Tigercat DIFFERENTIALS SERVICE AND REPAIR MANUAL - PDF DOWNLOAD

DIFFERENTIALS

SERVICE AND REPAIR MANUAL

ISSUE 4.0, AUGUST 2020 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat Differentials TABLE OF CONTENTS SECTION INTRODUCTION................................................................................................................................................. v NON-APPROVED FIELD PRODUCT / PARTS CHANGES............................................................................... vi TRADEMARKS..................................................................................................................................................vii EXPLODED VIEW, BARREL DIFFERENTIAL B15, B17...............................................................................viii EXPLODED VIEW, BARREL DIFFERENTIAL B20......................................................................................... x EXPLODED VIEW, FLANGE DIFFERENTIAL F17........................................................................................xii SAFETY..............................................................................................................................................................1 DISASSEMBLY....................................................................................................................................................2 ASSEMBLY..........................................................................................................................................................3 APPENDICES......................................................................................................................................................4

This Manual Part No. 47574AENG Axles SERVICE AND REPAIR Manual 47731AENG iii

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

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

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 service or repair the machine and/or components.

The information contained in this manual is current at the time of printing. Improvements to 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 provide updates on a regular basis. Report discrepancies between this manual and the components in question to the Tigercat Parts and 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 Differentials

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 TRADEMARKS ................................................................................................................................................vii

Tigercat Differentials

Introduction

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

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

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

TIGERCAT DIFFERENTIALS Tigercat manufactures differentials for assembly into Tigercat axles. Differentials are configured using the following parameters: Size - B15, B17, B20, F17 Type - Fixed position or oscillating differential Pinion Spiral Orientation - Left or Right Gear Ratios

vii

EXPLODED VIEW, BARREL DIFFERENTIAL B15, B17...............................................................................viii

Introduction

Tigercat Differentials *

12

24 27 63

59

54 55

3

10

20

17

#

19 16 21

1

#

21

18

20

2

62

2 5

4

##

33 29

60

##

28

31 32

26

25

30 41

38 9

43 40

8

6

7

42

22 13

44

28 34 39

56

37 36

50

*23 24

14 53

58

52

54 55

35

61

15

46

47

45

59

48

50

51 3

49

64

C00690

Barrel Style B15, B17 Fixed and Oscillating Differential NOTE: This exploded view is representative of Tigercat B15 and B17, fixed and oscillating barrel-style differentials. Some parts may appear differently from this view.

viii

11

Tigercat Differentials ITEM

Introduction DESCRIPTION

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

HOUSING, DIFFERENTIAL PIN, DOWEL NUT, ADJUSTMENT PINION, SPIRAL BEVEL GEAR, SPIRAL BEVEL RING, BACKUP, INNER O-RING O-RING RING, BACKUP, OUTER COVER, DIFFERENTIAL CASE HOUSING, DIFF-LOCK PIN, SPRING FLANGE,CASE SET SCREW SLEEVE, MANIFOLD GEAR,SPIDER GEAR,SIDE GEAR, SIDE, DIFF-LOCK SPIDER WASHER, THRUST, SIDE GEAR WASHER, GEAR, SPIDER # PISTON, DIFF-LOCK *BOLT WASHER PLATE, FRICTION PLATE, REACTION *BOLT BEARING, TAPERED (CUP AND CONE) BEARING, TAPERED (CUP AND CONE) BEARING, TAPERED (CUP AND CONE) SHIM, PINION SHIM, PINION ##

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 58 59 60 61 62 63 64

#

Denotes alternate part selection. Refer to, SPIDER WASHER CONFIGURATIONS on page 2.13.

##

Denotes alternate part selection. Refer to, PINION BEARING PRELOAD AND ROLLING TORQUE TEST on page 3.21.

*

INSPECT. See, FASTENER TORQUE AND REUSE on page 1.14.

ix

DESCRIPTION

SHIM, PINION ## YOKE O-RING SPACER, O-RING SPACER, PINION O-RING V-RING WASHER, THRUST SEAL,OIL SEAL, GREASE CARTRIDGE, SEAL RETAINING FITTING, LUBE HOUSING, MANIFOLD, ROTARY PLUG, EXPANDER PLUG, EXPANDER SEAL, OIL SEAL, OIL RING, RETAINING INTERNAL BOLT RING,SPLIT O-RING SCREW, BLEEDER SEAT, BLEEDER NUT, M30 RETAINER, DIFFERENTIAL BOLT PLUG, MAGNETIC O-RING SLEEVE (OSCILLATING DIFFERENTIALS ONLY) LOCK, ADJUSTMENT NUT BOLT

EXPLODED VIEW, BARREL DIFFERENTIAL B20......................................................................................... x

Introduction

Tigercat Differentials 24 27

*

10

20

12

16

17

19

21

#

21 59

63

1

54 55

#

18

20

11

5

2

3 2

28

26

4

25

60

13 29

57

31 32 33

##

##

65 66 67 68

14

22 9

30

##

8

6

*

7

38

15

41 43 40

42

37

23 24

52

44

28 1

54 55 35

49

39

34

53 46

56

36

61

58

51 3

50

45

64

48

50

C00689

Barrel Style B20 Fixed Differential NOTE: This exploded view is representative of Tigercat B20 fixed barrel-style differentials. Some parts may appear differently from this view.

x

47 59

Tigercat Differentials ITEM

Introduction DESCRIPTION

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

HOUSING,DIFFERENTIAL PIN, DOWEL NUT, ADJUSTMENT PINION,SPIRAL BEVEL GEAR,SPIRAL BEVEL RING, BACKUP, INNER O-RING O-RING RING, BACKUP, OUTER COVER, DIFFERENTIAL CASE HOUSING,DIFF-LOCK,CASE PIN, SPRING FLANGE,CASE SET SCREW SLEEVE, MANIFOLD GEAR,SPIDER GEAR,SIDE GEAR,SIDE,DIFF-LOCK SPIDER WASHER,THRUST,SIDE GEAR WASHER,GEAR,SPIDER # PISTON,DIFF-LOCK *BOLT WASHER PLATE,FRICTION PLATE,REACTION *BOLT BEARING, TAPERED (CUP AND CONE) BEARING, TAPERED (CUP AND CONE) BEARING, TAPERED (CUP AND CONE) SHIM, PINION SHIM, PINION SHIM, PINION YOKE

#

Denotes alternate part selection. Refer to, SPIDER WASHER CONFIGURATIONS on page 2.13.

