Tigercat Axles SERVICE & REPAIR MANUAL - PDF DOWNLOAD

Axles

SERVICE AND REPAIR MANUAL

ISSUE 2.1, 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 SECTION INTRODUCTION................................................................................................................................................. v NON – APPROVED FIELD PRODUCT / PARTS CHANGES.............................................................................. vi TRADEMARKS...................................................................................................................................................vii TIGERCAT AXLES..............................................................................................................................................vii AXLE, EXPLODED VIEW– IB15 OSCILLATING REAR AXLE..........................................................................viii AXLE EXPLODED VIEW– OB20 FIXED AXLE .................................................................................................. x AXLE EXPLODED VIEW– WOB17 BOGIE AXLE .............................................................................................xii 68 IN BOGIE ARM WITH LUG...........................................................................................................................xiii AXLE EXPLODED VIEW– SERVICE AND SAHR BRAKE ...............................................................................xiv 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

TRADEMARKS...................................................................................................................................................vii TIGERCAT AXLES..............................................................................................................................................vii

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 preprinted 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 OSCILLATING REAR AXLE..........................................................................viii

Introduction

Tigercat Axles

10

11

8

12

13

9

A

C00843

C00844

19

32 31 30 29 28

* *

23 24

21 14

**

34

25

26

16

18 33

20 2

A 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

36

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 36

* INSPECT. See FASTENER TORQUE AND REUSE on page 1.13. ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

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 DOWEL PIN

AXLE EXPLODED VIEW– OB20 FIXED AXLE .................................................................................................. x

Introduction

Tigercat Axles

17

15

16

A

10

12

11

A

C00843

2

13

1

3

A

1

5

** ** 6

C00437

7

14 4

2

A

** **

12

8

9

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

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

* INSPECT. See FASTENER TORQUE AND REUSE on page 1.13. ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

A Parts may or may not be present. If present, remove and discard. Do not include in reassembly. See PSB2503. For PSB2503 contact Tigercat Service Department.

xi

AXLE EXPLODED VIEW– WOB17 BOGIE AXLE .............................................................................................xii

Introduction

Tigercat Axles 17

C00842

18

19 20 16

A

A

2

**

12

4

A

7

6

10

5 14

1

**

26 15

** **

13 9

23

1 14 5

4 11

3

** **

A

**

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

68 IN BOGIE ARM WITH LUG...........................................................................................................................xiii

Tigercat Axles

Introduction

ITEM PART DESCRI PTI O N ITEM PA R T D E S C R I P T I O N 1 HOUSING, BRAKE 17 SHIM 2 BEARING, SLEW 18 SHIM 3 SHAFT, AXLE 19 SHIM 4 RING, SCRAPER 20 SHIM 5 O-ring 21 PIN, SPRING 6 SEAL, OIL 22 SHAFT, BOGIE, OUTPUT 7 PIN 23 O-ring 8 O-ring 24 **WASHER 9 **BOLT 25 **BOLT 10 **BOLT 26 DIFFERENTIAL 11 **BOLT 27 PLANETARY 12 **BOLT 28 BOGIE ARM 13 **WASHER 29 GREASE FITTING 14 PLUG, MAGNETIC 30 BOGIE BALANCE LUG 15 KIT, BRAKE 31 SPHERICAL BUSHING 16 SPACER, BRONZE ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

A Parts may or may not be present. If present, remove and discard. Do not include in reassembly. See PSB2503. For PSB2503 contact Tigercat Service Department.

A

30 29

29 31

A C00377

68 in Bogie Arm with Lug

xiii

AXLE EXPLODED VIEW– SERVICE AND SAHR BRAKE ...............................................................................xiv

Introduction

Tigercat Axles

2

3

5

1

8 4 10

25

26

11 7

9 6

*

18

12

14

15

16 19 27

13 22

23

20

24

17 27

A 21

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

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

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 A BUSHING, NYLON A RING, RETAINING, INTERNAL HOUSING, BRAKE DIFFERENTIAL SERVICE BRAKE COMPONENTS SAHR BRAKE COMPONENTS

* INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

A Parts may or may not be present. If present, remove and discard. Do not include in reassembly. See PSB2503. For PSB2503 contact Tigercat Service Department.

xv

Introduction

Tigercat Axles

xvi

SAFETY..............................................................................................................................................................1

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

CONTENTS – SECTION 1 ONTENTS– SECTION 1

ISSUE 2.1, DECEMBER 2018

A

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.............................................................................................................................................. 1.11 COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING.................................................. 1.12

D

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

F

FASTENER TORQUE AND REUSE......................................................................................................................... 1.13 BOLTS..................................................................................................................................................................... 1.13 NUTS AND WASHERS.......................................................................................................................................... 1.13 TORQUE WRENCHES.......................................................................................................................................... 1.13

G

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

H

HAZARDS.................................................................................................................................................................... 1.5 COMPRESSED AIR................................................................................................................................................. 1.5 FLAMMABILITY........................................................................................................................................................ 1.5 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 SAFE SUPPORT OF COMPONENTS.................................................................................................................... 1.9

N

NOTICE........................................................................................................................................................................ 1.3

P

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 VITON SEALS.......................................................................................................................................................... 1.6 SHIPPING COMPONENTS........................................................................................................................................ 1.9

Safety

Tigercat Axles

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 TORQUE CHART, GENERAL................................................................................................................................... 1.14

W

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

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.

Minimize risks and promote safety at all times. This section of the manual provides basic safety rules to follow.

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

These safety rules highlight both general and specific measures the operator must be familiar with and adhere to. Pictograms on labels, in and on the machine, illustrate specific safety measures and warnings. Keep safety labels in good condition. Repair or replace damaged labels.

• 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.

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

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.

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

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

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

HAZARDS

WORKING WITH OIL Oil and oil additives are known skin irritants. Observe strict hygiene rules to remove oil residue from skin.

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

Other safety advice includes: • Attend to cuts and abrasions immediately. Clean them and apply first aid.

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

• Do not breath in oil fumes.

• Avoid contact with oil, particularly heated oil.

• Oil used in this machine may be hot enough to cause serious burns.

LIQUID NITROGEN

• Wash off oil on the skin immediately with soap and water. Wash hands and arms frequently (example: at each meal or break or when contaminated).

WARNING

• Wear protective gloves. Clean hands before putting on gloves. Apply protective cream to the hands to make washing easier.

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.

• Do not put oily rags in your pockets.

• Change oil soiled clothing as soon as possible. Keep an extra change of work clothes nearby.

COMPRESSED AIR

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

Compressed air is a concentrated, high pressure, high speed stream of air can seriously injure or kill.

Air pressures of 0.34 – 0.69 bar (5 – 10 psi) can cause serious injury. Most pneumatic tools operate at 5.5 – 8.3 bar (80 – 120 psi).

VENTILATION WARNING

Follow acceptable Health and Safety protocols for using compressed air.

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

• Do not clean clothing or skin using compressed air.

• 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 2.1 bar (30 psi) at the nozzle is permitted to dry objects.

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

• 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.

1.5

Safety

Tigercat Axles

HIGH PRESSURE INJECTION INJURIES

VITON SEAL WARNING

WARNING

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

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

O-rings and other seals manufactured of Viton fluroelastomer 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.

Train workers 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 has been subjected to high temperatures such as fire: • Visually inspect any seals or gaskets which have suffered from heat; they will appear black and sticky.

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 occurs, a fine, high velocity stream of fluid will result. A stream of liquid\fuel pressurized to as little as 7 bar (100 psi), can penetrate human skin as if it were a hypodermic needle.

If these are found, do not touch.

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

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

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation. There is a danger 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 tissue damage has already begun.

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

Similarly fluid injected directly into a blood vessel can spread rapidly through your circulatory system. The human body has little ability to purge injected fluid.

Diesel fuel or hydraulic oil 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.

1.6

Tigercat Axles

Safety

GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS

An injury of this type can become very serious or even fatal if not dealt with promptly and properly.

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.

WARNING Diesel fuel or hydraulic oil 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.

Seek 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:

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.

• Report the injury to your supervisor immediately.

• Seek professional medical attention immediately.

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.

• Do not operate a high pressure pneumatic grease gun unless you have been trained in the proper operation and are aware of all safety precautions of such a tool.

• Wear safety goggles.

• 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.

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

• Recognize 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.

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

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

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 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. Provide sufficient space to lay out and sort various parts and assemblies.

DANGER

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

Use recommended supports and stands. If other stands or supports are used they must be robust, stable and suited to the task. Failure to use proper supports and stands may lead to situations which, if not avoided, could result in death or serious injury.

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. Allow only trained, competent personnel to design and weld fabricated equipment.

WARNING

CALIBRATION

Only competent personnel are permitted to operate cranes or hoists.

NOTICE Calibrate mechanical and electrical instruments and tools used to measure values, weigh, or torque annually, as a minimum requirement.

Operators, test and carefully inspect all lifting device controls, chains, straps, hooks, cables and other lifting devices prior to 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 use damaged equipment.

Calibrate tools when:

• Do not exceed working load limits.

• Observe appropriate safety practices for safe equipment use.

• Align the hoist directly above the centre of the load and verify the load is properly balanced and secured.

• New • Repaired or changed • When the scheduled calibration period has passed as indicated in OEM literature.

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

• Conditions other than normal operating conditions occur. For example, a device is dropped or exposed to extreme temperature.

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

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

• Observations indicate incorrect readings.

See TORQUE WRENCHES on page 1.13.

1.8

Tigercat Axles

Safety

SHIPPING COMPONENTS

PERSONAL SAFE 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.

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, use mechanical devices for lifting and carrying.

