Tigercat BOGIE ARM SERVICE AND REPAIR MANUAL - PDF DOWNLOAD

BOGIE ARM

SERVICE AND REPAIR MANUAL

ISSUE 2.1, OCTOBER 2020 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat Bogie Arm TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v NON-APPROVED FIELD PRODUCT / PARTS CHANGES............................................................................... vi TRADEMARKS...................................................................................................................................................vii BOGIE ARM – EXPLODED VIEW......................................................................................................................viii BOGIE ARM – ORIENTATION TO DIFFERENTIAL............................................................................................. ix BOGIE ARM – OFFSET SPLINE, INPUT GEAR COMPONENTS....................................................................... x BOGIE ARM – BOGIE BALANCE LUG WITH HARDWARE............................................................................... xi SAFETY..............................................................................................................................................................1 DISASSEMBLY....................................................................................................................................................2 ASSEMBLY..........................................................................................................................................................3

AVAILABLE LITERATURE Service and Repair Manual (this manual).......................................................................................Part No. 47732AENG Axles, Service and Repair Manual .................................................................................................Part No. 47731AENG

iii

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

Tigercat Bogie Arm INTRODUCTION This service and repair manual is made available by Tigercat to assist service technicians with disassembly, servicing and reassembly of Tigercat Bogie Arms.

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 send out updates 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 Bogie Arm

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 Bogie Arm

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

TIGERCAT BOGIE ARM Tigercat manufactures different configurations of Bogie Arms. Despite the physical differences between the configurations, internal parts and assembly processes are similar for each bogie arm 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 bogie arms may be shown throughout the manual.

Bogie Arms are designated using several descriptors including model, housing and length. The following chart shows variables associated with bogie arm selection.

BOGIE ARM

MODEL

HOUSING TYPE

BOGIE ARM LENGTH

Wide Spread

W

Fabricated/Cast

1968.5 mm (77.5 in)

Fabricated/Cast

1727 mm (68 in)

High Clearance

H

Fabricated/Cast

1905mm (75 in)

Standard

R

Fabricated/Cast

1887 mm (74.3 in)

vii

BOGIE ARM – EXPLODED VIEW......................................................................................................................viii

Introduction

Tigercat Bogie Arm

*

3

7

17

14

12

15

14

8

16

18

8

5

4

20

11

1 19

9

19 16

15

5

19

13

*3

10

*3

14 12

4

17

14

7

6

19

2

C00420

Bogie Arm – Exploded View

NOTE: This exploded view is representative of a typical Tigercat bogie arm with a fabricated housing, centred input gear and centred input gear

cover and configuration. Some parts may not appear exactly as shown.

viii

BOGIE ARM – ORIENTATION TO DIFFERENTIAL............................................................................................. ix

Tigercat Bogie Arm ITEM 1 2 3 4 5 6 7 8 9 10

Introduction

PART DESCRIPTION HOUSING SUPPORT, BEARING *BOLT RING, RETAINING, INTERNAL SPACER O-RING O-RING PLUG, MAGNETIC GEAR, INPUT COVER, INPUT

ITEM 11 12 13 14 15 16 17 18 19 20

PART DESCRIPTION O-RING GEAR, IDLER GEAR, OUTPUT BEARING, ROLLER BUSHING, IDLER PIN PIN CAP, IDLER PIN PLUG, MAGNETIC BEARING, ROLLER PIN, SPRING

* INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12

C00421

Bogie Arm – Orientation To Differential

NOTE: This view shows the position of the bogie arms relative to the differential. The viewer is facing the yoke on the differential. ix

BOGIE ARM – OFFSET SPLINE, INPUT GEAR COMPONENTS....................................................................... x

Introduction

Tigercat Bogie Arm

18

1

*3

17

16

7

14

12

14

15

15

14 7

4

5

16 17

19

13

19

11

10

*3

14

12

8

4

5

9

*

3

19

6

2

C00695

ITEM

1 2 3 4 5 6 7 8 9 10

PART DESCRIPTION

HOUSING SUPPORT, BEARING *BOLT RING, RETAINING, INTERNAL SPACER O-RING O-RING PLUG, MAGNETIC GEAR, OFFSET INPUT COVER, OFFSET INPUT GEAR

ITEM

11 12 13 14 15 16 17 18 19 20

PART DESCRIPTION

O-RING GEAR, IDLER GEAR, OUTPUT BEARING, ROLLER BUSHING, IDLER PIN PIN CAP, IDLER PIN PLUG, MAGNETIC BEARING, ROLLER PIN, SPRING

* INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12

Offset Spline, Input Gear Components and Configuration– Exploded View

NOTE: This exploded view is representative of a Tigercat bogie arm with fabricated housing, offset input gear, offset input gear cover and

configuration. Some parts may not appear exactly as shown.

x

20

BOGIE ARM – BOGIE BALANCE LUG WITH HARDWARE............................................................................... xi

Tigercat Bogie Arm

Introduction

A

21 22 23

21

A

C00841 C00708

ITEM 21 22

PART DESCRIPTION

ITEM

GREASE FITTING BOGIE BALANCE LUG

23

PART DESCRIPTION

SPHERICAL BEARING

Bogie Arm, Bogie Balance Lug with Hardware

NOTE: This exploded view is representative of a Tigercat bogie arm with a bogie balance lug and accompanying hardware. Some parts may not appear exactly as shown.

Machines manufactured prior to the machine serial numbers listed below, do not use the offset input gear components and configuration.

MACHINE MODEL

To quickly identify the difference between previous and current components, determine which cover plate is installed.

There are two configurations of input gear/cover used in Tigercat manufactured bogie axles and three different covers.

MACHINE SERIAL NUMBER

615C

6150152

615E

6151028

625E

6250558

635G

6353143

1075C

10751053

1085B

10850148

1085C

10850553

2160

21600110

C00699

Tigercat recommends bogie arms exhibiting failed drive shaft splines, input gears and/or input bearings be replaced using offset input gear components and configurations. For further information contact the Tigercat Service Department.

A B C

xi

A

B

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

C

Introduction

Tigercat Bogie Arm

Configuration A is a centred spline input gear with bearings on each side of the input gear secured by a cover, featureless on the outside, with six mounting holes. There is an internal recess for the bearing housing to sit in on the inside.

Configurations B and C utilize an offset spline input gear with both bearings positioned in the input gear.

