing (90° away on the same side as the input port fitting.)

D

4. Repeat step 2 to step 3 on the input grease fitting opposite the first input grease fitting.

5. Install the plug in the outlet port at the top of the slew bearing. See, INSTALL BLEED SCREWS, FITTINGS AND PLUGS on page 3.4.

C

A C00454 A B C D E

C00469 A B C D

D

C

B

A

Input Grease Fitting Outlet Port Slew Bearing Bogie Arm

6. Remove the outlet plug from the outlet port at the bottom of the slew bearing.

7. Repeat step 2 to step 3 for the input grease fittings.

8. Install the plug in the outlet port at the bottom of the slew bearing.

9. Clean any excess grease.

Outer Race Ball Fill Plug (reference only) Grease Fitting (bottom) Slew Bearing Low Pressure Grease Supply

1. Apply a low pressure grease applicator to the bottom grease fittings, then gradually apply pressure until grease begins to purge from the gap between the bearing and the brake housing.

2. Repeat step 1 until all grease fittings have grease applied and grease is purged from the gap around the slew bearing.

3. Remove excess grease from around each fitting.

4. Rotate the bearing 90° and return to center, then rotate 90° the other direction and return to center.

5. Visually inspect that grease has vented past the scraper seal through the inward face of the bearing and towards the brake housing. The purged grease must be evenly distributed around the perimeter of the bearing.

3.17

Assembly

Tigercat Axles

INSTALL BOGIE ARM The bogie arm may come in a variety of states of assembly or disassembly.

Verify that there is no debris in the bogie arm or the mating components. Remove the necessary covers to facilitate assembly of the bogie arm and the differential.

B

A

G

F

E

8. The left bogie arm input gear cover, shaft spacer and retaining ring must be removed prior to installing the axle shaft/sun gear. If these parts are already serviced or new, leave them in place until the axle shaft/sun gear is ready to install. Remove them when ready for installation. See, LEFT AXLE SUN GEAR/AXLE SHAFT on page 3.21AXLE INSTALLATION

C

D

C00490 A B C D E F G

Bolt Bogie Arm Planetary (may or may not be present during bogie arm install) Oil Seal Dowel Pin Slew Bearing/Brake Housing Differential

1. Prepare to lift the bogie arm using lift rings and chains. See MOVING AXLES/AXLE COMPONENTS on page 2.3.

2. Apply a light coat of oil to the oil seal then install the seal onto the oil seal seat in the bogie arm with the open "U" shape facing the bogie arm.

3. Insert a dowel pin in the bogie arm on each side of the slew bearing mount, then tap the dowels to fully seat them.

4. Insert guide pins into bogie housing 5. Prepare the bolts (24) with Loctite 242 and Loctite 7649 Primer. See, APPLYING LOCTITE PRODUCTS on page 1.12.

6. Align the slew bearing with the bogie arm and mount it on the bogie arm using the dowels. Note the orientation of the individual slew bearings as indicated in INSTALL SLEW BEARINGS on page 3.14. The oil seal must be seated so that it does not roll an edge or come free from the seat.

7. Insert and thread bolts finger tight, then torque each to 386Nm (285 lbf-ft) in a star pattern. DO NOT use a swivel type adapter when torquing to spec. Use a torque bar with 3/4" drive socket and a shortened M14 stub.

3.18

Tigercat Axles

Assembly

BOGIE INPUT/AXLE SHAFT

M

N

Q

P

A

L

G

H K

J

E

D

C

B

F C00484

C00391 A B C D E F G H

Bogie Arm Axle Shaft Input Gear Shaft Support Spacer Retaining Ring Punch Mark (on Input Gear Cover) Inner Race Outer Race

J K L M N P Q

WARNING

NOTICE

When removing the input cover on the bogie arms, the input gear and bearing may slide out of the bogie arm.

Bogie axles with SAHR( Spring Applied Hydraulic Release) brakes require that the SAHR brake be retracted before removing or installing the axle. Retraction pressure is 32-35 bar (470500 psi).

NOTICE Re-calculate endplay after removing and replacing axles, spacers, shims, input gears or input bearings. The spacer, shims and spring pin are attached to the long spline end of the left axle shaft. Install the right shaft first, then the left shaft.