When manually lifting components:

Mark axles containing oil to clearly show the axle contains oil.

• Wear appropriate PPE • Determine if the load is lifted, pushed, pulled or carried

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

• 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: • Assume a stable lifting stance

• Bearing Puller

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

• Isopropyl alcohol or equivalent solvent

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

• Clean rags

• Keep your back straight

• PPE

• Marking pen or other marking method

• Lift with legs

• Support Stands

• Keep load close to waist

• Wooden support blocks

• Do not twist your torso. Move your feet.

• Torque wrench up to 813 N-m (600 lbf-ft)

• Keep your head up and watch your route.

• Snap ring installation tool • Lead solder 3.05 mm (0.120 in) diameter

SAFE SUPPORT OF COMPONENTS 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 both components are adequately supported and level.

• Electrical Tape

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

• Brake Piston Installation Tool 80090B

• Lithium Based Assembly Grease • Loctite solvent or equivalent • Loctite 243 – SSA194 • Loctite 263 – SSA250 • Spring Guide Tool B7506000 • Ball Lock Pins (10X40mm) B7506001 • SAHR Brake Piston Installation Tool B9569000 • 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 GENERAL TORQUE SPECIFICATIONS on page 1.14.

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.

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.

C00440

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

B

A

A

C00440 C00498

A Spring Guide Tool B7506000

A Guide Pin B Grind Head From Fastener

To modify a fastener:

A

C00669

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.

A Brake Piston Mounting Tool 80090B

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 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.

A

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.

C00836

SAHR Piston Installation Tool B9569000

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 Threadlocker 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.

3. Wipe excess material from screw.

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

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

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 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.

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.

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. 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.

2. Degrease parts and wash with suitable cleaning solutions prior to priming.

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.

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

5. Wipe excess gasket forming product from the site.

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

COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING

4. Spray or brush both parts to be joined with primer and allow to dry for a minimum of 70 seconds.

Use parts within one month of priming. Keep parts primed for future use free of contamination.

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.

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

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

7. Wipe excess Loctite from the site.

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

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

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

More information is available on – line at http//:www. tigercat.com, or from the nearest Tigercat dealer.

1.12

Tigercat Axles

Safety

FASTENER TORQUE AND REUSE WARNING Follow instruction regarding reuse of fasteners.

Replace fasteners with those of the same size and specifications. Failure to do so may lead to catastrophic component failure leading to serious injury or death.

Some bolts used to assemble Tigercat axles are torqued to high values (90%+ proof stress) to provide consistent, even clamping force. Once a bolt has been torqued, it may stretch. If a bolt is reused there is a risk it will fail. It is by far less expensive to replace a bolt than to have it fail. Engineering calculations provide a margin of safety, taking into consideration material or process flaws, torque tool inaccuracies or the absence of torque tools.

To indicate which bolts may be reused and under what conditions, follow these conditions:

UNLESS OTHERWISE SPECIFIED

BOLTS Bolts join components in a way providing sufficient clamp force to resist tensile and sheer forces. Correct torque values are critical in order for parts to function as designed. If a bolt is too loose, it will fail to secure the parts. It a bolt is too tight, the bolt will break. In either case, bolt failure can lead to catastrophic damage to the machine.

If a procedure calls for a torque wrench to be used, use a torque wrench. Torque values cannot be felt or guessed.

Unless otherwise specified, torque bolts in compliance with the General Torque Specification using a standard bolt torque sequence. See GENERAL TORQUE SPECIFICATIONS on page 1.14. The bolt(s) is/are suitable for reuse.

INSPECT BOLT

* Inspect the bolt. The torque value used to tighten

these bolts exceeded 75% proof strength but was less than 90% proof strength. To determine if a bolt is suitable for reuse, thread a nut onto the entire length of the bolt.

If the nut binds anywhere along the thread, the bolt is not suitable for reuse. Replace the bolt.

DO NOT REUSE

LOAD

**Do Not Reuse – Replace [bolt(s)]. The torque value used to tighten the bolt(s) exceeded 90% of proof strength. The bolt(s) is/are not safe for reuse.

NUTS AND WASHERS Replace damaged nuts and/or washers with parts of the same original specifications. Check washers for signs of spalling or galling.

C

B

A

If the bolt is rated ** Do not reuse – replace the bolt and washer.

TORQUE WRENCHES There are two different types of torque wrench and 12 classes in accordance with ISO standard 6789: • Indicating torque wrenches (Type 1) LOAD

C00711

A Bolt Torqued Less Than Proof Stress B Bolt Torqued Greater Than Proof Stress C Bolt B Fails Upon Reused

• Setting torque wrenches (Type 2).

Select the torque wrench is best suited for the task at hand. Specialized torque wrench requirements and/or add-ons are listed in the procedures.

Make sure torque wrenches are clearly marked with the torque range capability and direction of torque.

Calibrate torque wrenches every 5,000 cycles or 12 months which ever comes first. See CALIBRATION on page 1.8.

1.13

Safety

Tigercat Axles

GENERAL TORQUE SPECIFICATIONS IMPERIAL

The torque values listed below are for general use only.

Do not use these values if a different torque value or tightening procedure is shown for a specific application.

GRADE 5 BOLTS

GRADE 8 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS

LUBRICATED COARSE N-m lbf-ft THREAD 1/4" - 20 9-9 6-7 5/16" - 18 18 - 19 13 - 14 3/8" - 16 31 - 35 23 - 25 7/16" - 14 50 - 55 37 - 41 1/2" - 13 77 - 84 57 - 62 9/16" - 12 111 - 122 82 - 90 5/8" - 11 153 - 168 113 - 124 3/4" - 10 271 - 298 200 - 220 7/8" - 9 437 - 480 322 - 354 1" - 8 654 - 720 483 - 531 1 1/8" - 7 808 - 888 596 - 655 1 1/4" - 7 1139 - 1253 840 - 924 FINE LUBRICATED N-m lbf-ft THREAD 1/4" - 28 10 - 11 7-8 5/16" - 24 20 - 22 14 - 16 3/8" - 24 36 - 39 26 - 29 7/16" - 20 56 - 62 41 - 46 1/2" - 20 86 - 95 64 - 70 9/16" - 18 123 - 136 91 - 100 5/8" - 18 173 - 190 127 - 140 3/4" - 16 302 - 332 223 - 245 7/8" - 14 482 - 530 355 - 391 1" - 14 735 - 808 542 - 596 1 1/8" - 12 906 - 996 668 - 735 1 1/4" - 12 1262 - 1388 930 - 1023

DRY COARSE N-m lbf-ft THREAD 11 - 13 8-9 1/4" - 20 24 - 26 17 - 19 5/16" - 18 42 - 46 31 - 34 3/8" - 16 67 - 74 49 - 54 7/16" - 14 102 - 112 75 - 83 1/2" - 13 147 - 162 109 - 120 9/16" - 12 203 - 224 150 - 165 5/8" - 11 361 - 397 267 - 293 3/4" - 10 582 - 640 429 - 472 7/8" - 9 873 - 960 644 - 708 1" - 8 1077 - 1185 794 - 874 1 1/8" - 7 1519 - 1671 1121 - 1233 1 1/4" - 7 FINE DRY N-m lbf-ft THREAD 13 - 14 10 - 11 1/4" - 28 26 - 29 19 - 21 5/16" - 24 47 - 52 35 - 38 3/8" - 24 75 - 82 55 - 61 7/16" - 20 115 - 127 85 - 93 1/2" - 20 164 - 181 121 - 133 9/16" - 18 230 - 253 170 - 187 5/8" - 18 403 - 443 297 - 327 3/4" - 16 642 - 706 474 - 521 7/8" - 14 979 - 1077 722 - 795 1" - 12 1207 - 1328 890 - 980 1 1/8" - 12 1682 - 1850 1241 - 1365 1 1/4" - 12

LUBRICATED N-m lbf-ft 12 - 13 9 - 10 25 - 27 18 - 20 44 - 49 33 - 36 71 - 78 52 - 58 108 - 119 80 - 88 156 - 172 115 - 127 215 - 237 159 - 175 383 - 421 282 - 310 616 - 678 455 - 500 924 - 1016 681 - 750 1310 - 1441 966 - 1063 1848 - 2033 1363 - 1499 LUBRICATED N-m lbf-ft 14 - 15 10 - 11 28 - 30 20 - 22 50 - 55 37 - 41 79 - 87 58 - 64 122 - 134 90 - 99 174 - 192 128 - 141 244 - 268 180 - 198 427 - 469 315 - 346 680 - 748 502 - 552 1037 - 1141 765 - 841 1468 - 1615 1083 - 1191 2046 - 2250 1509 - 1660

DRY N-m lbf-ft 16 - 18 12 - 13 33 - 37 25 - 27 59 - 65 44 - 48 95 - 104 70 - 77 144 - 159 106 - 117 208 - 229 154 - 169 287 - 316 212 - 233 510 - 561 376 - 414 822 - 904 606 - 667 1232 - 1355 909 - 999 1746 - 1921 1288 - 1417 2464 - 2710 1817 - 1999 DRY N-m lbf-ft 18 - 20 14 - 15 37 - 41 27 - 30 67 - 74 49 - 54 106 - 116 78 - 86 163 - 179 120 - 132 232 - 255 171 - 188 325 - 358 240 - 264 569 - 626 420 - 462 907 - 997 669 - 736 1383 - 1521 1020 - 1122 1958 - 2154 1444 - 1588 2728 - 3000 2012 - 2213