The gear is secured by a cover with either six or eleven mounting holes. The cover post fits into the cylindrical roller bearings pressed into the input gear.

xii

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

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

CONTENTS– SECTION 1 A

ISSUE 2.1, OCTOBER 2020

APPLY LOCTITE PRODUCTS................................................................................................................................. 1.11 GASKET FORMING PRODUCTS......................................................................................................................... 1.11 THREAD LOCKER AND PRIMER PRODUCTS.................................................................................................. 1.11

C

CALIBRATION............................................................................................................................................................. 1.8 CAUTION..................................................................................................................................................................... 1.3

D

DANGER...................................................................................................................................................................... 1.3

F

FASTENER TORQUE AND REUSE......................................................................................................................... 1.12 BOLTS..................................................................................................................................................................... 1.12 NUTS AND WASHERS.......................................................................................................................................... 1.12 TORQUE WRENCHES.......................................................................................................................................... 1.12

G

GREASE INJECTION INJURY................................................................................................................................... 1.7 GUIDE PINS............................................................................................................................................................... 1.10

H

HAZARDOUS MATERIALS........................................................................................................................................ 1.4 HAZARDS.................................................................................................................................................................... 1.5 COMPRESSED AIR................................................................................................................................................. 1.5 FLAMMABILITY........................................................................................................................................................ 1.5 LIQUID NITROGEN................................................................................................................................................. 1.5 VENTILATION........................................................................................................................................................... 1.5 VITON SEAL HAZARDS.......................................................................................................................................... 1.6 WORKING WITH OIL............................................................................................................................................... 1.5 HIGH-PRESSURE INJECTION INJURIES............................................................................................................... 1.6

L

LEGISLATIVE AUTHORITY........................................................................................................................................ 1.3 LOCTITE 242 THREAD LOCKER, REMOVE FASTENERS.................................................................................. 1.11 LOCTITE 518 FLANGE SEALANT, REMOVE......................................................................................................... 1.11 LOCTITE PRODUCTS, APPLYING.......................................................................................................................... 1.11

M

MATERIAL LIFTING AND HANDLING....................................................................................................................... 1.8

N

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

P

PERSONAL PROTECTIVE EQUIPMENT (PPE)...................................................................................................... 1.4 PICTOGRAMS............................................................................................................................................................. 1.4

R

READ THIS MANUAL FIRST...................................................................................................................................... 1.3 REMOVE LOCTITE 518 FLANGE SEALANT.......................................................................................................... 1.11

S

SAFETY, GENERAL.................................................................................................................................................... 1.4 SIGNAL WORDS, UNDERSTANDING...................................................................................................................... 1.3 SYMBOLS, SAFETY.................................................................................................................................................... 1.3

T

TORQUE CHART, GENERAL................................................................................................................................... 1.13

W

Safety

Tigercat Bogie Arm

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

1.2

Tigercat Bogie Arm

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 Bogie Arm 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.

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.

LEGISLATIVE AUTHORITY

WARNING

In the event of contradictory information regarding health and safety and or material handling/disposal, follow laws and regulations established by federal, provincial/state/regional and local agencies.

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

In the event the rules and information in the manual are more stringent than legislative sources, Tigercat recommends adherence to the more stringent measures as a best practice measure to provide optimal protection and productivity for workers, the company and equipment.

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 Bogie Arm

GENERAL SAFETY PRECAUTIONS

HAZARDOUS MATERIALS

Safety is a prime responsibility of all.

WARNING

To minimize the risks and promote safety at all times, this section of the manual details a number of safety rules to be observed.

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

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

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

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

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

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

PERSONAL PROTECTIVE EQUIPMENT (PPE)

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

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 Bogie Arm

Safety

HAZARDS

WORKING WITH OIL

FLAMMABILITY

CAUTION

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

Oil and oil additives are known to cause irritation to eyes, skin and respiratory system.

Wear appropriate PPE. Read and understand MSDS/PSDS literature.

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

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

LIQUID NITROGEN

Other safety advice includes: • Wash off oil on the skin immediately with soap and water.

WARNING

• Wear protective gloves. Clean hands before putting on gloves. Apply protective cream to 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 breath in oil fumes.

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

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

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

• Do not put oily rags in your pockets.

• Change oil soiled clothing as soon as possible.

VENTILATION

COMPRESSED AIR Compressed air is a concentrated, high pressure, high speed stream of air that 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).

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

Follow acceptable Health and Safety protocols for using compressed air.

• Do not clean clothing or skin using compressed air.

• Verify the air stream is not aimed at a fellow worker or directed 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 byproducts 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 Bogie Arm

HIGH-PRESSURE INJECTION INJURIES

VITON SEAL HAZARDS 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 oils or grease under pressure can penetrate the skin and could result in death or serious injury.

O-rings and other seals manufactured of Viton Fluoroelastomer materials (fluorine rubber) produce fluorine gas and a highly corrosive hydrofluoric acid when subjected to temperatures above 315°C (600°F).

This contamination can have extreme consequences on human tissue since it is almost impossible to remove after contact.

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

The following procedures are recommended when inspecting equipment 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 should occur, a fine, high velocity stream of fluid will result. Even for systems pressurized to as little as 7 bar (100 psi), this fluid stream can penetrate human skin as if it were a hypodermic needle.

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 Bogie Arm

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.

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.

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

• Seek professional medical attention immediately.

Prior to using a high-pressure pneumatic grease gun perform the following:

The best defense against suffering the effects of fluid injection is to prevent the accident from occurring in the first place.

When searching for possible fluid leaks:

• All operators must be trained in the operation and hazards of using high-pressure pneumatic grease guns 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 for using such a tool.

• Wear safety goggles for eye protection.

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

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

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

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

• Place the end of a long piece of wood in the suspected path of any fluid stream. Do not use any part of your body.

• 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 and/or hydraulic pressure before disconnecting any lines or otherwise working on the system.

• When badly positioned fittings are identified, replace them 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 any hydraulic equipment suspected of being defective.

1.7

Safety

Tigercat Bogie Arm

WORK CONDITIONS AND TOOLS

MATERIAL LIFTING AND HANDLING

For proper disassembly and assembly a clean, well lit workplace is recommended. Enough room should be available to lay out and sort various parts and assemblies.

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

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

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

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

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

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

WARNING

CALIBRATION

Only competent personnel are permitted to operate cranes or hoists.

NOTICE

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

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

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

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

• Do not exceed working load limits.

Tools must be calibrated when:

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

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

• New

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

• Repaired or changed • When the scheduled calibration period has passed

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

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

• Observations indicate incorrect readings.

1.8

Tigercat Bogie Arm

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

Mark axles containing oil to clearly show the axle is full of oil.

When manually lifting components: • Wear appropriate PPE

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

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

REQUIRED TOOLS

• Consider if a lifting device can be used • Determine if the load weight is within your safe lifting capacity

To disassemble a bogie arm 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 Tigercat approved 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

• Lift with legs

• Support Stands

• Keep load close to waist

• Wooden support blocks

• Do not twist your torso. Move your feet.

• Torque wrench

• Keep your head up and watch your route.

• Snap ring installation tool • Loctite solvent or Tigercat approved equivalent

SAFE SUPPORT OF COMPONENTS

• Loctite 242 – SSA001

Axles are very heavy and represent a significant crush hazard if not adequately supported and braced. Use robust stands or wooden blocks to 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.