O-ring Input Gear Cover Bolts Spring Pin (Left Bogie Axle Shaft Only) Shims (Left Bogie Axle Shaft Only) Spacer (Left Bogie Axle Shaft Only) Output Bearing Support

NOTICE Bogie arms and bogie arm components must be clean and free of all burs, debris or foreign objects. Inspect these parts diligently.

For information regarding service and repair of Tigercat bogie arms, see 47732AENG, BOGIE ARM SERVICE AND REPAIR MANUAL. 3.19

Assembly

Tigercat Axles

RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES

A

To install axle shafts or sun gears in axles that contain SAHR brakes, the SAHR brake must be released. This activity may require two persons; one to activate the hydraulic supply, the other to insert the axle shaft.

B

Depending upon the type of axle installed, some require the use of different ports to retract the SAHR brake. Review the Operator's Manual for the machine being serviced to determine the appropriate ports.

C00453

RIGHT AXLE SUN GEAR/AXLE SHAFT FOR SERVICE AND SAHR BRAKES

C

A Loctite 518 Sealant B Input Gear Cover Seat C Input Gear

4. Apply sealant to the input gear seat: a. Apply a light bead of Loctite 518 around the perimeter of the input gear cover seat on the bogie arm. See, APPLYING LOCTITE PRODUCTS on page 1.12. b. Apply a light bead around each bolt hole. DO NOT get sealant in the holes.

5. Wet the O-ring contact surface on the input cover with gear oil, then install the O-ring into the groove in the cover.

C00463

A Use indicated ports for SAHR brake retraction

6. Apply Loctite 242 and Loctite 7649 Primer to six bolts. See, APPLYING LOCTITE PRODUCTS on page 1.12.

1. Retract the brakes. a. Install an M14 input fitting suitable for use with the available hydraulic supply system into the port on the right rear side of the brake housing.

7. Insert the spring pin into the hole in the bogie arm at the 1 o'clock position of the cover. Tap the pin into position in the bogie arm.

b. Insert a plug into the port on the same side on the front of the differential. c.

Connect the hydraulic supply to the fitting and activate the hydraulic pump to retract the SAHR brake on the right side. The hydraulic supply must remain ON to maintain the SAHR brakes in the released step.

8. Align the punch mark on the input gear cover to the top of the opening.

9. Secure the cover to the arm using the prepared bolts. Tighten each to 75Nm (55 lbf-ft) in a star pattern.

d. Repeat steps 1a to 1c for the left hand side. e. Disconnect the hydraulic supply once the axle/ axle shaft or sun gear is successfully installed.

2. Install the axle shaft through the input gear into the differential. Oscillate the axle shaft to assist in aligning the spline teeth with the teeth of the friction plates.

3. Insert a shaft spacer and retaining ring in the input gear.

3.20

Tigercat Axles

Assembly

LEFT AXLE SUN GEAR/AXLE SHAFT

8. Secure the cover to the bogie arm using six M10x1.5 bolts. DO NOT use Loctite. Tighten each to 75Nm (55 lbf-ft) in a star pattern. This will crush the solder strip on the end of the sun gear/axle shaft.

1. Prepare the sun gear/axle shaft for installation. a. Insert the spring pin into the long spline end of the sun gear/axle shaft.

9. Remove the input gear cover from the bogie arm.

A

10. Extract the axle shaft from the differential. The solder strip, spacer, shims, roll pin and tape must be present on the end of the axle shaft.

B C

11. Measure the thickness of the crushed solder strip.

The target measurement is between 2.3mm (0.090") - 2.8mm (0.110").

D

12. If the measurement is: F

a. Less than 2.3mm (0.090") remove the spacer, then remove shims from the end of the axle shaft until the value falls within the target measurement.

E

C00412 A B C D E F

Axle Shaft Black Electrical Tape 0.120" Ø solder One Half of Shims ≈ 0.070 inches Shaft Spacer Target Measurement 2.3mm (0.090") - 2.8mm (0.110")

b. Greater than 2.8mm (0.110") remove the spacer, then add shims until the value falls within the target measurement.

13. Verify that the shaft spacer does not rotate freely on the pin.

b. Apply a light coat of assembly grease to the contact faces of the bronze spacer and the end of the axle. c.