METRIC

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

SIZE PITCH LUBRICATED mm N-m lbf-ft M6 1 8-9 6-7 M8 1.25 20 - 22 15 - 16 M10 1.5 39 - 43 29 - 32 M12 1.75 68 - 75 50 - 55 M14 2 109 - 120 80 - 89 M16 2 169 - 186 125 - 137 M18 2.5 234 - 257 172 - 190 M20 2.5 330 - 364 244 - 268 M22 2.5 451 - 496 332 - 366 M24 3 571 - 628 421 - 463 M27 3 837 - 921 618 - 679 M30 3.5 1135 - 1249 837 - 921 M33 3.5 1545 - 1699 1139 - 1253 M36 4 1985 - 2183 1464 - 1610

CLASS 10.9 LUBRICATED DRY N-m lbf-ft N-m lbf-ft N-m lbf-ft 11 - 12 8-9 11 - 12 8-9 15 - 17 11 - 12 26 - 29 19 - 21 27 - 30 20 - 22 36 - 40 27 - 30 52 - 57 38 - 42 54 - 60 40 - 44 72 - 79 53 - 59 91 - 100 67 - 74 94 - 104 70 - 77 126 - 138 93 - 102 145 - 160 107 - 118 151 - 166 111 - 122 201 - 221 148 - 163 226 - 248 166 - 183 234 - 257 173 - 190 312 - 343 230 - 253 312 - 343 230 - 253 323 - 356 239 - 262 431 - 474 318 - 350 441 - 485 325 - 357 457 - 503 337 - 371 610 - 670 450 - 495 601 - 661 443 - 487 623 - 686 460 - 506 831 - 914 613 - 674 761 - 838 562 - 618 790 - 869 583 - 641 1053 - 1159 777 - 855 1116 - 1228 823 - 906 1158 - 1274 854 - 940 1544 - 1699 1139 - 1253 1514 - 1665 1116 - 1228 1570 - 1727 1158 - 1274 2094 - 2303 1544 - 1699 2060 - 2266 1519 - 1671 2137 - 2351 1576 - 1734 2849 - 3134 2102 - 2312 2646 - 2911 1952 - 2147 2745 - 3020 2025 - 2227 3661 - 4027 2700 - 2970 DRY

1.14

CLASS 12.9 LUBRICATED DRY N-m lbf-ft N-m lbf-ft 13 - 14 10 - 11 18 - 19 13 - 14 32 - 35 24 - 26 43 - 47 31 - 35 63 - 70 47 - 51 84 - 93 62 - 68 110 - 121 81 - 90 147 - 162 109 - 119 176 - 194 130 - 143 235 - 259 173 - 191 274 - 301 202 - 222 365 - 401 269 - 296 378 - 416 279 - 307 504 - 554 372 - 409 534 - 588 394 - 433 712 - 784 525 - 578 728 - 801 537 - 591 971 - 1068 716 - 788 923 - 1016 681 - 749 1231 - 1354 908 - 999 1354 - 1489 998 - 1098 1805 - 1985 1331 - 1464 1835 - 2019 1354 - 1489 2447 - 2692 1805 - 1985 2498 - 2747 1842 - 2026 3330 - 3663 2456 - 2702 3208 - 3529 2366 - 2603 4278 - 4706 3155 - 3471

DISASSEMBLY...................................................................................................................................................2

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

CONTENTS – SECTION 2

ISSUE 2.1, DECEMBER 2018

A

AXLE/BRAKE HOUSING, REMOVE........................................................................................................................ 2.16 AXLE DISASSEMBLY................................................................................................................................................. 2.7 REMOVE TRUNNIONS (IB17, OB17, IB15 OSCILLATING DIFFERENTIALS)................................................... 2.7 AXLE, PREPARING TO DISASSEMBLE THE.......................................................................................................... 2.3

B

BOGIE ARM, REMOVE............................................................................................................................................. 2.11 BOGIE ARM ORIENTATION.................................................................................................................................. 2.12 DISCONNECT BOGIE ARM FROM SLEW BEARING........................................................................................ 2.15 BOGIE AXLE SHAFT................................................................................................................................................. 2.13 BOGIE BALANCE SPHERICAL BUSHINGS........................................................................................................... 2.19 BRAKES, REMOVE................................................................................................................................................... 2.17 SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKE COMPONENTS................................................. 2.18 SERVICE BRAKE COMPONENTS....................................................................................................................... 2.17

D

DIFFERENTIAL.......................................................................................................................................................... 2.19

H

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

M

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

O

OIL, REMOVE.............................................................................................................................................................. 2.5 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................................................................................................................................................................ 2.7 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

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 both components are adequately supported and level.

Follow instruction regarding reuse of fasteners.

Replace fasteners with those of the same size and specifications. Failure to do so may lead to catastrophic component failure leading to serious injury or death.

See MATERIAL LIFTING AND HANDLING on page 1.8.

See FASTENER TORQUE AND REUSE on page 1.13.

MACHINE ORIENTATION A

B

C

B

See PERSONAL SAFE LIFTING AND CARRYING on page 1.9.

A

See SAFE SUPPORT OF COMPONENTS on page 1.9.

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: • Must be level • Must be clean

D C00376

A B C D

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

Planetary Brake (optional) Differential Yoke F

• Must have components blocked to eliminate movement A

B

MOVING AXLES/AXLE COMPONENTS

C

Axles may be shipped as complete units or partially disassembled.

A

D E C00708

A B C D E F

Bogie Arm Brake Housing Differential Planetary Yoke Slew Bearing

C00382

A B C D

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

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 with suitable ratings.

2. Block each section of the axle so adjacent segments are supported independently of the others. Do not leave loads suspended.

BOGIE AXLES A

B

**

J

H

D

C

G

F

C00380

A Lifting Strap F Planetary B Bogie Arm G Bogie Slew Bearing C **Bolts H Differential D Lifting Chain J Brake Housing E Lifting Ring ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

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. See 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 in illustration C00380, above.

2.4

E

Tigercat Axles

Disassembly

REMOVE OIL

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

WARNING

4. 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.

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

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

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

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

NOTICE An axle may contain up to 63 L (16.6 US gal) of oil.

9. Clean all plugs of oil and debris.

10. Reinstall fill and drain plugs once clean.

A bogie axle may contain up to 250 L (66.2 US gal) of oil.

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

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

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

B

A

C

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

F

FROM AN AXLE 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.

Drain oil separately from the differential and brake housings/planetaries.

D

C00384

A B C D

E

Axle Housing Differential Fill Plug Magnetic Drain Plug

Follow steps 1 – 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.

E Approximate Fill Line

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

Take samples for the Tigercat Fluid Analysis program separately from the differential and each brake housing/ planetary.

2. Clean the area around the drain plug. See CLEAN AND INSPECT on page 1.11.

2.5

Disassembly

Tigercat Axles

FROM A BOGIE AXLE A

B

BOGIE AXLES AND AXLES WITH SAHR BRAKES, BUSHING REMOVED

A

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.

C

For oil filled axles, allow time for oil to flow between components.

E

Machine Model C B

D

C00383

A B C D E

Bogie Arm Magnetic Drain Plug Fill Plug Approximate Fill Line Differential

Serial Number/Date

1085B

10850536

2160

216000103

1075C

10751071

632E

6320221

615E

6151028

625E

6250524

635G

6353073

1185

after 05/15/2018

Machine Model/Serial Numbers for Machines Without Nylon Bushing and Retaining Ring

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

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

2. Loosen fill plugs.

From Axles Without Brakes Or With Service Brakes Only: 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.

From Axles With SAHR (Spring Applied Hydraulic Release) Brakes: 5. Axles with SAHR brakes may be equipped with a nylon bushing to segregate differential/brake oil from planetary/bogie arm oil.

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.

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.

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.

2.6

Tigercat Axles

Disassembly

AXLE DISASSEMBLY

Assess trunnion wear while trunnions are attached to the differential.

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

1. Place pry bars through the mounting tabs to move the trunnion on the differential.

REMOVE HYDRAULIC TUBING

2. Pull each trunnion straight off the differential.

3. Evaluate components if there is a notable amount of play.

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

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

Do not turn fittings using the tubing. Use the correct tools to loosen and tighten fittings.

DISASSEMBLE FRONT TRUNNIONS

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

A

B

C D

REMOVE TRUNNIONS (IB17, OB17, IB15 OSCILLATING DIFFERENTIALS) REMOVE TRUNNIONS (AXLE) A

E B

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. Place the trunnion on support blocks.

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

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

5. Remove the thrust washer.

C C00395

A Rear Trunnion B Axle C Front Trunnion

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.

2.7

Disassembly

Tigercat Axles

DISASSEMBLE REAR TRUNNIONS A

B

REMOVE TRUNNION PIN

C

A

B

D E

J

*

H*

C00398

G

F

C00397

A Trunnion Cap B Shims C Thrust Washer D Rear Trunnion E Oil Seal F Retaining Ring G Rear Trunnion Bushing H *Washer J *Bolt * INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

** C

A Differential B Trunnion Pin C **Bolts ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

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 bolts with washers securing trunnion cap to rear trunnion.

2. Remove trunnion cap, shims and thrust washer.

3. Remove the oil seal.

4. Remove the retaining ring.

5. 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

C00385

L

K

B

C

D

E

F

** **

J

G H

Inboard Planetary Axle

A Differential G **Washers B Brake Housing H **Bolts C O-ring J Spring Pin D Sun Gear K Shims E Ring Gear L Spacer F Axle Housing ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

A

L

K

B

C

D

J

M

C00386

Outboard Planetary Axle

A Differential G **Washers B Axle Housing H **Bolts C O-ring J Spring Pin D Axle Shaft K Shims E Ring Gear L Spacer F Planetary M Sun Gear ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

2.9

E

F

** **

G H

Disassembly

Tigercat Axles

A B C

D

E

** **

F

G H

C00387

Bogie Axle Planetary

A Bogie Arm E Ring Gear B Output Gear Support F Planetary C O-ring G **Washers D Bogie Output Shaft H **Bolts ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

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

WARNING The bogie axle output gear 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 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. b. Remove **bolts from the top half of the planetary.