• Loctite 5180 – SSA250 • Loctite Primer 7649 – 93996

A

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

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

C00802

A Bogie End Driving Tool B8161002

1.9

Safety

Tigercat Bogie Arm

GUIDE PINS

CLEAN AND INSPECT

Guide pins are modified fasteners, made by assembly 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.

B

A

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

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

C00028

A Guide Pin B Grind Head From Fastener

To modify a fastener:

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.

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.

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

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

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.

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.

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

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 and additional half turn.

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

1.10

Tigercat Bogie Arm

Safety

REMOVE LOCTITE PRODUCTS

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

Parts should be used within one month of priming.

Parts primed for future use must be kept free of contamination.

REMOVE FASTENERS SECURED WITH LOCTITE 242 THREAD LOCKER Fasteners secured with Loctite 242 Thread Locker compound are removable using hand tools.

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

1. Remove the fastener.

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

2. Clean threads with a wire brush.

3. Wipe excess material from screw.

6. Wipe excess Loctite from the site.

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

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

GASKET FORMING PRODUCTS

REMOVE LOCTITE 518 FLANGE SEALANT

CAUTION

Components mounted with Loctite 518 Flange Sealant leave residue on the component and mounting surface when removed. To clean the sealant:

Loctite 518 Gasket Maker is a known eye, skin and lung irritant. Use in well ventilated conditions in conjunction with appropriate PPE as specified in the MSDS.

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.

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

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.

2. Apply a bead of 518 gasket maker around the features of the part, leaving margin for the material to spread as the part parts are assembled.

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

3. Apply the mating part.

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

APPLY LOCTITE PRODUCTS CAUTION

5. Wipe excess Loctite from the site.

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.

COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING 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.

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

THREAD LOCKER AND PRIMER PRODUCTS The use of Threadlocker 242, 262 and Primer 7649 products requires a primer application to both parts being joined. Where primers are used with Threadlocker products, follow these directions and conditions.

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

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

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

1.11

Safety

Tigercat Bogie Arm

FASTENER TORQUE AND REUSE

Once a bolt has been torqued, it may stretch. If the 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:

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.

UNLESS OTHERWISE SPECIFIED

BOLTS Bolts join components to provide 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 1.15. 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

**Do Not Reuse – Replace [bolt(s)]. The torque value

LOAD

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, replace the 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) • Setting torque wrenches (Type 2).

LOAD

C00711

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

Some bolts used to assemble Tigercat axles are torqued to high values (90%+ proof stress) to provide consistent, even clamping force.

Select the torque wrench 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.

Torque wrenches must be calibrated every 5,000 cycles or 12 months which ever comes first. See CALIBRATION on page 1.8.

1.12

Tigercat Bogie Arm

Safety

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 8 BOLTS

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

COARSE THREAD 1/4" - 20 5/16" - 18 3/8" - 16 7/16" - 14 1/2" - 13 9/16" - 12 5/8" - 11 3/4" - 10 7/8" - 9 1" - 8 1 1/8" - 7 1 1/4" - 7 FINE THREAD 1/4" - 28 5/16" - 24 3/8" - 24 7/16" - 20 1/2" - 20 9/16" - 18 5/8" - 18 3/4" - 16 7/8" - 14 1" - 12 1 1/8" - 12 1 1/4" - 12

LUBRICATED DRY N-m lbf-ft N-m lbf-ft 12 - 13 9 - 10 16 - 18 12 - 13 25 - 27 18 - 20 33 - 37 25 - 27 44 - 49 33 - 36 59 - 65 44 - 48 71 - 78 52 - 58 95 - 104 70 - 77 108 - 119 80 - 88 144 - 159 106 - 117 156 - 172 115 - 127 208 - 229 154 - 169 215 - 237 159 - 175 287 - 316 212 - 233 383 - 421 282 - 310 510 - 561 376 - 414 616 - 678 455 - 500 822 - 904 606 - 667 924 - 1016 681 - 750 1232 - 1355 909 - 999 1310 - 1441 966 - 1063 1746 - 1921 1288 - 1417 1848 - 2033 1363 - 1499 2464 - 2710 1817 - 1999 LUBRICATED DRY N-m lbf-ft N-m lbf-ft 14 - 15 10 - 11 18 - 20 14 - 15 28 - 30 20 - 22 37 - 41 27 - 30 50 - 55 37 - 41 67 - 74 49 - 54 79 - 87 58 - 64 106 - 116 78 - 86 122 - 134 90 - 99 163 - 179 120 - 132 174 - 192 128 - 141 232 - 255 171 - 188 244 - 268 180 - 198 325 - 358 240 - 264 427 - 469 315 - 346 569 - 626 420 - 462 680 - 748 502 - 552 907 - 997 669 - 736 1037 - 1141 765 - 841 1383 - 1521 1020 - 1122 1468 - 1615 1083 - 1191 1958 - 2154 1444 - 1588 2046 - 2250 1509 - 1660 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

1.13

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

Safety

Tigercat Bogie Arm

1.14

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

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

CONTENTS – SECTION 2

ISSUE 2.1, OCTOBER 2020

B

BOGIE ARM, DISASSEMBLE.................................................................................................................................... 2.4 BEARING SUPPORT AND OUTPUT GEAR.......................................................................................................... 2.4 IDLER GEAR PINS FROM BOGIE ARM................................................................................................................ 2.5

I

IDLER GEARS, BOGIE ARM (PLANETARY SIDE).................................................................................................. 2.9 IDLER GEAR BEARINGS...................................................................................................................................... 2.10 INPUT GEAR............................................................................................................................................................... 2.6 CENTRED INPUT GEAR AND COVER.................................................................................................................. 2.6 INPUT/OUTPUT GEAR INNER BEARING RACES............................................................................................... 2.8 OFFSET INPUT GEAR AND COVER..................................................................................................................... 2.7 OFFSET INPUT GEAR ROLLER BEARINGS........................................................................................................ 2.8

M

MACHINE ORIENTATION........................................................................................................................................... 2.3

P

PREPARE TO DISASSEMBLE THE BOGIE ARM.................................................................................................... 2.3 OIL, REMOVE........................................................................................................................................................... 2.4

S

SAFETY........................................................................................................................................................................ 2.3 SPHERICAL BUSHING (FOR 68 IN BOGIES ONLY)............................................................................................ 2.10

Disassembly

Tigercat Bogie Arm

2.2

Tigercat Bogie Arm

Disassembly

SAFETY

PREPARE TO DISASSEMBLE THE BOGIE ARM

See READ THIS MANUAL FIRST on page 1.3. for references to safety warnings and messages.

WARNING

MACHINE ORIENTATION A

B

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.

C

F

This procedure is for use with a bogie arm removed from the bogie axle unit. See 47731AENG, AXLES, SERVICE AND REPAIR MANUAL, DISASSEMBLY to remove a bogie arm.