14. Repeat step 4 to 14 until the target measurement is achieved.

Install approximately one half of the thickness of the shims, 1.8mm (0.070 inches) onto the spring pin. Verify that the shims are free of burs so that the shim stack is parallel to the end of the axle shaft.

d. Install the shaft spacer onto the spring pin. e. Place a piece of 4mm Ø (0.120" Ø) solder over the end of the shaft spacer and secure it in place using black electrical tape.

2. Remove the input gear cover and release the SAHR brake as described in RIGHT AXLE, step 1 to 3.

15. Align the punch mark on the input gear cover to the top of the opening.

16. Apply Loctite 242 and Loctite 7649 Primer to six bolts. See, APPLYING LOCTITE PRODUCTS on page 1.12.

17. Secure the cover to the bogie arm using six M10x1.5 bolts. Tighten each bolt to 75Nm (55 lbf-ft) in a star pattern.

18. DO NOT fill the bogie arms with oil for a minimum of one hour to ensure Loctite thread locking compounds are dry.

3. Insert the axle, bronze spacer end first, through the left input gear. DO NOT damage the solder strip on the end of the axle shaft.

4. Strike the end of the axle shaft with a rubber mallet to verify it is fully seated.

5. Install a shaft support spacer and retaining ring in the left input gear.

6. Wet the O-ring contact surface on the input cover with gear oil, then install the O-ring into the groove in the cover.

7. Align the punch mark on the input gear cover to the top of the opening.

3.21

Assembly

Tigercat Axles

SUN GEAR, AXLE SHAFT AND PLANETARY

E

D

C B

A

NOTICE Axles with SAHR brakes require that the SAHR brake be released before removing or installing the axle. Retraction pressure is 32-35 bar (470500 psi).

F

G

NOTICE Re-calculate endplay after removing and replacing axles, spacers, shims, input gears or input bearings. The spacer, shims and roll pin are attached to the long spline end of the left axle shaft. Install the right shaft first, then the left shaft.

C00411 A B C D E F G

RIGHT SUN GEAR/AXLE SHAFT AND PLANETARY A

B

2. Clean the sun gear/axle shaft using isopropyl alcohol. Verify the parts are free of dirt and grease.

C D E

Axle with Outboard Planetaries, Right Side

Planetary Bolt Washer O-ring Sun Gear Right Axle Shaft Axle Housing

F

H

FOR AXLES WITH SAHR BRAKES: 3. Release the SAHR brakes to insert the sun gear/ axle shaft in the axle. See, RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES on page 3.20.

4. Install the sun gear/axle shaft. a. Insert the sun gear/axle shaft, long spline end first, into the differential through the brake housing/axle housing.

G

C00410 A B C D E F G H

b. Push the sun gear/axle shaft in as far as it will go into the differential.

Axle with Inboard Planetaries, Right Side

Dowel Guide Pin O-ring Right Sun Gear Bolt Washer Planetary Differential/Brake Housing

5. Install the planetary onto the differential/axle housing. a. Clean the bolts and threaded bolt holes in the planetary with isopropyl alcohol, then apply Loctite Thread Locker 242 and Loctite 7649 Primer to each bolt. See, APPLYING LOCTITE PRODUCTS on page 1.12.

1. Insert guide pins. See, GUIDE PINS on page 3.4

b. Oscillate the yoke to align the gear teeth while seating the planetary against the axle/brake housing.

3.22

Tigercat Axles

Assembly

6. Thread the bolts with washers finger tight, then torque in a star pattern to:

F G

M18 x 1.5 - 441Nm (325 lbf-ft)

H

J

L

K

M18 x 2.5 - 393Nm (290 lbf-ft) M16 x 2.0 - 278Nm (205 lbf-ft)

LEFT SUN GEAR/AXLE AND PLANETARY H

J

K

L

A

A E

D

C

B C00409

C

B

A B C D E F G H J K L

D

G

F

E

C00408

A B C D E F G H J K L

Axle with Inboard Planetaries, Left Side

Differential/Brake Housing Alignment Dowel Left Sun Gear Shim Spacer Spring Pin Planetary Bolt Washer O-ring Guide Pin

Axle with Outboard Planetaries, Left Side

Axle Housing Spacer Shims Spring Pin O-ring Bolt Washer Planetary Sun Gear Left Axle Shaft Guide Pin

1. Clean the sun gear/axle shaft using isopropyl alcohol. Verify the parts are free of dirt and grease.

2. Prepare the sun gear/axle shaft for installation. a. Insert the spring pin into the long spline end of the sun gear/axle shaft.