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.

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

REMOVE BOGIE ARM WARNING

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.

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 both components are adequately supported and level.

Planetaries IB15 ONLY d. Secure the axle brake housing to the differential using two bolts with washers. e. Remove the axle shaft/sun gear. A shaft spacer and shims are attached to the end of the left axle shaft. Verify they are present when the left shaft is removed.

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

CLEAN AND INSPECT on page 1.11.

See SAFETY on page 1.4.

See PERSONAL SAFE LIFTING AND CARRYING on page 1.9.

See SAFE SUPPORT OF COMPONENTS on page 1.9.

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

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

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

NOTICE Bogie axles with parking (SAHR) brakes require the parking brake be released before removing or installing the axle. Retraction pressure is 32 – 34 bar (470 – 500 psi).

2.11

Disassembly

Tigercat Axles

BOGIE ARM ORIENTATION A

C

B

F

D

E F

G C00421

A B C D E F G

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.

BOGIE AXLE SHAFT COVERS There are two configurations of axle shaft covers used to secure axle shafts in Tigercat manufactured bogie axles.

C00699

A B C

A

B

C

Centred Flat Input Gear Cover Offset Contoured Input Gear Cover (11 mounting holes) Offset Contoured Input Gear Cover (6 mounting holes)

• A flat cover with six mounting holes secures a centred spline input gear on the output side of the bogie arm. There is an internal recess for the bearing race to sit in on the inside.

• A contoured cover with either six or eleven mounting holes secures the offset spline input gear on the output side of the bogie arm. The cover post fits into the cylindrical roller bearings pressed into the input gear.

2.12

Tigercat Axles

Disassembly

BOGIE AXLE SHAFT

3. Thread an M12x1.75 bolt into the end of the axle shaft to assist with removal, if required.

NOTICE

4. Remove band tracks if they interfere with input gear removal from the bogie arm. See OEM literature for removal and installation procedures.

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

See LEFT AXLE SHAFT OFFSET INPUT GEAR on page 3.23 or LEFT AXLE SHAFT OFFSET INPUT GEAR on page 3.23.

F

*

M

Q

P

N

D

C

L

R

K

A

J

H

B J

C00705

A B C D E F G H

* G *F

K R

Bogie Arm Input Gear (Offset) Axle Shaft O-ring Input Gear Cover (Offset) *Bolt *Washer Punch Mark (on Input Gear Cover)

D

E J K L M N P Q R

Idler gear Shaft Support Spacer Retaining Ring Input Gear Cover (Centred) Spring Pin Shims Spacer Spring Pin

* INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

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

WARNING

1. Brace components with stands or wooden blocks so the central axle components do not drop when disconnected from the bogie arms.

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

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

2.13

Disassembly

Tigercat Axles

5. 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. Refer to the associated machine service manual to determine which ports on the axle must be energized to release the brakes. b. Install an M14 input fitting suitable for use with the available oil supply system into the port indicated in the machine service manual. c.

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

17. Inspect the post portion of the input cover for scoring. Scoring on the post that leaves significant scoring or ridging and cannot be buffed out requires the cover to be replaced.

18. Remove Loctite 518 sealant from the cover and the cover seat in the bogie arm. See REMOVE 518 LOCTITE FLANGE SEALANT on page 1.11.

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

FOR CENTRED INPUT BEARING CONFIGURATIONS 6. Remove bolts securing the cover to the housing, then thread two M10 x 1.5 x 90mm long bolts into the cover jacking holes.

7. Incrementally turn each bolt alternately to extract the input gear cover from the bogie arm.

The post portion of the input gear cover may bind in the input gear bearings and pull the input gear out with the cover.

8. Remove the input gear and bearing outer race.

9. Remove the O-ring from the input gear cover.

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

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

C00463

A Use indicated ports for SAHR brake retraction

REMOVE THE AXLE SHAFT 19. Remove the right axle shaft from the differential by pulling the shaft straight out, perpendicular to the differential.

20. Remove the left axle shaft from the differential by pulling the shaft straight out, perpendicular to the differential.

12. Remove the shaft support spacer.

NOTICE

FOR OFFSET INPUT BEARING CONFIGURATIONS

Do not leave shaft spacer, shims or spring pin in the differential. If left in the differential they will cause catastrophic damage.

13. Remove bolts securing the cover to the housing, then thread two M10 x 1.5 x 90mm long bolts into the cover jacking holes.

NOTICE Do not mar or damage the bearing contact surfaces on the post of the input gear cover.

14. Incrementally turn each bolt alternately to extract the input gear cover from the bogie arm.

21. Verify 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.

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

The post portion of the input gear cover may bind in the input gear bearings and pull the input gear out with the cover.

15. Remove and inspect the O-ring from the input gear cover. Replace as required.

2.14

Tigercat Axles

Disassembly

SLEW BEARINGS INSPECTING SLEW BEARINGS AND SLEW BEARING FASTENERS

9. 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.

To determine if a slew bearing requires replacement refer to the machine specific information in the machine Operator's and Service Manual.

REMOVE SLEW BEARINGS

10. Follow steps 1 – 6 to remove the other bogie arm.

DISCONNECT BOGIE ARM FROM SLEW BEARING E

F

A

B

C

D

E

**

A

F C00393

D

C

A B C D E F

B

C00392

A Differential B **Bolts C Slew Bearing D Bogie Arm (with axle shaft removed) E Slew Bearing Mounting Surface F Oil Seal ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

Brake Housing O-ring Scraper Ring Slew Bearing Bolts Differential

** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

Different configurations of slew bearing are used in the manufacture of Tigercat axles.

Single Row Slew Bearing

1. Mark slew bearing ball ports relative to the brake housing and the bogie housing.

2. 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 COMPONENTS on page 2.3.

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

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

5. Remove **bolts from the top half of the slew bearing securing it to the bogie arm.

6. Leave two bolts horizontally opposed in the slew bearing.

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

8. Remove the two remaining **bolts from the slew bearing.

Dual Row Slew Bearing

Lubed for Life Manual Lube 24 Hole Mounting Pattern NA

33 Hole Mounting Pattern

Replace a dual row, 24 hole mounting pattern slew bearings with a dual row 33 hole mounting pattern slew bearings.

A 33 hole slew bearing can be mounted on a 24 hole pattern bogie arm.

Do not mount a 24 hole slew bearing on a 33 hole pattern bogie arm.

Replace 33 hole slew bearings with 33 hole slew bearings only.

1. Brace components with stands or wooden blocks.

2. 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 from the top half of housing.

4. Leave two bolts in the housing, horizontally opposed.

2.15

Disassembly

Tigercat Axles

5. Remove the **bolts from bottom half of housing.

6. Remove the two remaining **bolts, then remove the slew bearing.

7. Remove the scraper ring from the slew bearing.

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

REMOVE AXLE/BRAKE HOUSINGS A

B

C

D

E

F

G

H

J

*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

Service Brakes

F G H J

Brake Piston Reaction Plate Friction Plate Piston Return Spring

SAHR (Spring Applied Hydraulic Release) Brakes

K SAHR Brake Rod Seal L SAHR Brake Piston M *Bolt N *Washer P Brake Housing * INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

1. Brace components with stands or wooden blocks.

2. Cinch lifting straps to the axle/brake housing and tension them in preparation to support and move the housing. See SAFE SUPPORT OF COMPONENTS on page 1.9.

Q R S T U

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

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

6. Verify straps are positioned and tensioned correctly.

CAUTION

3. Remove *bolts from the top half of the axle/bearing housing.

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

4. Leave two bolts horizontally opposed in the axle/ bearing housing.

2.16

Tigercat Axles

Disassembly

7. 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 BRAKES SERVICE BRAKE COMPONENTS CAUTION

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

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

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

A B

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

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

11. Remove and discard the O-ring from between the brake housing and differential.

C

C00389

A Air Pressure Device B Differential C Brake Piston

1. Insert an air nozzle into the input port.

2. Apply a heavy rag (not shown) against the brake piston. Hold it firmly in place using the rag and a gloved hand and apply air pressure. Air pressure must not exceed 0.34 bar – 0.69 bar (5 – 10 psi).

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

A

B

C00390

A Differential B Pry Bars C Brake Piston

2.17

C

Disassembly

Tigercat Axles

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

SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKE COMPONENTS WARNING

A

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.

B C

D

E

F

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.

C00459

A B C D E F

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

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

A*

B

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

C D

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

E

C00457

A *Bolts B SAHR Spring Retainer C Belleville Washers D SAHR Brake Thrust Washer E Brake Housing * INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

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

2.18

Tigercat Axles

Disassembly

DIFFERENTIAL

3. Remove the SAHR spring retainer.

4. Remove the Belleville washers.

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

5. Remove the SAHR brake thrust washer.

A

BOGIE BALANCE SPHERICAL BUSHINGS (FOR 68 IN BOGIE AXLES ONLY)

B

C A

C00710

A

B

Example of Bogie Balance Lug (68 in Bogie Arm) C00458

A B C D E F

F

E

A 68 in Bogie Arm B Bogie Balance Lug

D

SAHR Brake Piston Dowel Axle/Brake Housing SAHR Brake Piston Seal SAHR Brake Rod 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.

Machines with the bogie balance system use bogie arms with a lug on top of each arm containing a spherical bushing. The bogie balance system assists in equally distributing machine/load weight across all wheels to maximize tractive effort.