D E

There are two kinds of bogie arm used in Tigercat Bogie Axles: cast bogie arms and fabricated bogie arms. Both types may be shown in this manual.

F

See PERSONAL SAFE LIFTING AND CARRYING on page 1.9.

G C00421

A B C D E F G

See SAFE SUPPORT OF COMPONENTS on page 1.9.

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

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

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

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

• Must have components blocked to eliminate movement.

2.3

Disassembly

Tigercat Bogie Arm

DISASSEMBLE A BOGIE ARM

REMOVE OIL Drain oil from the axle as directed in 47731AENG, AXLE, SERVICE AND REPAIR MANUAL, OIL REMOVE in SECTION 2. For additional drainage, follow steps 2 – 4 below.

REMOVE THE BEARING SUPPORT AND OUTPUT GEAR WARNING

WARNING

The bearing support, ring gear and planetary are secured to the bogie arm using the same bolts and washers. Once removed, the components are unattached and could fall if not supported.

Take precautions to eliminate the risk of components falling.

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.

A

E

A

D

C

B

C00430

A B C D E

Bogie Housing Bearing Output Gear O-ring Bearing Support

1. Remove the planetary and ring gear from the bogie arm. See manual, 47731AENG Tigercat AXLES SERVICE AND REPAIR.

B

2. Remove the bearing support from bogie arm.

C00421

3. Remove the O-ring from the bearing support and discard.

A Magnetic Plug B Oil Container

4. Remove the bearing from the top of the output gear.

1. Place a container of suitable size beneath the magnetic drain plugs at each end of the bogie housings to capture any residual oil.

5. Lift the output gear from the bogie arm. The lower bearing will remain in the bogie arm.

6. Remove the bearing from the bogie arm.

2. Remove magnetic drain plugs from the bogie arms.

7. Clean and inspect the bearings, output gears and bearing supports.

3. Inspect each drain plug for debris and metal filings, then clean each thoroughly.

4. Drain any residual gear oil from inside the bogie housing. Remove remaining oil when the inside of the housing is accessible, using clean rags. Absorb excess gear oil, then dispose of rags in a fireproof container.

2.4

Tigercat Bogie Arm

Disassembly

REMOVE IDLER GEAR PINS FROM BOGIE ARM A

*A

B

B C

C

D

D E

C00425

E

A B C D E

C00424

A *Bolt B Idler Pin Cap C Pin D O-ring E Housing * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12.

Pry Bar Edge of Cap Recess Pin Bolt Oversize Washer

3. Extract the idler pin from the idler gear. a. Place an oversized washer on the top of the idler pin, then insert an M12x1.75 bolt into the threaded hole in the top of the idler pin. Do not tighten the bolt fully. Leave a gap between the bottom of the washer and the top of the pin.

1. Place bogie arm on support blocks, on a work surface with the planetary side of the housing facing down. Use lifting straps or chains and lifting rings.

2. Remove four *bolts securing the idler pin cap to the housing, then remove the idler pin cap.

b. Rest two pry bars on the edge of the raised cap recess with the end of the pry bars inserted under the oversized washer. c.

Pry the idler pin from the idler gear by incrementally prying upwards and rotating the position of the pry bar ends.

4. Remove Loctite 518 sealant from the top of the housing and the bottom of the idler pin cap. See REMOVE LOCTITE 518 FLANGE SEALANT on page 1.11.

5. Flip the bogie arm on support blocks, so the differential side of the housing is facing down. Use lifting straps or chains and lifting rings.

2.5

Disassembly

Tigercat Bogie Arm

INPUT GEAR

REMOVE CENTRED INPUT GEAR AND COVER

There are two configurations of input gear/cover used in Tigercat manufactured bogie axles and three different covers.

*

A B C D

C00699

A B C

A

B

E

G

C

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

F

Configuration A is a centred spline input gear with bearings on each side of the input gear secured by a cover, featureless on the outside, with six mounting holes. There is an internal recess for the bearing housing to sit in on the inside.

Configurations B and C utilize an offset spline input gear with both bearings positioned in the input gear. The gear is secured by a cover with either six or eleven mounting holes. The cover post fits into the cylindrical roller bearings pressed into the input gear.

C00426

A *Bolts B Cover C O-ring D Spring Pin E Retaining Ring F Bearing Outer Race G Spacer * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12.

NOTICE The inner and outer race of each bearing are factory matched and must be kept together as a pair. Remove each bearing and mark/label each half to ensure they remain together during installation.

CAUTION The bearing outer race may adhere to the cover when the cover is removed.

The axle shaft was removed when the bogie arm was removed from the axle/brake housing. The cover is in place to keep the bearing in place and debris from the inside of the bogie arm.

2.6

Tigercat Bogie Arm

Disassembly REMOVE OFFSET INPUT GEAR AND COVER

1. Remove six *bolts securing the cover to the housing, then thread two M10 x 1.5 x 90 mm long bolts into the cover jacking holes. Incrementally turn each bolt in to remove the cover. The bearing outer race may adhere to the cover when the cover is removed.

CAUTION

2. Remove the O-ring from the cover.

The input gear may adhere to the post of the input cover when the cover is removed.

3. Remove the spacer from the gear.

4. Remove the retaining ring from the gear.

5. Remove the bearing outer race, if present.

NOTICE

CAUTION

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

Gear teeth are sharp. Handle with care to avoid personal injury. Avoid finger and/or gear teeth contact with the housing.

G

A

F A E

B

B D

C

C

C00702

A Jack Holes B Post C Input Gear D O-ring E Bearing Input Cover (Offset) F Washer G *Bolt * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12.

1. Remove *bolts securing the cover to the housing, then thread two M10 x 1.5 x 90 mm long bolts into the cover jacking holes. Incrementally turn each bolt to free the cover.

C00428

A Bearing Inner Race B Input Gear C Bearing Outer Race (from Bogie Housing)

2. Pull the input gear cover from the input gear. The input gear may bind on the post of the input gear cover. If replacing the input gear and input gear cover while the machine is in the field it may be necessary to release the parking brake. See the machine Operator and Maintenance Manual.

6. Remove the input gear with bearing inner race.

7. Remove the bearing outer race from the bogie housing.

3. Remove the O-ring and discard. Replace the O-ring during reassembly.

8. Match and store the inner bearing races with the removed outer bearing races.

4. Inspect the post portion of the input cover for scoring. If scoring on the post leaves significant scoring or ridging that cannot be buffed out, replace the cover.

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

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

2.7

Disassembly

Tigercat Bogie Arm

REMOVE OFFSET INPUT GEAR ROLLER BEARINGS

REMOVE INPUT/OUTPUT GEAR INNER BEARING RACES

A B

A

C

B

C D C00703

A B C D

A

Roller Bearing Retaining Ring Shaft Support Spacer Input Gear (Offset Spline Input Gear Configuration)

D E

1. Place the input gear, spline side down on the work surface.

C00474

2. Remove the bearings using an internal bearing puller.

A B C D E

3. Remove the retaining ring.

4. Remove the shaft support spacer.

Outer Bearing Race Inner Bearing Race Output Gear Spacer Retaining Ring

NOTICE The inner and outer race of each bearing are factory matched and must be kept together as a pair. Verify the match before installation.

