Tigercat Bogie Arm Service and Repair MANUAL - PDF DOWNLOAD

Bogie Arm

Service and Repair MANUAL

ISSUE 1.0, August 2018 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 BOGIE ARM - EXPLODED VIEW......................................................................................................................viii BOGIE ARM - ORIENTATION TO DIFFERENTIAL...........................................................................................viii SAFETY...............................................................................................................................................................1 DISASSEMBLY....................................................................................................................................................2 ASSEMBLY..........................................................................................................................................................3

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 re-assembly 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

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 Wide Spread

Model W

Housing Type

Bogie Arm Length

Fabricated/Cast

1968.5mm (77.5 inches)

Fabricated/Cast

1727mm (68 inches)

High Clearance

H

Fabricated/Cast

1905mm (75 inches)

Standard

R

Fabricated/Cast

1887mm (74.3 inches)

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. Some parts may not appear exactly as shown.

viii

BOGIE ARM - ORIENTATION TO DIFFERENTIAL...........................................................................................viii

Tigercat Bogie Arm ITEM

1 2 3 4 5 6 7 8 9 10

Introduction PART DESCRIPTION

ITEM

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

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

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

Introduction

Tigercat Bogie Arm

x

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 1.0, August 2018

APPLYING LOCTITE PRODUCTS GASKET FORMING PRODUCTS............................................................................................................................ 1.11 THREAD LOCKER AND PRIMER PRODUCTS...................................................................................................... 1.11 C

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

DANGER....................................................................................................................................................................... 1.3 G

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

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

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 Compressed Air................................................................................................................................................... 1.5 Working With Oil................................................................................................................................................. 1.5 Safety, General...................................................................................................................................................... 1.4 Signal Words, Understanding.......................................................................................................................... 1.3 Symbols, Safety..................................................................................................................................................... 1.3 T

Tools, Disassembly and Assembly................................................................................................................. 1.10 W

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

Safety

Tigercat Bogie Arm

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.

UNDERSTANDING SIGNAL WORDS

DANGER

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

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

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

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

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

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

1.3

Safety

Tigercat Bogie Arm

GENERAL SAFETY PRECAUTIONS

HAZARDOUS MATERIALS

Remember, 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 which should always be followed and obeyed.

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.

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

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

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

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

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.

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

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

1.4

Tigercat Bogie Arm

Safety

LIQUID NITROGEN HAZARDS

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

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

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

• Avoid contact with oil, particularly heated oil.

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

• Oil on the skin should be washed off immediately with soap and water.

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

VENTILATION HAZARDS

• Don't put oily rags in your pockets.

• Oil soiled clothing should be changed as soon as possible.

• Always keep an extra change of work cloths nearby.

• Cuts and abrasions must be attended to immediately. Clean them and apply first-aid.

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

• Avoid breathing in oil fumes.

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

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

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

Follow acceptable Health and Safety protocols for using compressed air.

• 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.

• Never clean clothing or skin using compressed air.

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

• Use a chip guard.

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

1.5

Safety

Tigercat Bogie Arm HIGH-PRESSURE INJECTION INJURIES

VITON SEAL HAZARDS

WARNING

WARNING

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

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

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

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

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

The following procedures are recommended when inspecting equipment that has been subjected to high temperatures such as fire:

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

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

If these are found, do not touch.

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

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

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

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

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

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

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

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

1.6

Tigercat Bogie Arm

Safety GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS

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

Pneumatic grease guns can deliver grease at pressures from 17 – 400 bar (246 – 5801 psi). It takes less than 7 bar (100 psi) to inject a substance through human skin.

Always get professional medical treatment immediately after any type of injection injury.

Provide the physician with information on the type of grease, the pressure setting of the gun, and similar details.

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

The amount of fluid injected, type of fluid (or material), pressure at which it was injected, and the elapsed time between injection and surgery all influence the chances of successful treatment for this type of serious injury.

• Seek professional medical attention immediately.

As always, the best defence against suffering the effects of fluid injection is to prevent the accident from occurring in the first place.

When searching for possible fluid leaks:

Prior to using a high-pressure pneumatic grease gun perform the following: • All operators must be trained in the operation and hazards of using high-pressure pneumatic grease guns the treatment for such injuries.

• Never search for leaks with your bare hands. Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

• 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.

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

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

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

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

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

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

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

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

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

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

• When badly positioned fittings are identified, replace them with angled or swivel fittings for easier access.

• Never handle any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

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

WARNING Never 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 Only competent personnel are permitted to operate cranes or hoists.

CALIBRATION

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.

• Do not exceed working load limits.

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.