For more information, refer to the Bogie Arm Service and Repair Manual, Section 3, Disassembly and the machine specific Operator's and Service Manual.

a. Place a protective barrier in the planetary side of the housing to protect the SAHR brake piston if it falls. b. Tap lightly, 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 (if present).

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

Square backup rings and O-rings (step 8 – 9) are replaced with pentagonal shaped brake piston seal and brake rod seal.

10. Remove and discard the retaining ring and nylon bushing from the SAHR brake piston (if present).

2.19

Disassembly

Tigercat Axles

2.20

ASSEMBLY..........................................................................................................................................................3

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

CONTENTS – SECTION 3

ISSUE 2.1, DECEMBER 2018

A

AIR PRESSURE TESTING....................................................................................................................................... 3.32 AXLE LEAK TEST.................................................................................................................................................. 3.32 SERVICE BRAKE TEST........................................................................................................................................ 3.33 AXLE INSTALLATION............................................................................................................................................... 3.20 INSTALL BOGIE INPUT/AXLE SHAFT................................................................................................................. 3.20 INSTALL SUN GEAR, AXLE SHAFT AND PLANETARY..................................................................................... 3.25 LEFT AXLE SUN GEAR/AXLE SHAFT................................................................................................................. 3.22 RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES............................................... 3.21 RIGHT AXLE SUN GEAR/AXLE SHAFT FOR SERVICE AND SAHR BRAKES..................................... 3.21, 3.22 RIGHT SUN GEAR/AXLE SHAFT AND PLANETARY......................................................................................... 3.25

B

BEARING INSTALLATION.......................................................................................................................................... 3.3 COOLING BEARINGS AND SLEEVES FOR INSTALLATION.............................................................................. 3.3 HEATING BEARINGS FOR INSTALLATION......................................................................................................... 3.4 BOGIE ARMS............................................................................................................................................................. 3.14 INSTALL BOGIE ARM............................................................................................................................................ 3.19 BOGIE AXLES AND STRAIGHT AXLES WITH SAHR BRAKES........................................................................... 3.34 BOGIE AXLE........................................................................................................................................................... 3.35 STRAIGHT AXLE.................................................................................................................................................... 3.34 BOGIE BALANCE SPHERICAL BUSHINGS........................................................................................................... 3.31

C

CLEANING AND INSPECTION.................................................................................................................................. 3.3

D

DIFFERENTIAL............................................................................................................................................................ 3.4

F

FILL THE AXLE WITH OIL........................................................................................................................................ 3.33 BOGIE AXLE........................................................................................................................................................... 3.35 STRAIGHT AXLE.................................................................................................................................................... 3.34 FITTINGS AND PLUGS.............................................................................................................................................. 3.4 FILL/OIL LEVEL PLUGS.......................................................................................................................................... 3.4 MAGNETIC PLUGS................................................................................................................................................. 3.4

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 NO BRAKE OF SERVICE BRAKE ONLY............................................................................................................. 3.14 INSTALL BRAKES....................................................................................................................................................... 3.5 SAHR PISTON PRESSURE TEST....................................................................................................................... 3.12 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 HYDRAULIC TUBING............................................................................................................................... 3.36 INSTALL SUN GEAR, AXLE SHAFT AND PLANETARY........................................................................................ 3.25 LEFT SUN GEAR/AXLE AND PLANETARY......................................................................................................... 3.26 PLANETARIES TO BOGIE ARM........................................................................................................................... 3.27 RIGHT SUN GEAR/AXLE SHAFT AND PLANETARY......................................................................................... 3.25

Assembly

Tigercat Axles

M

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

O

OIL, FILL THE AXLE.................................................................................................................................................. 3.33 AXLES WITH NO BRAKES/SERVICE BRAKES ONLY...................................................................................... 3.34 AXLES WITH SAHR BRAKES.............................................................................................................................. 3.34 BOGIE AXLES AND STRAIGHT AXLES WITH SAHR BRAKES........................................................................ 3.34

P

PRESSURE TESTING, AIR...................................................................................................................................... 3.32 AXLE LEAK TEST.................................................................................................................................................. 3.32 PRIOR TO ASSEMBLY............................................................................................................................................... 3.3

S

SLEW BEARINGS..................................................................................................................................................... 3.14 FASTENING SLEW BEARINGS........................................................................................................................... 3.15 GREASE A BOGIE SLEW BEARING.................................................................................................................... 3.18 GREASE A LUBED FOR LIFE SLEW BEARING................................................................................................. 3.17 INSTALL SLEW BEARINGS.................................................................................................................................. 3.15 SLEW BEARING ORIENTATION.......................................................................................................................... 3.15 TYPES OF SLEW BEARINGS.............................................................................................................................. 3.17 SLEW BEARINGS, LUBRICATE.............................................................................................................................. 3.17

T

TRUNNIONS, INSTALL............................................................................................................................................. 3.28 ALTERNATE TRUNNION BUSHING INSTALLATION......................................................................................... 3.31 FRONT TRUNNION............................................................................................................................................... 3.30 REAR TRUNNION.................................................................................................................................................. 3.29 TRUNNION BUSHINGS........................................................................................................................................ 3.29 TRUNNION PIN...................................................................................................................................................... 3.28 TYPES OF SLEW BEARINGS................................................................................................................................. 3.17 GREASABLE.......................................................................................................................................................... 3.17 LUBE FOR LIFE..................................................................................................................................................... 3.17

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

WARNING

WARNING

Follow instruction regarding reuse of fasteners.

Replace fasteners with those of the same size and specifications. Failure to do so may lead to catastrophic component failure leading to serious injury or death.

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

See FASTENER TORQUE AND REUSE on page 1.13.

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

MACHINE ORIENTATION

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.

See MACHINE ORIENTATION on page 3.3 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.

WARNING

MOVING AXLE COMPONENTS 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.

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.

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

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

When cooling bearings:

PRIOR TO ASSEMBLY

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

Prior to axle assembly:

2. Do not cool standard product bearings below –54°C ( – 65°F).

1. Have all required parts readily available.

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

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

• Ensure they are the right parts.

• Verify orientation.

• Replace damaged or worn components as required.

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

BLEED SCREW FITTINGS

WARNING Heated bearings are extremely hot. Use appropriate PPE when handling hot parts.

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

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

C00455

3. Do not heat standard product bearings, gears, or steel sleeves 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.

A Bleed Screw B Bleed Screw Seat

When completing final installation of bleed screw seats and bleed screws:

4. Heat and cool bearing components gradually.

1. Apply a small amount of gear oil to the bleed screw seat.

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

2. Insert the cone with the chamfer on the seat facing up to fit into the bottom of the bleed screw.

FITTINGS AND PLUGS

3. Insert the bleed screw.

4. Tighten the bleed screw finger tight, then torque the bleed screw to 27 N-m (20 lbf-ft).

Over– tightened fittings and plugs may result in damaged threads or O-rings, rendering the parts unusable. Tighten plugs and hydraulic fittings using a turning method or a torque (preferred) method.

GUIDE PINS NOTICE

Install fittings/plugs requiring removal or replacement finger tight only, until final assembly. Do not paint mark as torqued until final assembly.

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

MAGNETIC PLUGS 1. Apply a small amount of gear oil to the plug seat.

Guide pins are modified fasteners, made by 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.

2. Insert the plug, finger tight, then torque to 68 N-m (50 lbf-ft).

FILL/OIL LEVEL PLUGS 1. Apply a small amount of gear oil to the plug seat.

DIFFERENTIAL

2. Insert the plug, finger tight, then torque to 68 N-m (50 lbf-ft).

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

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

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

Service Brakes

F G H J

Brake Piston Reaction Plate Friction Plate Piston Return Spring

SAHR (Spring Applied Hydraulic Release) Brakes

K SAHR Brake Rod Seal L SAHR Brake Piston M *Bolt N *Washer P Brake Housing * INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

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 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.

A

G

B

F

C

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.

A B D

E D

E

C

B D C

C00399 A B C D E F G

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 axle components are adequately supported.

C00486

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

A B C D E F

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

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

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 27 N-m (20 lbf-ft).

4. Install inner and outer backup rings into the differential. a. Apply a coat of thick assembly grease to each backup ring.

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

b. Insert the inner and outer backup ring. Note the orientation of each ring, relative to 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. Do not force the brake piston.

A

B C

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 D

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

C C00402 A B C D

9. Loosen the brake piston instillation tool 12.75 mm (0.50 in) so there is a gap between the bottom surface of the tool and the brake piston.

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 the piston deflects properly. c.

B

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

d. Repeat steps 10 – 11.

12. Remove the brake piston installation tools.

13. Repeat steps 1 – 12 for the opposite side of the differential.

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 only. Do not use grease.

A

B

C

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

3.8

Tigercat Axles

Assembly WITHOUT SAHR BRAKE INSTALLATION TOOL B9569000

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

3. Lubricate the SAHR brake piston seal with gear oil only, then install it on the piston. Pass finger around O-ring to resize and set the O-ring in groove.

4. Insert the piston into the brake housing so 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.

NOTICE

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

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

A

A

B

C00652

F

A Spring Retainer B Bolts Set Equally Spaced E

B

6. Align the holes in the spring retainer with those in the piston.

7. Insert four lubricated *bolts positioned 90° to one another, through the retainer, to engage the piston threads.

D

8. Tighten the *bolts finger tight in a star crossed pattern, then continue to tighten the bolts incrementally, one turn at a time until the piston is flush with the spring retainer.

C C00651

A Brake Housing B Spring Retainer C *Bolts D SAHR Brake Piston E SAHR Brake Piston Seal F SAHR Brake Rod Seal * INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

9. Remove the bolts, then remove the retainer.

10. Inspect both sides of the piston bore for seal shavings. a. Hair – thin pieces of shaved seal are permissible as they will not affect seal performance. b. Remove the piston and inspect the seals if larger portions of seal are evident. c.