1. Remove the outer race of each bearing from both sides of the output gear.

2. Remove the inner race of each bearing from both sides of the output gear using a bearing puller.

3. Match and store the inner bearing races with the removed outer bearing races.

4. If the inner or outer race is damaged, the bearing is unsuitable for reuse. Discard the bearing.

2.8

Tigercat Bogie Arm

Disassembly

REMOVE BOGIE ARM (PLANETARY SIDE) IDLER GEARS *

A

A B C B C00429

D

A Idler Gear B Gear Opening

E

4. Pry the edge of the idler gear next to the nearest input or output opening, up and towards the nearest gear opening, using finger tips.

5. Slide the idler gear by placing fingers against the input gear and/or idler openings and finger tips against the gear hub.

6. Place fingers in the centre bore when the idler gear is aligned with the nearest gear opening, then lift the gear straight up and out of the housing.

C00427

7. Remove the remaining idlers by repeating step 4 until all idler gears are removed.

A *Bolt B Idler Pin Cap C Idler Pin D O-ring E Housing * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12.

1. Remove four *bolts securing the idler pin cap to the housing, then remove the idler pin cap.

2. Extract the idler pin from the idler gear. See the illustration in, REMOVE IDLER GEAR PINS FROM BOGIE ARM on page 2.5.

3. Remove Loctite 518 sealant from the top of the housing and the bottom of the idler pin cap. See REMOVE LOCTITE 518 FLANGE SEALANT on page 1.11.

CAUTION Gear teeth are sharp. Handle with care to avoid personal injury. Remove gears carefully to avoid finger and/or gear teeth contact with the housing. Do not contact gear teeth with a pry bar.

2.9

Disassembly

Tigercat Bogie Arm

SPHERICAL BUSHING (FOR 68 IN BOGIES ONLY)

REMOVE IDLER GEAR BEARINGS

A A

B

B C A A

C

C00712

A B C D

D

1. Thoroughly clean and inspect the bushing for excessive play or damage. Replace if required.

C00472

A B C D

Spherical Bushing Bogie Balance Lug Grease Fittings Flat Punch (on outer ring of bushing)

Large Punch (on inner race of bottom bearing) Upper Bearing Idler Gear Lower Bearing

1. Place the bearing/idler gear on wooden blocks (not shown).

2. To remove the bushing, place a flat end punch on the outer ring of the bushing and incrementally tap the circumference of the outer ring. Do not contact the inner ring. Do not mar the inside surface of the bore.

OR

2. Insert a punch through the opening in the inner race of the upper bearing and rest it on the inner race of the lower bearing.

A

3. Drive the bottom bearing from the idler gear. Discard the damaged bottom bearing.

A

B

4. Flip the idler gear over on the wooden blocks.

C A D

B B

C C00709

C00473

A B C D

A Punch on Outer Bearing Race B Idler C Inner Race/Rollers

5. Place a flat end punch onto the top of the outer bearing race on the lower bearing.

6. Tap incrementally around the circumference of the outer bearing race.

A

Bogie Balance Lug Grease Fittings Spherical Bushing Bogie End Driving Tool B8161002

3. Place the bogie end driving tool 8161002B into the spherical bushing, then align the bushing with the bogie balance lug. The bushing must be perpendicular to the lug face.

7. Remove the bearing.

2.10

Tigercat Bogie Arm

Disassembly

4. Strike the flat of the bogie end driving tool, carefully, with a dead blow hammer to drive the bushing through the bore in the lug.

5. Remove the bushing.

6. Remove and inspect grease fittings from the lug.

7. Replace as required.

2.11

Disassembly

Tigercat Bogie Arm

2.12

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

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

CONTENTS – SECTION 3

ISSUE 2.1, OCTOBER 2020

A

ASSEMBLY, PRIOR TO............................................................................................................................................... 3.3

B

BEARING INNER RACE IN CENTRED SPLINE INPUT GEAR............................................................................ 3.12 CENTRED INPUT BEARING AND BOGIE AXLE COVER.................................................................................. 3.12 BEARING INSTALLATION INSTRUCTIONS............................................................................................................ 3.4 BEARINGS IDLER BEARINGS................................................................................................................................................... 3.4 INPUT/OUTPUT INNER RACE............................................................................................................3.4, 3.10, 3.11

C

CLEAN AND INSPECT................................................................................................................................................ 3.3

G

GUIDE PINS................................................................................................................................................................. 3.3

I

INPUT BEARING AND COVER, INSTALL..................................................................................................... 3.12, 3.14 INSTALL IDLER GEARS ALL IDLERS.............................................................................................................................................................. 3.6 FOR BOGIE AXLES 1727MM (68 IN)...................................................................................................................... 3.5 FOR BOGIE AXLES 1888MM (74.3 IN), 1905MM (75 IN) AND 1969MM (77.5 IN)............................................... 3.5 VERIFY IDLER GEAR BACKLASH........................................................................................................................ 3.8 VERIFY IDLER GEAR ENDPLAY........................................................................................................................... 3.7

M

MACHINE ORIENTATION........................................................................................................................................... 3.3

O

OFFSET INPUT BEARING AND BOGIE AXLE COVER........................................................................................ 3.14 OFFSET INPUT GEAR BEARINGS......................................................................................................................... 3.14 OUTPUT GEAR, INSTALL.......................................................................................................................................... 3.8

S

SAFETY........................................................................................................................................................................ 3.3 SPHERICAL BUSHINGS (FOR 68 IN BOGIES ONLY).......................................................................................... 3.16

Assembly

Tigercat Bogie Arm

3.2

Tigercat Bogie Arm

Assembly

SAFETY

PRIOR TO ASSEMBLY

See READ THIS MANUAL FIRST on page 1.3 of this manual for references to safety warnings and messages.

Prior to bogie arm assembly:

MACHINE ORIENTATION

2. Clean and visually inspect the bogie housing.

1. Have all required parts readily available.

• Look for presence of machining chip, metal shavings, sharp corners, and casting porosity.

See MACHINE ORIENTATION ON PAGE 3.3. for pictorial references to bogie arm views. These are based on viewing the bogie arm with the differential yoke facing the observer.

• Use a die grinder to remove any sharp edges.

• Use an air gun to remove any shavings from the tapped and dowel holes on the bogie.

WARNING

• Spray alcohol inside the bogie, including the tapped and dowel holes as well as the bushing and bearing bores.

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.

• Use a rag to clean all areas inside of the bogie.

• Use the air gun to push any debris to one side of the output opening.

• Use a vacuum to remove the debris and a magnet to remove any small shavings.