A B C F

D

E C00412

A B C D E F

Axle Shaft Black Electrical Tape 0.120" Ø solder One Half of Shims ≈ 0.070 inches Shaft Spacer Target Measurement 2.3mm (0.090")- 2.8mm (0.110")

b. Apply a light coat of assembly grease to the contact faces of the bronze spacer and the end of the axle.

3.23

Assembly c.

Tigercat Axles

Install approximately one half of the thickness of the shims, 1.8mm (0.070 inches) onto the spring pin. Verify that the shims are free of burs so that the shim stack is parallel to the end of the axle shaft.

12. Apply Loctite 242 and Loctite 7649 Primer to each bolt, thread the bolts with washers finger tight.

Tighten each using the values listed in step 6. See, APPLYING LOCTITE PRODUCTS on page 1.12.

PLANETARIES TO BOGIE ARM

d. Install the shaft spacer onto the spring pin.

For information about planetaries see, 47738AENG, Planetaries, SERVICE AND REPAIR MANUAL.

e. Place a piece of 4mm Ø (0.120" Ø) solder over the end of the shaft spacer and secure it in place using black electrical tape.

For information about bogie arms see, 47732AENG, Bogie Arm, SERVICE AND REPAIR MANUAL.

FOR AXLES WITH SAHR BRAKES

A

3. Release the SAHR brakes to insert the sun gear/ axle shaft in the axle. See, RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES on page 3.20.

B C

4. Install the axle shaft, bronze spacer end first, through the brake housing into the differential.

D

5. Install the planetary onto the differential/axle housing. DO NOT damage the solder strip on the end of the sun gear/axle shaft

E

M

6. Thread the bolts with washers finger tight, then torque in a star pattern to:

F

L

M18 x 1.5 - 441Nm (325 lbf-ft) M18 x 2.5 - 393Nm (290 lbf-ft)

K

M16 x 2.0 - 278Nm (205 lbf-ft) This will crush the solder strip on the end of the sun gear/axle shaft.

C00493

A B C D E F G H J K L M

7. Remove the planetary from the differential/axle housing.

8. Measure the thickness of the crushed solder strip.

The target measurement is between 2.3mm (0.090") to 2.8mm (0.110").

9. If the measurement is: a. Less than 2.3mm (0.090") remove the spacer, then remove shims from the end of the axle shaft until the value falls within the target measurement. b. Greater than 2.8mm (0.110") remove the spacer, then add shims until the value falls within the target measurement.

H

G

Bolt Washer Planetary Planet Retaining Ring Ring Gear Retaining Ring Bogie Housing O-ring Sun Gear Bearing Support Guide Pin O-ring

1. Install guide pins into the bogie arm/bearing support in the positions shown. See, GUIDE PINS on page 3.4.

2. Install the ring gear on top of the bearing support. a. Wet the ring gear O-ring and O-ring groove with gear oil, then install the O-ring into the groove.

10. Verify that the shaft spacer does not rotate freely on the pin.

11. Repeat step 4 to step 10 until the target measurement is achieved.

J

b. Install the ring gear onto the bearing support, with the O-ring facing down.

3. Install the sun gear, spline first, into the output gear in the bogie arm.

3.24

Tigercat Axles

Assembly INSTALL TRUNNIONS

4. Verify that the planetary is correctly prepared for installation to the bogie arm.

INSTALL TRUNNION PIN

a. Verify that planetary retaining rings are present. b. Verify that centre retaining ring is present.

A

5. Raise the planetary using a lifting device, then lower it onto the guide pins until the planet gears and sun gear almost meet.

B

6. Align the sun gear teeth and the planet gear teeth, then lower the planetary. Use a pry bar to carefully rotate each planet gear as required to achieve alignment.