3.9

Repeat steps 1 – 10 if seal replacement is required.

Assembly

Tigercat Axles

WITH SAHR BRAKE INSTALLATION TOOL B9569000

A

11. Insert the piston into the brake housing so 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.

B

A

B

C D

C00447

A SAHR Brake Thrust Washer B Groove in Brake Housing E

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

F

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

C00837

A B C D E F

NOTICE

Brake Housing SAHR Brake Piston Installation Tool B9569000 Bolt Washer O-ring SAHR Brake Piston

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

12. Insert the SAHR brake piston installation tool B9569000 from the other side of the brake housing.

13. Engage the bolts from the installation tool with the threaded holes in the brake piston, then seat piston by incrementally turning bolts evenly. Do not use hammer/mallet.

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

3.10

Tigercat Axles

Assembly

A

*

A

B

B*

C

C D

D

E

E

F

C00448 A B C D E

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

C00449 A Spring Guide Tool B7506000 B *Bolt C Ball Lock Pins B7506001 D SAHR Spring Retainer E Belleville Washers F Brake Housing * INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

* INSPECT. See on page 1.13.

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

A A

A

A

A–A

GAP

A

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

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

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

B

C

D

22. Apply Loctite #262 and primer 7649 to*bolts, then install into the SAHR spring retainer. Torque *bolts to 45 N-m (33 lbf-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.

C00407 A B C D

Belleville Washers Spring Guide Tool B7506000 SAHR Brake Piston Brake Housing

18. 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.

3.11

Assembly

Tigercat Axles

SAHR PISTON PRESSURE TEST A

SERVICE BRAKES NOTICE

B

Reaction plate inspection tabs must align with the inspection port.

C

H

A

B H D

G F

C

F E

G

C00450 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

E

D

C00404

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

A B C D E F G H

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

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

4. 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.

5. 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.

6. Apply and release hydraulic pressure to move the piston through the range of motion. Required pressure is up to 44 bar (635 psi). Displacement must be 5.7 – 6.2 mm (0.225 – 0.245 in).

7. Apply hydraulic pressure, then zero the dial indicator. Slowly relieve pressure until the dial indicator registers 0.025 mm (0.001 in). Pressure must read between 32 – 35 bar (470 – 500 psi).

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

1. Install a reaction plate into the brake housing.

Ensure the inspection tabs align with the inspection port.

2. Apply a light coat of clean gear oil to each friction plate.

3. Install a friction plate in the housing.

4. Repeat steps 1 – 3 until all reaction and friction plates are installed. The number of reaction plates and friction plates depends upon the axle configuration.

5. Verify the oil passages in the friction plates align.

3.12

Tigercat Axles

Assembly A

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.

BRAKE HOUSING IB15 AXLE A

E

B

C

B C D D C00406

C00461 A B C D E

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

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

A B C D

Guide Pin O-ring Brake Housing Differential

BRAKE/AXLE HOUSING OB17, IB17, OB20 AXLE A

B

C

F

C00405

E D

A Guide Pin B O-ring C Axle Housing D *Bolt E Washer F Differential * INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

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

3.13

Assembly

Tigercat Axles SLEW BEARINGS

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

Different configurations of slew bearing are used in the manufacture of Tigercat axles.

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

Single Row Slew Bearing

Lubed for Life

NO BRAKE OF SERVICE BRAKE ONLY

Manual Lube

4. Install the brake housing onto the differential.

24 Hole Mounting Pattern to Bogie Arm NA

a. Hold brake components (if present) in position. b. Align brake housing with the temporary dowel pins on the differential and engage the housing to the differential. c.

Verify the brake piston (if present) aligns with the axle housing.

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.

33 Hole Mounting Pattern to Bogie Arm

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

Refer to the Lubrication and Maintenance section of the associated machine Operator's and Service Manual for further information.

The outer race of the slew bearing mounts to the bogie arm. The inner race of the slew bearing mounts to the brake housing.

a. Align brake housing with differential.

H

b. Loosen the bleed screw on the brake housing. c.

Dual Row Slew Bearing

A

B

C

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

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

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

C00705

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.

A B C D E F G H

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

3.14

G

F

Slew Bearing (dual row, 24 mounting holes) Upper Grease Circulation Port Manufacturer's Grease Fill ( No Service Required) Slew Bearing (dual row, 33 mounting holes) Grease Inlet Port Ball Fill Plugs Lower Grease Circulation Port Grease Inlet Port

E

D

Tigercat Axles

Assembly

FASTENING SLEW BEARINGS

SLEW BEARING ORIENTATION

Retorque all fasteners securing slew bearings: • prior to start– up after extended machine downtime.

A

• every 2,000 operating hours • annually or • when axle has been removed for service.

G

B

E

NOTICE Bolts having lost 20% or more of the prescribed preload must be replaced. Replace washer. Two bolts and washers on each side of the tested bolt must also be replaced.

C

NOTICE Where 20% of the bolts of a single ring of a slew bearing are tested to have 80% or less of the prescribed preload all bolts and washers must be replaced.

E

C00412 A B C D E F G

NOTICE Do not loosen or replace more than one bolt at a time. Use the same tightening methods and calibrated equipment. Do not use thread locker compounds.

Replace a dual row 24 hole mounting pattern slew bearing with a dual row 33 hole mounting pattern slew bearing (preferred upgrade). Replace a dual row 24 hole pattern slew bearing with the same, only if installed as original equipment.

Do not mount a slew bearing with 24 mounting holes on a bogie arm with 33 mounting holes.

Replace 33 hole slew bearings with 33 hole slew bearings only.

D

F

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

Install reusable 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.

INSTALL SLEW BEARINGS NOTICE

For more information contact the Tigercat Parts and Service Department.

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

3.15

Assembly

Tigercat Axles

For A New, Greasable, Slew Bearing c.

G

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

B

**

C

E C

D

C00466

F

A B C D E F G

E

C00452 A B C D E F

B

F

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.

A

A

Scraper Ring O-ring **Bolt Oil Seal Slew Bearing (24 hole pattern shown) 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.

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.

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.

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:

** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

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

D

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 the other ball port is off centre in the same direction and by the same amount.

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 549 N-m (405 lbf-ft) in a star pattern.

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

3.16

Tigercat Axles

Assembly

TYPES OF SLEW BEARINGS

LUBE FOR LIFE

Two types of slew bearings are utilized in Tigercat bogie axles, lube for life and greasable.

The, lube for life, slew bearing is a sealed, self – lubricated bearing requiring minimal service.

A

G

B

F

The outer ring is fitted with 4 grease fittings requiring periodic lubrication to replace soiled grease in the grease buffer chamber.

See the LUBRICATION AND MAINTENANCE section of the machine Operator and Service manuals.

GREASABLE 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

E

D

C

A

GREASE A LUBED FOR LIFE SLEW BEARING

H

A

B

B F C

E J

D

C

A

B

F

F

D

C00453

E

C00467

A B C D E F G H J

E

D

A B C D E F

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

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.

3.17

Assembly

Tigercat Axles GREASE A BOGIE SLEW BEARING

B

A

A

B

C

B

D

C00468 A B C D

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 steps 2 – 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 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 steps 2 – 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 centre, then rotate 90° the other direction and return to centre.

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.

3.18

Tigercat Axles

Assembly

INSTALL BOGIE ARM

7. Insert and thread **bolts finger tight, then torque each to 386 N-m (285 lbf-ft) in a star pattern. Do not use a swivel type adapter when torqueing to spec.

Use a torque bar with 3/4 in drive socket and a shortened M14 stub.

The bogie arm may come in a variety of states of assembly\disassembly.

Verify 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.

A

G

**

F

B

E

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.

C

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 SHAFT CENTRED INPUT GEAR on page 3.22.

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

** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

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. Pre-measure the length of the dowel and depth of hole for the dowel pins to be inserted in the bogie arm on each side of the slew gearing mount. The height of the installed dowels must not exceed 41.500 mm (1.634 in). If the dowels exceed this dimension, grind the end of the dowels to comply.

4. Insert a dowel pin in the bogie arm on each side of the slew bearing mount, then tap the dowels to fully seat them. 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 3.15. The oil seal must be seated so it does not roll an edge or come free from the seat.

3.19

Assembly

Tigercat Axles

AXLE INSTALLATION BOGIE INPUT/AXLE SHAFT

F

*

M

Q

P

N

D

C

L

R

K

A

J

H

B J

C00705

A B C D E F G H

* G *F

K R

Bogie Arm Input Gear (Offset) Axle Shaft O-ring Input Gear Cover (Offset) *Bolt *Washer Punch Mark (on Input Gear Cover)

D

E J K L M N P Q R

Idler gear Shaft Support Spacer Retaining Ring Input Gear Cover (Centred) Spring Pin Shims Spacer Spring Pin

* INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

WARNING

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

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

NOTICE

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

Bogie axles with SAHR( Spring Applied Hydraulic Release) brakes require the SAHR brake be retracted before removing or installing the axle. Retraction pressure is 32 – 35 bar (470 – 500 psi).

3.20

Tigercat Axles

Assembly

RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES To install axle shafts or sun gears in axles containing 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.

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.

RIGHT AXLE SHAFT FOR SERVICE AND SAHR BRAKES, CENTRED INPUT GEAR

1. Remove the input gear cover.

2. Install the axle shaft, with the longest spline facing the differential, 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.

A B

C00453

C00463

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

A Use indicated ports for SAHR brake retraction

To retract the brakes.