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

Tools must be calibrated when:

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

• 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

PERSONAL SAFE LIFTING AND CARRYING

SHIPPING COMPONENTS

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.

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

When manually lifting components:

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

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

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

• Consider if a lifting device can be used

REQUIRED TOOLS

• 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,

• Bearing Puller

• Assume a stable lifting stance

• Isopropyl alcohol or Tigercat approved equivalent solvent

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

• Clean rags

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

• Marking pen

• Keep your back straight

• PPE

• 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

SAFE SUPPORT OF COMPONENTS

• Loctite solvent or Tigercat approved equivalent

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 that both components are adequately supported and level.

• Loctite 242 - SSA001 • Loctite 518 - SSA250 • Loctite Primer 7649 - 93996

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.

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 a bogie arm, 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.

NOTICE Clean the inside of the bogie arm so that it is free of all debris, metal filings and the like. DO NOT mar, chip or scratch gear teeth contact surfaces when removing.

C00028

A Guide Pin B Grind Head From Fastener

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

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

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

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

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

5. Mark and retain guide pins for future use.

When using guide pins: 1. Insert the guide pins finger tight, then 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.

b. Rinse components after cleaning. c.

Use cleaning methods in keeping with materials used and surface finishes to avoid scratches or marring of contact surfaces.

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

5. Install temporary supports or mounts as required and place the assembly on a clean, secure workbench.

6. 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.

7. Inspect housings, covers and manifolds for burrs, nicks, scratches, misalignment or cracks.

8. Clean the bogie arm and components using compressed air, vacuum and or brushes to remove all debris from inside the bogie arm.

1.10

Tigercat Bogie Arm

Safety

REMOVE FASTENERS SECURED WITH LOCTITE 242 THREAD LOCKER

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

Fasteners secured with Loctite 242 Thread Locker compound are removable using hand tools.

1. Remove the fastener.

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

2. Clean threads with a wire brush.

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

3. Wipe excess material from screw.

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

7. Wipe excess Loctite from the site.

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

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

GASKET FORMING PRODUCTS

CAUTION

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.

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.

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.

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

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

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.

APPLYING LOCTITE PRODUCTS

3. Apply the mating part.

cAUTION

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

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.

5. Wipe excess Loctite from the site.

COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING

THREAD LOCKER AND PRIMER PRODUCTS 1. The use of these products 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.

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

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

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

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

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

1.11

Safety

Tigercat Bogie Arm

1.12

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

Tigercat Bogie Arm SECTION 02 – DISASSEMBLY Read and understand the safety section in this manual prior to servicing any machine components.

CONTENTS – SECTION 2

ISSUE 1.0, August 2018

B

BOGIE ARM, DISASSEMBLE....................................................................................................................................... 2.4 BEARING SUPPORT AND OUTPUT GEAR, REMOVE............................................................................................ 2.4 COVER AND INPUT GEAR, REMOVE...................................................................................................................... 2.6 IDLER GEAR PINS FROM BOGIE ARM, REMOVE.................................................................................................. 2.5 IDLER GEARS, PLANETARY SIDE........................................................................................................................... 2.7 REMOVE FROM IDLER GEARS............................................................................................................................... 2.8 REMOVE INNER RACES.......................................................................................................................................... 2.8 M

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

PREPARING TO DISASSEMBLE THE BOGIE ARM.................................................................................................... 2.3 REMOVE OIL............................................................................................................................................................. 2.4 S

SAFETY......................................................................................................................................................................... 2.3

Disassembly

Tigercat Bogie Arm

2.2

Tigercat Bogie Arm

Disassembly

SAFETY

PREPARING 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 that 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

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

See SAFE SUPPORT OF COMPONENTS on page 1.9.

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

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

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

• Must have components blocked to eliminate movement

2.3

Disassembly

Tigercat Bogie Arm

REMOVE OIL

DISASSEMBLE A BOGIE ARM

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

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 HAZARDS 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.

2. Remove magnetic drain plugs from the bogie arms.

6. Remove the bearing from the bogie arm.

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

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

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

E

C00425

C00424

A B C D E

A B C D E

Bolt Idler Pin Cap Pin O-ring Housing

Pry Bar Edge of Cap Recess Pin Bolt Oversize Washer

3. Extract the idler pin from the idler gear.

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.

a. Insert an M12x1.75 bolt with an oversized washer into the threaded hole in the top of the idler pin.

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 that the differential side of the housing is facing down. Use lifting straps or chains and lifting rings.

2.5

Disassembly

Tigercat Bogie Arm

REMOVE COVER AND INPUT GEAR

CAUTION

A

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.

B C D E

G

A B F

C

C00426

A B C D E F G

Bolts Cover O-ring Spring Pin Retaining Ring Bearing Outer Race Spacer

C00428

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

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.