7. Apply Loctite 7649 Primer to the bolts and threaded holes used to secure the planetary on the bogie arm.

See, APPLYING LOCTITE PRODUCTS on page 1.12.

8. Apply Loctite 242 Thread Locker to the bolts and threaded holes used to secure the planetary on the bogie arm. See, APPLYING LOCTITE PRODUCTS on page 1.12.

C00397

A Differential B Trunnion Pin C Bolts

9. Insert bolts finger tight, then torque each: a. For bogie axles 74.3", 75.0 in. and 77.5" long, tighten M18 bolts in a star-shaped pattern. Verify the thread pitch and torque to values listed. b. For bogie axles 68 inches long, tighten M16 bolts in a star-shaped pattern. Verify the thread pitch and torque to values listed.

M18 x 1.5 - 441Nm (325 lbf-ft) M18 x 2.5 - 393Nm (290 lbf-ft)

C

1. Clean the trunnion pin, bolts and threaded bolt holes in the differential with isopropyl alcohol, then apply Loctite Thread Locker 242 and Loctite 7649 Primer to each bolt. See, APPLYING LOCTITE PRODUCTS on page 1.12.

2. Seat the trunnion pin against the differential and thread bolts finger tight. Torque each to 339Nm (250 lbf-ft) in a star pattern. Verify that there is no gap between the trunnion pin and the differential housing.

M16 x 2.0 - 278Nm (205 lbf-ft)

3.25

Assembly

Tigercat Axles REAR TRUNNION

INSTALL TRUNNION BUSHINGS

WARNING

A

Chilled components are extremely cold and may damage exposed tissues. Use appropriate PPE when handling chilled parts. See LIQUID NITROGEN on page 1.5

B C D

NOTICE The inner surface of the bushings must be free of burs.

A-A A

NOTICE

B

Grease grooves inside the bushings MUST be oriented to be centred with the grease input opening on the flat surface of the trunnion.

C D

A

E A

A

C00413

A B C D

B

Oil Seal Retaining Ring Trunnion Bushing (with internal spiral groove) Rear Trunnion

1. Clean the trunnion and components using isopropyl alcohol. Verify the parts are free of dirt and grease.

E

2. Cool the trunnion bushing (with internal spiral grooves) in liquid nitrogen. See PRIOR TO ASSEMBLY on page 3.3.

C

NOTICE The diagonal oil groove must be centred to align with the flat portion of the trunnion.

D C00443

A B C D E

Front Trunnion Bushing Front Trunnion Rear Trunnion Bushing Rear Trunnion Flat Surface

3. Insert the trunnion bushing into the trunnion. Centre the diagonal oil groove to align with the flat on the trunnion. Verify that the edge of the bushing sits fully on the bushing seat in the trunnion.

4. Install the retaining ring in the trunnion.

5. Install the oil seal.

6. Install the thrust washer.

7. Install the shim pack totalling 2.8mm (0.110").

NON-INPUT SIDE BUSHING: 8. Install the trunnion cap and secure using bolts with ROTATE THE BUSHING DURING THE washers torqued in a star pattern to 136Nm (100 INSTALLATION TO ENSURE GREASE lbf-ft).

3.26

GROOVES ARE ORIENTATED AS SHOWN.

Tigercat Axles

Assembly FRONT TRUNNION A

B

C

D

A

D E C00415

A B C D E F G

G

F

A-A

E

Differential Rear Trunnion (with Seal, Ring and Bushing) Thrust Washer Trunnion Cap Bolt Washer Shims

B C

A

D E

9. Apply assembly grease generously to the interior surfaces of the trunnion unit.

A

C00414

10. Push the completed trunnion unit onto the trunnion pin. Oscillate the trunnion as pressure is applied to verify that it turns smoothly.

A B C D E

Oil Seal Trunnion Bushing (with parallel internal grooves) Front Trunnion Urethane Seal Thrust Washer

1. Clean the trunnion and components using isopropyl alcohol. Verify the parts are free of dirt and grease.

2. Cool the trunnion bushing (with internal perpendicular grooves) in liquid nitrogen. See PRIOR TO ASSEMBLY on page 3.3.

NOTICE Position the trunnion bushing with the oil grooves centred on the flat of the trunnion.