1. 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.

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

3. 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.

4. Repeat steps 1 – 3 for the left side.

5. Disconnect the hydraulic supply once the axle shaft or sun gear is successfully installed.

C

4. 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.

5. Apply a light bead around each bolt hole. Do not get sealant in the holes.

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

8. 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.

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

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

3.21

Assembly

Tigercat Axles

LEFT AXLE SHAFT CENTRED INPUT GEAR

14. If the measurement is greater than 2.8 mm (0.110 in) remove the spacer, then add shims until the value falls within the target measurement.

1. Insert the spring pin into the long spline end of the axle shaft.

15. Verify the shaft spacer does not rotate freely on the pin.

16. Repeat steps 4 – 14 until the target measurement is achieved.

17. Apply a light bead of Loctite 518 around the perimeter of the input gear cover seat on the bogie arm. See GASKET FORMING/SEALANT PRODUCTS on page 1.12.

E

D

C

B

18. Apply a light bead around each bolt hole. Do not get sealant in the holes.

A

C00412

A B C D E

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

Axle Shaft Black Electrical Tape Shaft Spacer 3 mm (0.120 in) Ø solder Target Measurement 2.3 – 2.8 mm (0.090 – 0.110 in)

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

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

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

3. Install the shaft spacer onto the spring pin.

4. Place a piece of lead solder 3.00 mm (0.120 in) diameter over the end of the shaft spacer and secure it in place using black electrical tape.

22. Do not fill the bogie arms with oil for a minimum of one hour to ensure Loctite thread locking compounds are dry.

5. Remove the input gear cover and release the SAHR brake. See RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES on page 3.21.

RIGHT AXLE SHAFT FOR SERVICE AND SAHR BRAKES, OFFSET INPUT GEAR If replacing an entire bogie arm, the offset input gear and offset input gear cover will be installed in the bogie arm.

The axle shaft is separate.

NOTICE Do not strike the end of the axle.

If installing a kit, all components including the axle shaft are included.

6. 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.

WARNING

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

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

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

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

1. Remove the input gear cover from the right bogie arm.

10. Secure the cover to the bogie arm using six M10x1.5 bolts. Do not use Loctite. Tighten each to 75 N-m (55 lbf-ft) in a star pattern. This will crush the solder strip on the end of the axle shaft.

2. Assemble and install the offset input gear components. See Bogie Arm, Service and Repair Manual 47732AENG for details about offset input gear components and assembly.

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

3. Insert the offset input gear into the bogie arm.

12. 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.

13. Measure the thickness of the crushed solder strip.

The target measurement is between 2.3 – 2.8 mm (0.090 – 0.110 in).

3.22

Tigercat Axles

Assembly

4. Insert the axle shaft, with the longest spline on the axle shaft facing the differential, through the splines in the right input gear, then into the differential.

Release the brakes if necessary. Oscillate the axle shaft to assist in aligning the spline teeth with the teeth of the friction plates. See RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES on page 3.21.

5. Insert the spring pin into the long spline end of the axle shaft.

5. Clean the input gear cover O-ring with alcohol and apply a light coat of gear oil to the O-ring groove.

E

6. Install the O-ring on the input gear cover.

A B C D E

7. Apply a light bead of Loctite 518 gasket maker sealant around the perimeter of the output gear cover and around each bolt hold. Do not get sealant in the holes.

NOTICE Do not strike the end of the axle.

8. Insert the input gear cover, with the alignment pin and orientation indicator facing the top of the bogie arm, into the input gear. Do not use a mallet or hammer to seat the input cover into the input gear.

9. Apply Loctite 7649 Primer and Loctite 242 to six *bolts. See THREAD LOCKER AND PRIMER PRODUCTS on page 1.12.

1. Remove the input gear cover from the right bogie arm.

2. Assemble and install the offset input gear components. See Bogie Arm, Service and Repair Manual 47732AENG for details about offset input gear components and assembly.

3. Insert the offset input gear into the bogie arm.

C

B

A

Axle Shaft Black Electrical Tape Shaft Spacer 3.0 mm Ø (0.120 in Ø) solder Target Measurement 2.3mm – 2.8mm (0.090 – 0.110 in)

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

7. Install the shaft spacer onto the spring pin.

8. Place a piece of 3mm Ø (0.120 in Ø) solder over the end of the shaft spacer and secure it in place using black electrical tape. Verify the shaft spacer does not rotate freely on the pin.

9. Release the brakes if necessary. See RELEASE THE SAHR (SPRING APPLIED HYDRAULIC RELEASE) BRAKES on page 3.21.

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

LEFT AXLE SHAFT OFFSET INPUT GEAR

D

C00412

NOTICE Do not strike the end of the axle.

10. 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.

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

12. Secure the cover to the bogie arm using M10x1.5 *bolts. Do not use Loctite. Tighten each to 75 N-m (55 lbf-ft) in a star pattern. This will crush the solder strip on the end of the sun gear/axle shaft.

13. Remove the left input gear cover from the bogie arm.

14. 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.

A

15. Remove, then measure the thickness of the crushed solder strip to establish the value of the measured endplay. a. Gears 82837B with Revision numbers R00, R01 and R02 have an endplay target value of 0.76 – 1.27 mm (0.030 – 0.050 in).

C00706

Gear Marking

A Example Part Number and Revision Etched Into Gear

b. All other gears have an endplay target value of 2.3 – 2.8 mm (0.090 – 0.110 in).

4. Note and record the part number and revision of the input gear. This information is required to set the endplay correctly.

3.23

Assembly

Tigercat Axles

16. Calculate the endplay of gears 82837B Revision numbers R00, R01 and R02. Example: Measured Thickness of Solder Strip

2.29 mm (0.090 in)

Average of Target Endplay

1.02 mm (0.040 in)

Result (Shims to Add)

1.27 mm (0.050 in)

A

If the result is not within the endplay target value of 0.76 – 1.27 mm (0.030 – 0.050 in) add or remove shims as required to meet target value.

B

If the solder strip is not crushed, verify all components are installed correctly, then add shims as required to the roll pin / spacer on the end of the axle.

C

Remove burrs from the spacers so the shim pack seats squarely against the shaft.

F

Average of Target Endplay

2.54mm (0.100 in)

Result (Shims to Remove)

0.51 mm (0.020 in)

*

A O-ring B Input Cover C Washer D *Bolt E Spring Pin F Input Gear (Offset) * INSPECT. See FASTENER TORQUE AND REUSE on page 1.13.

17. Calculate the endplay for all other gears. Example: 2.03 mm (0.080 in)

D

C00700

Acceptable shim packs range from 1.27 – 8.38 mm (0.050 – 0.330 in). If shim packs are out of size range, contact Tigercat Parts and Services Department.

Measured Thickness of Solder Strip

E

21. Install the O-ring on the input gear cover.

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

If the result is not within the endplay target value of 2.3 mm (0.090 in) – 2.8 mm (0.110 in) add or remove shims as required to meet target value.

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

If the solder strip is not crushed, verify all components are installed correctly, then add shims to the roll pin / spacer on the end of the axle.

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

Remove burrs from the spacers so the shim pack seats squarely against the shaft.

25. Do not fill the bogie arms with oil for a minimum of one hour to ensure Loctite thread locking compounds are dry.

Acceptable shim packs range from 1.27 – 8.38 mm (0.050 – 0.330 in). If shim packs are out of size range, contact Tigercat Parts and Services Department.

18. Repeat steps 8 – 17 until the target measurement is achieved.

19. Clean the input gear cover O-ring with alcohol and apply a light coat of gear oil to the O-ring groove.

20. Apply a light bead of Loctite 518 gasket maker sealant around the perimeter of the output gear cover and around each bolt hold. Do not get sealant in the holes.

3.24

Tigercat Axles

Assembly

AXLE SHAFT AND PLANETARY

E

D

** C

B **

A

NOTICE Axles with SAHR brakes require the SAHR brake to be released before removing or installing the axle. Retraction pressure is 32 – 35 bar (470 – 500 psi).

F

G

NOTICE C00411

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.

Axle with Outboard Planetaries, Right Side

A Planetary B **Bolt C **Washer D O-ring E Sun Gear F Right Axle Shaft G Axle Housing ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

RIGHT AXLE SHAFT AND PLANETARY For information about planetary assembly See Planetaries Service and Repair Manual 44738AENG. A

B

C D

**F**

E

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 3.21.

NOTICE Do not strike the end of the axle.

H

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.

C00410

G

Axle with Inboard Planetaries, Right Side

A Dowel B Guide Pin C O-ring D Right Sun Gear E **Bolt F **Washer G Planetary H Differential/Brake Housing ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

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

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

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

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

6. Thread the bolts with washers finger tight, then torque in a star pattern to: **M18 x 2.5 – 393 N-m (290 lbf-ft), B17, B20 **M16 x 2.0 – 278 N-m (205 lbf-ft), B15

3.25

Assembly

Tigercat Axles

LEFT AXLE AND PLANETARY ** ** H

J

K

L

**

A

**

F G

H

J

K

L

A C

B E

D

C

D B G

F

C00409

E

Axle with Outboard Planetaries, Left Side

C00408

A Axle Housing B Spacer C Shims D Spring Pin E O-ring F **Bolt (See Step 6) G **Washer H Planetary J Sun Gear K Left Axle Shaft L Guide Pin ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

Axle with Inboard Planetaries, Left Side

A Differential/Brake Housing B Alignment Dowel C Left Sun Gear D Spacer E Shim F Spring Pin G Planetary H **Bolt (See Step 6) J **Washer K O-ring L Guide Pin ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

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

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

C00412

A B C D E

E

D

C

B

A

Axle Shaft Black Electrical Tape Shaft Spacer Lead solder 3.00 mm (0.120 in) diameter Target Measurement 2.3 mm (0.090 in) – 2.8 mm (0.110 in)

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

4. Install the shaft spacer onto the spring pin.

5. Place a piece of lead solder 3.00 mm (0.120 in) diameter over the end of the shaft spacer and secure it in place using black electrical tape.