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

This procedure is for use with a bogie arm removed from the bogie arm assembly. See 47731AENG Axles, SERVICE AND REPAIR MANUAL, DISASSEMBLY to remove a bogie arm.

• Verify they are the right parts.

• Verify orientation.

• Replace damaged or worn components as required.

See PERSONAL SAFE LIFTING AND CARRYING on page 1.9.

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

See PERSONAL SAFE LIFTING AND CARRYING on page 1.9.

Bogie arms may be shipped separately, attached to a bogie axle unit, or shipped with ring gear and planetary attached.

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

NOTICE

• Must be clean

Clean the inside of the bogie housing so it is clear of dirt, debris and tools. Foreign materials inside the bogie housing will cause premature failure of bogie axle components.

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

CLEAN AND INSPECT

GUIDE PINS

See CLEAN AND INSPECT on page 1.10 for references to cleaning and inspecting the unit.

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

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

3.3

Assembly

Tigercat Bogie Arm

INSTALL BEARING INNER BEARINGOUTPUT INSTALLATION INSTRUCTIONS RACE

INSTALL IDLER BEARINGS

Bearings are easily contaminated and damaged if not handled and installed correctly. This section provides information to minimize bearing damage and provide consistent bearing installation: A

A B

1. Work in a clean, dust-free workspace.

2. Leave bearings in packages until ready forB assembly.

C

3. Verify bearing usage with assembly drawings C and by measuring the bearing and mating parts.

4. Wear PPE when heating or cooling bearings or associated components.

5. Use feeler gauges to ensure the bearing A components are fully seated after the parts are positioned. Another method requires the use D of backlighting to visually inspect for a gap between components and bearing seat.

B

E

C00474

A B C D E

Outer Bearing Race Inner Bearing Race Output Gear Spacer Retaining Ring

D C00431

A B C D

NOTICE

Paint Marks Idler Bearing Idler Gear Retaining Ring

1. Remove the idler bearings from packaging.

The inner and outer race of each bearing are factory matched and must be kept together as a pair. Remove each bearing and mark/label each half to ensure they remain together during installation.

2. Mark the retaining ring with a paint marker to verify the manufacturer's retaining ring is present and fully seated in the bearing. If the ring is not seated, seat the ring. If the ring will not seat or the ring is not present, reject the bearing.

3. Press an idler bearing into an idler gear. The retaining ring must face out.

1. Press a bearing inner race onto each side of the output gear. The shoulder of the inner race must rest evenly against the bearing shoulder of the gear.

4. Turn the idler bearing by hand to verify it turns freely without binding.

2. Place the input/output gear on the work surface with the retaining ring groove up.

5. Turn the idler gear over and press a second idler bearing into the gear. The retaining ring must face out.

3. Insert a spacer into the gear then, insert the retaining ring to hold it in place. The retaining ring must fit snugly in the retaining groove without spinning or being loose. If it spins or is loose, remove and replace it.

6. Cover with a clean covering to protect the bearings from contamination until ready for use.

4. Set the matching bearing outer races with the output gears and cover with a clean covering to protect the bearings from contamination until ready for use.

3.4

Tigercat Bogie Arm

Assembly

INSTALL IDLER GEARS CAUTION Gear teeth are sharp. Handle with care to avoid personal injury. Avoid finger and/or gear teeth contact with the housing.

FOR 1727 MM (68 IN) BOGIE AXLES Install the idler gears in the sequence shown in the 68 in Bogie Axle Idler Gear Installation Sequence illustration.

5

3

1

2

6

4

C00475

68 in Bogie Axle Idler Gear Installation Sequence

Numbers represent order of installation of idler gears. Use the output openings to slide all idler gears into place.

FOR BOGIE AXLES 1888 MM (74.3 IN), 1905 MM (75 IN), AND 1969 MM (77.5 IN) Install the idler gears in the sequence shown in the Multiple Bogie Axle Idler Gear Installation Sequence illustration.

1

3

5

6

2

4

C00476

Multiple Bogie Axle Idler Gear Installation Sequence

Numbers represent order of installation of idler gears. Use the input gear opening to install idler gears, 3, 4, 5, and 6. Use the output openings to install idler gears 1 and 2.

3.5

Assembly

Tigercat Bogie Arm

ALL IDLERS

*

1. Lubricate the idler bushing bores and idler gear pins using a water displacing lubricant such as WD-40.

A B C

E D

A C00477

B

A *Bolts B Idler Pin Cap C Idler Pin D Idler Gear E Idler Pin Bushing * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12

C C00492

A Idler Pin B Idler Bushing C Bogie Housing

CAUTION

2. Install the idler pin bushing: a. Install the idler pin bushing on the end of the idler pin. Do not install the O-ring on the idler pin.

Gear teeth are sharp. Handle with care to avoid personal injury. Avoid finger and/or gear teeth contact with the housing.

b. Insert the idler pin with bushing into the idler pin bushing bore then, tap the pin/bushing with a rubber mallet, to seat the bushing in the bogie housing. c.

6. Insert an idler gear to align with an idler pin bushing through the nearest accessible input opening. Follow the described order of installation.

Remove the idler pin.

7. Insert the idler pin through the corresponding opening in the bogie housing, through the idler gear and into the idler pin bushing.

3. Lubricate the O-ring groove on the idler pin with gear oil then, install the O-ring onto the idler pin.

4. Lubricate the bearing races with gear oil.

B

A

5. Lubricate the idler pin with gear oil.

0.5 mm (0.021in) 0.08 mm (0.003 in)

C00479

A Idler Pin Cap B Bogie Housing

a. Seat the bearings and idler pin using a rubber mallet. The top of the idler pin must be recessed 0.5 – 0.08 mm (0.003 – 0.021 in) below the bogie housing.

3.6

Tigercat Bogie Arm

Assembly *

VERIFY IDLER GEAR ENDPLAY

A

As each idler gear is installed, verify idler gear end play.

B

NOTICE

C

Do not pry the idler gear with the pry bar against the gear teeth.

D

A

B

E C00472

C

A Bolt B Idler Pin Cap C Loctite 518 Sealant D Idler Pin E Bogie Housing * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12

D E

8. Apply a bead of Loctite 518 sealant around the perimeter of the idler pin bore hole and bolt holes.

Do not get sealant in the bolt holes.

C00480

9. Install the idler pin cap:

A B C D E

a. Apply Loctite 7649 primer to bolt holes and M10x1.5 *bolts. See THREAD LOCKER AND PRIMER PRODUCTS on page 1.11. b. Apply Loctite 242 Threadlocker to both contact surfaces then, install bolts. c.

Pry Bar Idler Pin Cap Idler Pin Idler Gear Bogie Housing

1. Insert the end of a pry bar under the idler gear so pressure is applied to the non-toothed portion of the gear.

Torque each *bolt to 68 N-m (50 lbf-ft) using an opposing pattern.