3. Insert the trunnion bushing into the trunnion.

Position the centre most oil grooves in the bushing to align with the flat top surface of the trunnion.

Verify the edge of the bushing sits fully on the bushing seat in the trunnion.

4. Install the oil seal.

5. Install the thrust washer.

6. Apply assembly grease generously to the interior surfaces of the trunnion unit.

3.27

Assembly

Tigercat Axles ALTERNATE TRUNNION BUSHING INSTALLATION C

WARNING

B

Heated bearings/components are extremely hot.

Use appropriate PPE when handling hot parts.

Bushings that cannot be sufficiently cooled may be installed by gradually heating the trunnion to 120°C (250°F) using an oil bath (preferable), oven or a torch with a rosebud tip fitting to disperse heat more evenly.

See HEATING BEARINGS FOR INSTALLATION on page 3.4.

A

C00416

1. Heat the trunnion to 120°C (250°F).

A Input Side Trunnion Unit B Sleeve C Differential Input Side

2. Insert the bushing in the trunnion by carefully tapping it into place using a piece of wood between the edge of the bushing and the hammer.

7. Push the completed trunnion unit onto the steel sleeve on the differential input side. Oscillate the unit as pressure is applied to ensure it turns smoothly.

3. Seat the bushing fully on the bushing seat in the trunnion after the trunnion is cooled to the touch.

8. Secure the trunnions to each other on the differential using a piece of wire.

3.28

Tigercat Axles

Assembly

AIR PRESSURE TESTING L

K

A

M

J

B

H

C

D

G

E

F

C00495

A B C D E F

Diff Lock Pressure Input Port Diff Lock Tank Port Right Service Brake Bleeder Valve Right SAHR Brake Input Port Right SAHR Brake Bleeder Valve Right Oil Level Port

Axle Air Testing Port Locations

AXLE LEAK TEST 1. Insert and tighten all drain plugs in the axle. Torque each to 34Nm (25 lbf-ft).

2. Insert and tighten all fill plugs except the right oil level port in the axle. Torque each to 34Nm (25 lbf-ft).

3. Install test gauge B8590000 fitting into the right oil level port. Torque to 34Nm (25 lbf-ft).

4. Attach pressure test gauge B8590000 to a regulated air supply.

5. Turn the air supply valve ON to pressurize the system to 1bar (15 psi).

G H J K L M

Right Service Brake Input Port Left Service Brake Input Port Left Service Brake Bleeder Valve Left Oil Level Port Left SAHR Brake Input Port Left SAHR Brake Bleeder Valve

7. If pressure falls below 1bar (15 psi), within 20 minutes, re-pressurize the system, then apply a light spray of soapy water to all seams, drain plugs, fill plugs, and seals. Visually inspect for bubbles which indicate a leak.

8. If a leak is found, verify that all bolts have been torqued to the proper values, then repeat step 6 to step 7.

9. If pressure cannot be maintained, disassemble the necessary components and inspect parts for nicks or tears in seals, incorrect seating of components or other damage.

10. Replace seals and parts as required.

6. Turn the air supply valve OFF once the axle is pressurized.

3.29

Assembly 11. Follow step 5 to step10 until the problem is corrected. If after several attempts there is still a leak, contact your Tigercat dealer or the Tigercat parts department.

SERVICE BRAKE TEST Without SAHR brakes 1. Attach pressure test gauge B8590000 to an air supply (90 psi - 120 psi).

For axles with axle brake pressure tubes 2. Attach the other end to the service brake input port.

Tigercat Axles With SAHR brakes 1. Attach the compressed oil supply pump capable of 35 bar (500 psi) to the SAHR brake input port.

2. Pressurize the system to 35 bar (500 psi) to release the SAHR brake.

3. Follow step 1 to step 7 or step 8 to step 13 to test the service brakes.

4. Turn the hydraulic compression pump OFF. 5. Depressurize the system by loosening and disconnecting the oil supply pump.