6. Remove the input gear with bearing inner race.

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

NOTICE

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

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.

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.

1. Remove six bolts securing the cover to the housing, then remove the cover. The bearing outer race may adhere to the cover when the cover is removed.

2. Remove the o-ring from the cover.

3. Remove the spacer from the gear.

4. Remove the retaining ring from the gear.

5. Remove the bearing outer race, if present.

2.6

Tigercat Bogie Arm

Disassembly

REMOVE IDLER GEARS FROM PLANETARY SIDE OF BOGIE ARM

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.

A B C

A D

E

B C00429

A Idler Gear B Gear Opening C00427

A B C D E

4. Remove the idler gears next to the nearest input or output opening.

Bolt Idler Pin Cap Idler Pin O-ring Housing

a. Pry the edge of the idler gear up and towards the nearest gear opening using finger tips. b. Slide the idler gear by placing fingers against the input gear and/or idler openings and finger tips against the gear hub.

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

c.

a. Insert an M12x1.75 bolt with an oversized washer into the threaded hole in the top of the idler pin.

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

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.

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.

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

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.

2.7

Disassembly

Tigercat Bogie Arm

REMOVE INNER BEARING RACES FROM INPUT/OUTPUT GEARS

REMOVE BEARINGS FROM IDLER GEARS

A A B

B

C C A D E C00474

A B C D E

D

Outer Bearing Race Inner Bearing Race Output Gear Spacer Retaining Ring

C00472

A B C D

NOTICE

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).

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

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.

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

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

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

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

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

A

B

C C00473

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

5. Remove the bottom bearing from the idler gear: a. Place a flat end punch onto the top of the outer bearing race on the lower bearing. b. Tap incrementally around the circumference of the outer bearing race. c.

Remove the bearing.

2.9

Disassembly

Tigercat Bogie Arm

2.10

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 1.0, August 2018

A

Assembly, Prior to................................................................................................................................................. 3.3 B

BEARING INSTALLATION INSTRUCTIONS................................................................................................................ 3.3 BEARINGS INSTALL IDLER BEARINGS...................................................................................................................................... 3.4 INSTALL INPUT/OUTPUT INNER RACE.................................................................................................................. 3.4 C

Cleaning and Inspection..................................................................................................................................... 3.3 G

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

INPUT BEARING AND COVER, INSTALL.................................................................................................................. 3.10 INSTALL IDLER GEARS ALL IDLERS............................................................................................................................................................... 3.6 FOR BOGIE AXLES 1727MM (68 INCH)................................................................................................................... 3.5 FOR BOGIE AXLES 1888MM (74.3INCH), 1905MM (75 INCH) AND 1969MM (77.5 INCH).................................... 3.6 VERIFY IDLER GEAR BACKLASH........................................................................................................................... 3.8 VERIFY IDLER GEAR ENDPLAY.............................................................................................................................. 3.8 M

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

OUTPUT GEAR, INSTALL............................................................................................................................................ 3.9 P

Prior to assembly................................................................................................................................................. 3.3 S

SAFETY......................................................................................................................................................................... 3.3

Assembly

Tigercat Bogie Arm

3.2

Tigercat Bogie Arm

Assembly

SAFETY

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

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

• Ensure they are the right parts.

MACHINE ORIENTATION

• Verify orientation.

See MACHINE ORIENTATION on page 2.3 for pictorial references to bogie arm views. These are based on viewing the bogie arm with the differential yoke facing the observer.

• Replace damaged or worn components as required.

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

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

WARNING Bogie arm components are heavy. Use appropriate lifting devices. Support and brace major components so they do not fall or roll.

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

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

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.

GUIDE PINS NOTICE

See PERSONAL SAFE LIFTING AND CARRYING on page 1.9.

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

See SAFE SUPPORT OF COMPONENTS on page 1.9.

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

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

• Must be level • Must be clean

BEARING INSTALLATION INSTRUCTIONS

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

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:

• Must have components blocked to eliminate movement

CLEANING AND INSPECTION

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

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

2. Leave bearings in packages until ready for assembly.

PRIOR TO ASSEMBLY

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

Prior to bogie arm assembly:

4. Always wear PPE when heating or cooling bearings or associated components.

1. Have all required parts readily available.

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

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

3.3

Assembly

Tigercat Bogie Arm

INSTALL IDLER BEARINGS

INSTALL INPUT/OUTPUT BEARING INNER RACE A A

B

B C C

A B

D E C00474

A B C D E

D C00431

A B C D

Paint Marks Idler Bearing Idler Gear Retaining Ring

Outer Bearing Race Inner Bearing Race Output Gear Spacer Retaining Ring

NOTICE

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 that the manufacturer's retaining ring is present and that it is 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.