3.26

Tigercat Axles

Assembly

FOR AXLES WITH SAHR BRAKES

PLANETARIES TO BOGIE ARM For information about planetaries See 47738AENG, Planetaries, SERVICE AND REPAIR MANUAL.

6. 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 3.21.

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

NOTICE

** B **

A

Do not strike the end of the axle.

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

C

8. Install the planetary onto the differential/axle housing. Do not damage the solder strip on the end of the sun gear/axle shaft.

D

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

E

M

F

**M18 x 2.5 – 393 N-m (290 lbf-ft), B17, B20 **M16 x 2.0 – 278 N-m (205 lbf-ft), B15

L

This will crush the solder strip on the end of the sun gear/axle shaft.

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

K C00493

11. Measure the thickness of the crushed solder strip.

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

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

15. 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.

H

G

A **Bolt B **Washer C Planetary D Planet Retaining Ring E Ring Gear F Retaining Ring G Bogie Housing H O-ring J Sun Gear K Bearing Support L Guide Pin M O-ring ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

12. If the measurement is:

14. Repeat steps 4 – 12 until the target measurement is achieved.

J

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. 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.

4. Verify the planetary is correctly prepared for installation to the bogie arm. a. Verify planetary retaining rings are present. b. Verify centre retaining ring is present.

3.27

Assembly

Tigercat Axles

INSTALL TRUNNIONS

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

INSTALL TRUNNION PIN

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.

A

B

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.

9. Insert bolts finger tight, then torque each: a. For bogie axles 1887 mm (74.3 in), 1905 mm (75.0 in). and 1969 mm (77.5 in) long, tighten M18 bolts in a star – shaped pattern. Verify the thread pitch and torque to values listed.

C00397

A Differential B Trunnion Pin C **Bolts

b. For bogie axles 1727 mm (68 in) long, tighten M16 bolts in a star – shaped pattern. Verify the thread pitch and torque to values listed. **M18 x 2.5 – 393 N-m (290 lbf-ft) for B17 Standard/B20 **M16 x 2.0 – 278 N-m (205 lbf-ft) for B15

** C

** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13

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 339 N-m (250 lbf-ft) in a star pattern. Verify there is no gap between the trunnion pin and the differential housing.

3.28

Tigercat Axles

Assembly

INSTALL TRUNNION BUSHINGS

REAR TRUNNION

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

E

E

A B C D

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.

2. Cool the trunnion bushing (with internal spiral grooves) in liquid nitrogen. See COOLING BEARINGS AND SLEEVES FOR INSTALLATION 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

A

C00413

A

B

A

3. Insert the trunnion bushing into the trunnion. Centre the diagonal oil groove to align with the flat on the trunnion. Verify 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 4.1 mm (0.162 in).

8. Install the trunnion cap and secure using bolts with washers torqued in a star pattern to 136 N-m (100 lbf-ft).

NON-INPUT SIDE BUSHING:

ROTATE THE BUSHING DURING THE INSTALLATION TO ENSURE GREASE

3.29

GROOVES ARE ORIENTATED AS SHOW

Assembly

Tigercat Axles FRONT TRUNNION A

B

C

D

A

D E C00415

G

** F**E

A–A B

A Differential B Rear Trunnion (with Seal, Ring and Bushing) C Thrust Washer D Trunnion Cap E **Bolt F **Washer G Shims ** Do Not Reuse – Replace. See FASTENER TORQUE AND REUSE on page 1.13.

C

A

D E

A

C00414

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

10. Push the completed trunnion unit onto the trunnion pin. Oscillate the trunnion to verify it turns smoothly.

A B

Oil Seal Trunnion Bushing (with parallel internal grooves)

C

Front Trunnion

D E

Thrust Washer Urethane Seal

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.

3.30

Tigercat Axles

Assembly

BOGIE BALANCE SPHERICAL BUSHINGS (FOR 68 IN BOGIES ONLY)

C B

A

C00416

A Input Side Trunnion Unit B Sleeve C Differential Input Side

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.

A

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

ALTERNATE TRUNNION BUSHING INSTALLATION

WARNING Heated bearings/components are extremely hot.

Use appropriate PPE when handling hot parts.

Bushings not 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.

B

C00710

Example of Bogie Balance Lug (68 in Bogie Arm) A 68 in Bogie Arm B Bogie Balance Lug

Machines with the bogie balance system use bogie arms with a lug on top of each arm containing a spherical bushing. The bogie balance system assists in equally distributing machine/load weight across all wheels to maximize tractive effort.

For more information, refer to the Bogie Arm Service and Repair Manual, Section 3, Assembly and the machine specific Service Manual.

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

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.

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

3.31

Assembly

Tigercat Axles

AIR PRESSURE TESTING L

C00495

A B C D E F

K

M

A

J

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

B

H

C

D

G

E

F

Axle Air Testing Port Locations

AXLE LEAK TEST 1. Insert and tighten all drain plugs in the axle. Torque each to 68 N-m (50 lbf-ft).

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

3. Install test gauge B8590000 fitting into the right oil level port. Torque to 68 N-m (50 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

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

11. Follow steps 5 – 10 until the problem is corrected.

If after several attempts there is still a leak, contact your Tigercat dealer or the Tigercat Parts Department.

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

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.

3.32

Tigercat Axles

Assembly

SERVICE BRAKE TEST

FILL THE AXLE WITH OIL

Without SAHR brakes

NOTICE

1. Attach pressure test gauge B8590000 to an air supply 6.2 – 8.3 bar (90 – 120 psi).

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

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

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

NOTICE

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

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

5. Release pressure by opening the bleeder valve.

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

NOTICE

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

An axle assembly may contain up to 63 L (16.6 US gal ) of oil.

For axles without axle brake pressure tubes

A bogie axle may contain up to 250 L (66.2 US gal) of oil.

8. Install test gauge B8590000 fitting into the right service brake input port.

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

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.

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.

12. Repeat steps 9 – 13 for the left brake input port. In this case the left spindle must not turn and the right spindle must turn.

Oil Capacity (Volume in Liters) Axle Model Number W/Brakes OB20 63 L OB17 39 L IB17 36 L IB15W 33 L IB15 26 L ROB17 / HOB17 / WOB17 250 L WOB15 195 L

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

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

WO/Brakes / 42 L 39 L 36 L 28 L 250 L 195 L

Oil Additive BW047 Differential Only (Volume in Liters) 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 2 L None WOB15 2L None

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

3. Follow steps 1 – 7 or steps 8– 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.

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 complement of oil, mark the axle clearly to show it is full of oil.

3.33

Assembly

Tigercat Axles BOGIE AXLES AND STRAIGHT AXLES WITH SAHR BRAKES

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

Gear oil in axles with SAHR brakes may be segregated by a nylon bushing positioned between the planetary and the differential. With the nylon bushing in place, oil must be drained and added separately from/to the differential and brake housings/bogie arm – planetaries.

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

A

B

A

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

C

STRAIGHT AXLE B

A

E

C

D

C00384

A B C D E

Axle Housing Differential Fill Plug Magnetic Drain Plug Approximate Fill Line

F

2. Remove the fill plugs from the axle.

C00470

3. Verify magnetic drain plugs are installed. Torque each to 68 N-m (50 lbf-ft).

A B C D E F

NOTICE Do not leave the oil transfer pump unattended when operating.

D

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

To fill a straight axle with the bushing in place:

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.

1. Remove the fill plugs from the brake housing.

2. Remove the fill plug from the differential.

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 68 N-m (50 lbf-ft).

E

3. Verify magnetic drain plugs are installed. Torque each to 68 N-m (50 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 steps 4 – 5.

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

9. Repeat steps 4 – 5.

10. Disconnect the pump and reinstall the fill plugs.

Torque each to 68 N-m (50 lbf-ft).

3.34

Tigercat Axles

Assembly

BOGIE AXLE A

B

A

C

BOGIE AXLES AND AXLES WITH SAHR BRAKES, BUSHING REMOVED 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.

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

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

E

Machine Model

C B

D

C00383 A B C D E

Bogie Arm Magnetic Drain Plug Fill Plug Approximate Fill Line Differential

To fill a bogie axle with the bushing in place:

Serial Number/Date

1085B

10850536

2160

216000103

1075C

10751071

632E

6320221

615E

6151028

625E

6250524

635G

6353073

1185

after 05/15/2018

1. Remove the fill plugs from the brake housing.

To fill an axle without bushing:

2. Remove the fill plug from the bogie arms.

STRAIGHT AXLE

3. Verify magnetic drain plugs are installed. Torque each to 68 N-m (50 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 bogie arm and begin pumping operations.

7. Repeat steps 4 – 5.

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

9. Repeat steps 4 – 5.

10. Disconnect the pump and reinstall the fill plugs.

Torque each to 68 N-m (50 lbf-ft).

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

2. Place a container beneath the fill port.

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 magnetic drain plugs are installed. Torque each to 68 N-m (50 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 3.35.

3.35

Assembly

Tigercat Axles

INSTALL HYDRAULIC TUBING Install previously removed hydraulic tubing on the differential.

Do not reuse bent, creased or crushed tubing or fittings.

Do not turn fittings using the tubing. Use correct tools to loosen and tighten fittings.

A

B

K

C

J

D

H G F E C00417

A B C D E F G H J K

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 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.

3.36