3. Pressurize the system to 6 bar (90 psi) using the pressure test gauge.

4. Apply 11Nm (100 in/lb of torque to the yoke using a breaker bar. The yoke must not turn.

5. Release pressure by opening the bleeder valve.

6. Apply torque to the yoke. The yoke must turn to verify that the brakes have disengaged. Both spindles must turn.

7. Verify that all fittings and tubes are reconnected and that all plugs are secured.

For axles without axle brake pressure tubes 8. Install test gauge B8590000 fitting into the right service brake input port.

9. Pressurize the system to 6 bar (90 psi).

10. Apply torque to the yoke using a breaker bar. The right spindle must not turn. The left spindle must turn.

11. Loosen the right service brake bleeder valve. Air must escape through the valve to confirm through flow.

12. Repeat step 9 to step 13 for the left brake input port.

In this case the left spindle must not turn and the right spindle must turn.

13. Verify that all fittings and tubes are reconnected and that all plugs are secured.

3.30

Tigercat Axles

Assembly

FILL THE AXLE WITH OIL

If shipping an axle without oil, mark the axle clearly to notify the shipper/receiver that there is no oil contained within.

NOTICE Tigercat recommends the use of separate, dedicated, hydraulic oil, gear oil and fuel pumps on Tigercat machines and components.

AXLES WITH NO BRAKES/SERVICE BRAKES ONLY 1. Place oil pans beneath the fill plugs on the axle.

NOTICE

A

B

A

C

Allow one hour drying time for components installed using Loctite products before filling axles with oil.

NOTICE An axle assembly may contain up to 63 US litres (16.6 US gallons) of oil.

E

A bogie axle may contain up to 250 US litres (66.2 US gallons)of oil.

A B C D E

Drain plugs vary in number and location depending upon axle model.

Depending upon the type of axle the amount of oil and oil additives varies. The Oil Capacity chart shows approximate volumes. For specific amounts, see the Operator and Service manual for each machine.

Oil Capacity (Volume in Litres) Axle Model Number W/Brakes OB20 63L OB17 42L IB17 39L IB15W 36L IB15 28L ROB17 / HOB17 / WOB17 250L WOB15 195L

WO/Brakes / 39L 36L 33L 26L 250L 195L

Oil Additive API GL-5 Differential Only (Volume in Litres) Axle Model Number W/Brakes WO/Brakes OB20 1L None OB17 1L None IB17 1L None IB15W 1L None IB15 1L None ROB17 / HOB17 / WOB17 2L None WOB15 2L None

Depending upon the service/ repair action and the machine, repair or delivery/warehouse site location, the axle may or may not be filled with oil prior to delivery.

Be aware of supply, shipping and storage constraints as legislated by local, regional, state or federal agencies. If shipping an axle with a full compliment of oil, mark the axle clearly to show that it is full of oil.

D

C00384

Axle Housing Differential Fill Plug Magnetic Drain Plug Approximate Fill Line

2. Remove the fill plugs from the axle.

3. Verify that magnetic drain plugs are installed. Torque each to 34Nm (25 lbf-ft).

NOTICE DO NOT leave the oil transfer pump unattended when operating.

4. Insert the oil transfer pump nozzle into one end of the axle and begin pumping operations. Verify the approximate amount of oil using the Oil charts.

5. When the amount pumped nears the recommended amount of oil, cease pumping operations and visually observe the open port at the other end of the axle to verify oil flow through. Allow approximately 10 minutes for oil to disperse evenly through the whole system. Slowly continue to fill with oil until oil is level with the bottom of the fill port.

6. Disconnect the pump and reinstall the fill plugs.

Torque each to 34Nm (25 lbf-ft).

3.31

Assembly

Tigercat Axles

BOGIE AXLES AND STRAIGHT AXLES WITH SAHR BRAKES Gear oil in axles with SAHR brakes may be segregated by a nylon bushing positioned between the planetary and the differential. Withe the nylon bushing in place, oil must be drained and added separately from/to the differential and brake housings/bogie arm-planetaries.

8. Insert the oil transfer pump nozzle into the other fill port of an axle housing and begin pumping operations.

9. Repeat step 4 to step 6.

10. Disconnect the pump and reinstall the fill plugs.

Torque each to 34Nm (25 lbf-ft).

BOGIE AXLE

Samples for the Tigercat Fluid Analysis program must be taken separately from the differential and each brake housing/bogie arm-planetary.