2. Move the idler gear up and down several times to verify there is axial endplay.

10. Verify each idler gear has axial endplay.

11. Install remaining idler gears following the correct sequence of installation using steps 1 – 9.

3. Repeat steps 1 – 2 for all idler gears.

3.7

Assembly

Tigercat Bogie Arm

VERIFY IDLER GEAR BACKLASH

INSTALL OUTPUT GEAR

CAUTION

NOTICE

Gear teeth are sharp. Handle with care to avoid personal injury. Wear gloves and be aware of turning gears while checking for idler gear backlash.

D

E

The inner and outer race of each bearing are factory matched and must be kept together as a pair. Verify the match before installation.

See INSTALL OUTPUT BEARING INNER RACE on page 3.4.

A

1. Verify the inside of the bogie arm is free of debris.

CAUTION Gear teeth are sharp. Handle with care to avoid personal injury. Insert gears carefully to avoid finger and/or gear teeth contact with the housing.

C

A B B

C00481

A B C D E

Pry Bar Input Gear Opening Rotational Movement Output Gear Opening Idler Gear

C

D

1. Insert a pry bar or wedge to immobilize the idler gear nearest the input gear location.

E

2. Position a dial indicator on a tooth of one of the outer idler gears. Orient the dial indicator tip is perpendicular to the tooth direction.

C F

3. Measure and record the backlash value then, repeat for all accessible outer and inner idler gears.

4. Continue until rotational movement is verified for all idler gears. Measured backlash values must be 0.38 – 0.635 mm (0.015 – 0.025 in).

5. If rotational movement is not detected, call the Tigercat Service Department.

H

6. Remove dial indicator. Verify there are no tools remaining in the bogie arm.

C00482

A B C D E F G H

G

Bearing Support O-ring Outer Race Output Gear Inner Race Guide Pin Bearing Seat Bogie Arm Bogie Arm

2. Install a guide pin in the bogie housing to assist with bearing support installation.

3.8

Tigercat Bogie Arm

Assembly

3. Verify the bearing components are matched as described in INSTALL OUTPUT GEAR on page 3.8.

4. Install the outer race, matching the inner race on the bottom of the output gear, into the bearing seat in the bogie arm.

5. Tap the outer race into place using a rubber mallet.

6. Install the output gear into the bogie housing. The output bearing spacer and retaining ring face down.

A

B

C

D

E

F

C00497

A B C D E F

Bearing Support O-ring Outer Race (top bearing on output gear) Output Gear/Inner Races/Bearing Support Spacer/Retaining Ring Outer Race (bottom bearing in bogie arm) Bogie Arm

7. Install the matching outer bearing race onto the top inner race of the output gear. The outer race retaining ring faces outward.

8. Apply assembly grease to the O-ring and O-ring groove on the inside of the bearing support.

9. Install the O-ring. The O-ring must not be twisted.

NOTICE Verify all tools and foreign materials are removed from inside the bogie housing to avoid premature failure of bogie axle components.

10. Install the bearing support using the guide pin for orientation.

11. Insert two temporary bolts to hold the bearing support in place until the ring gear is installed.

12. Repeat steps 1 – 11 for the other output gear.

13. To install planetaries to the bogie arm see assembly in 47731AENG, AXLES, SERVICE AND REPAIR MANUAL. 3.9

Assembly

Tigercat Bogie Arm

INPUT BEARING GEAR CONFIGURATION There are two configurations used in Tigercat manufactured bogie axles: • Centred spline input gear with bearings on each side of the input gear.

• Offset spline input gear with both bearings positioned in the input gear and a six or eleven hole input gear cover.

CENTRED SPLINE INPUT GEAR CONFIGURATION

Q

A

B

O

P

*C

N

Q H G F E D C B

A

N

E

F E

H

G

D

Q

R

B M L K

Q

J

*C

I

S

T H G

D

S D C B R U

O

T

P

OFFSET SPLINE INPUT GEAR CONFIGURATION

U

C00697

A B C D E F G H I J K

Input Gear Cover Washer *Bolts O-ring Roller Bearing Input Gear (Centred Spline Input Gear Configuration) Retaining Ring Shaft Support Spacer Spring Pin Shim# Shim#

L M N O P Q R S T U

Shim# Shim# Output Shaft# Spacer# Lead Wire# Spring Pin# Input Cover (Offset Spline Input Gear Configuration) Roller Bearing Input Gear Output Shaft#

#Items are part of the axle assembly procedure and are shown to provide clarity. See Axles, Service and Repair Manual, 47731AENG. * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12

3.10

Tigercat Bogie Arm

Assembly

GEAR AND COVER CONFIGURATIONS

OFFSET INPUT GEAR COVERS

There are two configurations of input gears and covers.

There are two configurations of input gear covers for the offset spline input gear.

The interchangeable covers have either 6 mounting holes or 11 mounting holes. Tigercat recommends using the full compliment of mounting holes if corresponding holes are present in the bogie arm.

C00699

A B C

A

B

C

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

Configuration A is a centred spline input gear with bearings on each side of the input gear secured by a cover, featureless on the outside, with six mounting holes. There is an internal recess for the bearing housing to sit in on the inside.

C00699

Offset Input Gear Cover, 11 Hole, 6 Hole

Configurations B and C utilize an offset spline input gear with both bearings positioned in the input gear. The gear is secured by a cover with either six or eleven mounting holes. The cover post fits into the cylindrical roller bearings pressed into the input gear. Tigercat bogie arms used in machines with serial numbers matching those in the input gear chart below, and serial numbers after, are manufactured using offset spline input gears and components.

Machines with serial numbers prior to those listed in the input gear configuration chart, were manufactured using the centred spline input gear configurations and should be replaced using the offset spline input gear configuration when servicing bogie arms. Contact Tigercat Parts and Service Department for information regarding the necessary replacement part kits.

Non-Tigercat bogie arms and hybrid Tigercat/third party bogie axles are not impacted.

Machine Model

Machine Serial Number

615C

6150152 – 6150152

615E

6151028 – 6151028

625E

6250558 – 6250558

635G

6353143 – 6353143

1075C

10751001, 10751041, 10751051, 10751053

1085B

10850111 – 10850148

1085C

10850501 – 10850553

2160

21600101 – 21600110

Tigercat Input Gear Configuration Usage

3.11

Assembly

Tigercat Bogie Arm

BEARING INNER RACE IN CENTRED SPLINE INPUT GEAR

BOGIE AXLE COVER See BEARING INNER RACE IN CENTRED SPLINE INPUT GEAR on page 3.12.

NOTICE The inner and outer race of each bearing are factory matched and must be kept together as a pair. Verify the match before installation.