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.

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

4. Turn the idler bearing by hand to verify that 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 input/ 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 Idler gears are installed in a specific sequence depending on the size of the bogie axle.

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

3 1

5

2 4

6

C00475

68 inch Bogie Axle Idler Gear Installation Sequence Numbers represent order of installation of idler gears.

3.5

Assembly

Tigercat Bogie Arm

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

1 3 5 2

6 4

C00476

Multiple Bogie Axle Idler Gear Installation Sequence Numbers represent order of installation of idler gears.

ALL IDLERS

2. Install the idler pin bushing:

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

a. Install the idler pin bushing on the end of the idler pin. DO NOT install the O-ring on the idler pin. 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.

Remove the idler pin.

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.

5. Lubricate the idler pin with gear oil.

A B C C00492

A Idler Pin B Idler Bushing C Bogie Housing

3.6

Tigercat Bogie Arm

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

A B

A

C E

B D

C D

E

C00477

A B C D E

C00472

Bolts Idler Pin Cap Idler Pin Idler Gear Idler Pin Bushing

A B C D E

CAUTION

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.

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.

9. Install the idler pin cap: a. Apply Loctite 7649 primer to bolt holes and M10x1.5 bolts. See THREAD LOCKER AND PRIMER PRODUCTS on page 1.11

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

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

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

A

Bolt Idler Pin Cap Loctite 518 Sealant Idler Pin Bogie Housing

c.

Torque each bolt to 75Nm (55 lbf-ft) using an opposing pattern.

10. Install remaining idler gears using the correct sequence of installation using step 1 to 9.

B

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

C00479

A Idler Pin Cap B Bogie Housing

3.7

Assembly

Tigercat Bogie Arm

VERIFY IDLER GEAR ENDPLAY

VERIFY IDLER GEAR BACKLASH

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

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.

DO NOT pry the idler gear with the pry bar against the gear teeth.

A

D

B

E

A

C

C

D E

B C00481

A B C D E

C00480

A B C D E

Pry Bar Idler Pin Cap Idler Pin Idler Gear Bogie Housing

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

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

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

2. Turn the idler gear immediately adjacent to the immobilized gear manually. There must be rotational movement between the teeth of the immobilized idler gear and the teeth of the rotating gear in each direction.

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

3. Repeat step 1 to 2 for all idler gears.

3. Proceed to the next idler gear.

4. Immobilize the idler gear ( the gear previously verified for rotational play) and manually turn the next gear. There must be rotational movement between the immobilized idler gear teeth and the next gear, in each direction.

5. Continue until rotational movement is verified for all idler gears.

6. If rotational movement is not detected, call the Tigercat service department.

3.8

Tigercat Bogie Arm

Assembly

INSTALL OUTPUT GEAR

3. Verify that the bearing components are matched as described in INSTALL OUTPUT GEAR on page 3.9.

NOTICE

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

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

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

See INSTALL INPUT/OUTPUT BEARING INNER RACE on page 3.4.

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

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

A

CAUTION

B

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

D

B C

E

D C00497

E

A B C D E F

C F

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.

H C00482

A B C D E F G H

G

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

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

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 step1 to 11 for the other output gear.

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

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

3.9

Assembly

Tigercat Bogie Arm

INSTALL INPUT BEARING AND BOGIE AXLE COVER

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

See INSTALL INPUT/OUTPUT BEARING INNER RACE on page 3.4.

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

A

D E

A

B

B

F

C C

H C00496

D

A B C D E F G H

E F

Outer Race (bottom bearing in bogie arm) Bogie Arm Input Gear/Inner Races/Spacer/Retaining Ring Spring Pin O-ring Bolt Input Cover Outer Race (top bearing in bogie housing input cover)

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

C00483

A B C D E F

G

Input Gear Spring Pin (in bogie housing input cover seat) Outer Race O-ring Input Cover Bolt

8. Install the O-ring.

A

B

C

2. Verify that 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.

C00462

3. Verify that the bearing components are matched as described in INSTALL INPUT/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.

A B C D

D

Loctite 518 Sealant Spring Pin Input Cover Seat Input Gear

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

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

3.10

Tigercat Bogie Arm

Assembly

10. Apply sealant to the input gear seat: a. Apply a light bead of Loctite 518 around the perimeter of the input gear cover seat on the bogie arm. b. Apply a light bead around each bolt hole. DO NOT get sealant in the holes.

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

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

13. Prepare the bolts: 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.

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

3.11

Assembly

Tigercat Bogie Arm

3.12