A

STRAIGHT AXLE B

A

B

A

C

C

E

C B

D

F C00383 C00470 A B C D E F

E

A B C D E

D

Planetary Fill Plug Differential Approximate Fill Line Magnetic Drain Plug Brake/Axle Housing

Bogie Arm Magnetic Drain Plug Fill Plug Approximate Fill Line Differential

To fill a bogie axle with the bushing in place: 1. Remove the fill plugs from the brake housing.

To fill a straight axle with the bushing in place:

2. Remove the fill plug from the bogie arms.

1. Remove the fill plugs from the brake housing.

3. Verify that magnetic drain plugs are installed. Torque each to 34Nm (25 lbf-ft).

2. Remove the fill plug from the differential.

3. Verify that magnetic drain plugs are installed. Torque each to 34Nm (25 lbf-ft).

4. Insert the oil transfer pump nozzle into the differential fill port and begin pumping operations.

5. Cease pumping operations when the amount pumped can be visually observed in the open port.

Slowly continue to fill with oil until oil is level with the bottom of the fill port.

6. Insert the oil transfer pump nozzle into the fill port of one axle housing and begin pumping operations.

7. Repeat step 4 to step 6.

4. Insert the oil transfer pump nozzle into the differential fill port and begin pumping operations.

5. Cease pumping operations when the amount pumped can be visually observed in the open port.

Slowly continue to fill with oil until oil is level with the bottom of the fill port.

6. Insert the oil transfer pump nozzle into the fill port of one bogie arm and begin pumping operations.

7. Repeat step 4 to step 6.

8. Insert the oil transfer pump nozzle into the fill port of the other bogie arm and begin pumping operations.

9. Repeat step 4 to step 6.

3.32

Tigercat Axles

Assembly INSTALL HYDRAULIC TUBING

10. Disconnect the pump and reinstall the fill plugs.

Torque each to 34Nm (25 lbf-ft).

Install previously removed hydraulic tubing on the differential.

BOGIE AXLES AND AXLES WITH SAHR BRAKES, BUSHING REMOVED

DO NOT re-use bent, creased or crushed tubing or fittings.

Bogie axles and straight axles constructed after the listed serial numbers/date, or after SAHR brakes have been serviced no longer utilize the nylon bushing and retaining ring. With the bushing and retaining ring no longer used, oil is free to flow between major axle components.

DO NOT turn fittings using the tubing. Use correct tools to loosen and tighten fittings.

A

Fill axle assemblies using the fill ports on the brake housings. Allow time for oil to flow between components.

Axles with 15 inch and 17 inch differentials require up to 10 minutes to disperse oil evenly.

Machine Model

B

Serial Number/Date

1085B

10850536

2160

216000103

1075C

10751071

632E

6320221

615E

6151028

625E

6250524

635G

6353073

1185

after 05/15/2018

K J

D

H G

To fill an axle without bushing:

F

STRAIGHT AXLE 1. Remove the fill plugs from the brake housing fill port.

E C00417

2. Place a container beneath the fill port.

A B C D E F G H J K

BOGIE AXLE 3. Remove the fill plug from the bogie arm fill port.

4. Place a container beneath the fill port.

ALL AXLES 5. Verify that magnetic drain plugs are installed. Torque each to 34Nm (25 lbf-ft).

6. Insert the oil transfer pump nozzle into the differential fill port and begin pumping operations.

7. Cease pumping operations when the amount pumped can be visually observed in the open port.

Slowly continue to fill with oil until oil is level with the bottom of the fill port.

See, BOGIE AXLES AND AXLES WITH SAHR BRAKES, BUSHING REMOVED on page 3.33

C

Differential Lock Return Differential Air Supply Right Service Bleed Fitting SAHR Brake Bleed Fitting Right Service Brake Pressure Port Left Service Brake Pressure Port Left Service Bleed Fitting Brake Pressure Tube Brake Input Pressure Port

Air pressure testing is used to verify that the axle unit does not leak. Hydraulic pressure is used to test brakes and verify oil passages are open and operating as designed. Note the variations in tubing and fittings on the differential.

Review the Operator's Manual for the machine being serviced to determine the appropriate components and ports.

3.33

Assembly

Tigercat Axles

3.34