1. Place bogie arm, upright, on a work surface. Use lifting straps or chains and lifting rings.

A B

A

C B

D

C

E

A

*

D C00483

E

A Input Gear B Spring Pin (in bogie housing input cover seat) C Outer Race D O-ring E Input Cover F *Bolt * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12

C00861

A B C D E

Outer Race (Part of Factory Matched Set) Top and Bottom Inner Race (Part of Factory Matched Set) Top and Bottom Input Gear (Centred Spline Input Gear) Shaft Support Spacer Retaining Ring

1. Press a bearing inner race onto each side of the input/output gear. The shoulder of the inner race must rest evenly against the bearing shoulder of the gear.

2. Verify the inside of the bogie arm is free of debris or tools.

CAUTION Gear teeth are sharp. Handle with care to avoid personal injury. Insert gears carefully to avoid finger and/or gear teeth contact with the housing.

2. Place the input/output gear on the work surface with the retaining ring groove up.

3. Insert a spacer into the gear then, insert the retaining ring to hold it in place. The retaining ring must fit snugly in the retaining groove without spinning or being loose. If it spins or is loose, remove and replace it.

4. Set the matching bearing outer races with the input/ output gears and cover with a clean covering to protect the bearings from contamination until ready for use.

INSTALL CENTRED INPUT BEARING AND

F

3. Verify the bearing components are matched as described in INSTALL OUTPUT BEARING INNER RACE on page 3.4.

4. Install the outer race into the bearing seat in the bogie arm. Tap the outer race into place using a rubber mallet.

5. Install the input gear into the bogie housing. The spacer and retaining ring face the input cover.

6. Install the top outer race into the bearing seat of the input cover.

3.12

Tigercat Bogie Arm

Assembly 12. Align the punch mark on the input cover to the top of the opening.

13. Install the input cover/outer race/O-ring onto the bogie housing.

A

D

14. Prepare the bolts: a. Apply Loctite 7649 primer to bolt holes and M10x1.5 *bolts. See APPLY LOCTITE PRODUCTS on page 1.11.

E B

b. Apply Loctite 242 Threadlocker to both contact surfaces then, install *bolts.

C

c.

*F

C00496

H

G

A Outer Race (bottom bearing in bogie arm) B Bogie Arm C Input Gear/Inner Races/Spacer/Retaining Ring D Spring Pin E O-ring F *Bolt G Input Cover H Outer Race (top bearing in bogie housing input cover) * INSPECT. See FASTENER TORQUE AND REUSE on page 1.12

7. Lubricate the O-ring groove with gear oil.

8. Install the O-ring.

A

C00462

A B C D

B

C

D

Loctite 518 Sealant Spring Pin Input Cover Seat Input Gear

9. Install the spring pin into the input cover seat.

10. Apply a light bead of Loctite 518 sealant around the perimeter of the input gear cover seat on the bogie arm.

11. Apply a light bead of Loctite 518 sealant around each bolt hole. Do not get sealant in the holes.

3.13

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.

Assembly

Tigercat Bogie Arm

OFFSET INPUT GEAR BEARINGS

OFFSET INPUT BEARING AND BOGIE AXLE COVER

3.3 – 2.8 mm (0.132 – 0.112 in)

CAUTION A

Gear teeth are sharp. Handle with care to avoid personal injury. Insert gears carefully to avoid finger and/or gear teeth contact with the housing.

A

B

A

C

Install an offset input bearing and bogie axle cover in the right bogie arm.

D

E C00698

A B C D E

Installation Spacer (discard after use) Roller Bearing Retaining Ring Shaft Support Spacer Input Gear (Offset Spline Input Gear Configuration)

A

1. Insert the shaft support spacer into the input gear.

2. Install the retaining clip in the input gear.

3. Remove the bearings from packaging.

C00421

4. Mark the retaining ring with a paint marker to verify the manufacturer's retaining ring is present and fully seated in the bearing. If the ring is not seated, seat the ring. If the ring will not seat or the ring is not present, reject the bearing.

A Right Bogie Arm

The determination of which side is right or left, is made when looking at the differential yoke.

1. Place the assembled bogie arm, upright, on a work surface. Use lifting straps or chains and lifting rings.

5. Press the first bearing into the input gear with the retaining ring facing towards the cover. It must face towards the cover. Press only on the outer race.

2. Verify the inside of the bogie arm is free of debris or tools.

6. Press the second bearing into the input gear.

7. Press the second bearing into the input gear with the retaining ring facing towards the cover. It must face towards the cover. Press only on the outer race.

8. Verify the bearings are fully seated on the inner abutment and the top of the second bearing is recessed 2.8 – 3.3 mm (0.112 – 0.132 in) from the top edge of the shaft bore.

9. Turn the bearings by hand to verify they turn freely without binding.

10. Cover with a clean covering to protect the bearings from contamination until ready for use.

3.14

Tigercat Bogie Arm

Assembly 9. Apply Loctite 242 Threadlocker to both contact surfaces then install *bolts.

10. Install the bogie input goer onto the cover.

11. Secure the cover to the bogie arm using the appropriate number of M10x1.5 *bolts. Tighten each *bolt to 68 N-m (50 lbf-ft) in a star pattern.

A B

13. Install an offset input bearing and bogie axle cover in the left bogie arm.

C

F

E

12. Install the offset input gear cover post into the offset input gear.

14. Follow steps 1 – 5.

*D

C00700

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 1.12

15. Install the offset input cover in the left bogie arm and secure without using Loctite 518 around the perimeter of the offset input gear cover and around each bolt hole. Do not apply Loctite 7649 primer to bolt holes and M10x1.5 *bolts.

3. Install the spring pin into the inside face of the input cover.

4. Lubricate the O-ring groove on the input cover with gear oil.

5. Clean the O-ring with alcohol then, install on the input cover.

C A

B

C00701

A Input Cover (11 hole, viewed from post side) B Loctite 518 (fine bead around all holes and outer perimeter) C Spring Pin

6. Apply a light bead of Loctite 518 around the perimeter of the offset input gear cover and around each bolt hole. Do not get sealant in the holes.

7. Align the orientation mark on the outside of the input cover with the top of the opening.

8. Apply Loctite 7649 primer to bolt holes and M10x1.5 *bolts. See APPLY LOCTITE PRODUCTS on page 1.11.

3.15

Assembly

Tigercat Bogie Arm

SPHERICAL BUSHINGS (FOR 68 IN BOGIES ONLY) A

B C

B

D C00707

A B C D

Bogie Balance Lug Grease Fittings Spherical Bushing Bogie End Driving Tool B8161002

1. Keep the bushing in factory packaging until ready for use.

2. Thoroughly clean and inspect the bushing bore.

Remove any burrs impeding bushing installation.

3. Install the bushing onto bogie end driving tool B8161002 then, align the bushing with the bogie balance lug. The bushing must be perpendicular to the lug face.

4. Carefully strike the flat of the bogie end driving tool with a dead blow hammer until the bushing is centred in the lug.

5. Verify the bushing turns freely.

6. Install grease fittings if they have been removed.

7. Grease as directed in Section 03, Lubrication and Maintenance, of the machine specific Operator's manual.

3.16