##

Denotes alternate part selection. Refer to, PINION BEARING PRELOAD AND ROLLING TORQUE TEST on page 3.21.

*

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 63 64 65 66 67 68

INSPECT. See, PINION BEARING PRELOAD AND ROLLING TORQUE TEST on page 3.21.

xi

DESCRIPTION

O-RING SPACER, O-RING SPACER, PINION O-RING V-RING WASHER, THRUST SEAL,OIL SEAL,GREASE CARTRIDGE, SEAL RETAINING FITTING, LUBE HOUSING, MANIFOLD, ROTARY PLUG,EXPANDER PLUG,EXPANDER SEAL, OIL SEAL, OIL RING, RETAINING INTERNAL BOLT RING,SPLIT O-RING SCREW, BLEEDER SEAT, BLEEDER NUT, M30 SPACER, YOKE, PINION RETAINER, DIFFERENTIAL BOLT PLUG, MAGNETIC SQ HD O-RING LOCK, ADJUSTMENT NUT BOLT SHIM, YOKE, DIFFERENTIAL SHIM, YOKE, DIFFERENTIAL## SHIM, YOKE, DIFFERENTIAL ## SHIM, YOKE, DIFFERENTIAL ##

EXPLODED VIEW, FLANGE DIFFERENTIAL F17........................................................................................xii

Introduction

40

Tigercat Differentials

42

35

36

43

41

34

1

39

38 56

37

68

65

67

44 70

69

71 30

## ##

31 32 33

29

5

65 4

13

28

14

24

*27

28

3

54 52

46

47

17

53

15

12

3

50

* 23 #

24 21

25 26 50

48

59

51

45

49 16

11

20 22

7

6

8

26

18

#

21

20

10

19

25

9

C00691

Flange Style F17 Differential NOTE: This exploded view is representative of a Tigercat flange-style F17 differential. Some parts may appear differently from this view.

xii

66

Tigercat Differentials

ITEM

Introduction

DESCRIPTION

ITEM

1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

HOUSING,DIFFERENTIAL FLANGE NUT, ADJUSTMENT PINION,SPIRAL BEVEL GEAR,SPIRAL BEVEL RING, BACKUP, INNER O-RING O-RING RING, BACKUP, OUTER COVER, DIFFERENTIAL CASE HOUSING,DIFF-LOCK,CASE PIN, SPRING FLANGE, CASE SET SCREW SLEEVE, MANIFOLD GEAR,SPIDER GEAR,SIDE GEAR,SIDE,DIFF-LOCK SPIDER WASHER,THRUST, SIDE GEAR WASHER,GEAR, SPIDER PISTON,DIFF-LOCK # *BOLT WASHER PLATE,FRICTION PLATE,REACTION *BOLT BEARING, TAPERED (CUP AND CONE) BEARING, TAPERED (CUP AND CONE) BEARING, TAPERED (CUP AND CONE) SHIM, PINION

#

Denotes alternate part selection. Refer to, SPIDER WASHER CONFIGURATIONS on page 2.13

##

Denotes alternate part selection. Refer to, PINION BEARING PRELOAD AND ROLLING TORQUE TEST on page 3.21

*

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 51 52 53 56 59 65 66 67 68 69 70 71

INSPECT. See, FASTENER TORQUE AND REUSE on page 1.14.

xiii

DESCRIPTION

SHIM, PINION ## SHIM, PINION ## YOKE O-RING SPACER, O-RING SPACER, PINION O-RING V-RING WASHER, THRUST SEAL,OIL SEAL,GREASE CARTRIDGE, SEAL RETAINING FITTING, LUBE HOUSING, MANIFOLD, ROTARY PLUG,EXPANDER PLUG,EXPANDER SEAL, OIL SEAL, OIL BOLT RING,SPLIT O-RING NUT, M30 BOLT CLAMP, HOUSING, DIFFERENTIAL BOLT WASHER DOWEL FITTING, STRAIGHT FITTING, STRAIGHT BOLT

Introduction

Tigercat Differentials

xiv

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

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

CONTENTS – SECTION 1

ISSUE 4.0, AUGUST 2020

C

CALIBRATION............................................................................................................................................................. 1.8 CAUTION..................................................................................................................................................................... 1.3 CLEAN AND INSPECT.............................................................................................................................................. 1.11 COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING.................................................. 1.13

D

DANGER...................................................................................................................................................................... 1.3 DISASSEMBLY, DURING......................................................................................................................................... 1.12

F

FASTENER TORQUE AND REUSE......................................................................................................................... 1.14 BOLTS..................................................................................................................................................................... 1.14 NUTS AND WASHERS.......................................................................................................................................... 1.14 TORQUE WRENCHES.......................................................................................................................................... 1.14

G

GREASE INJECTION INJURY................................................................................................................................... 1.7

H

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

M

MATERIAL LIFTING AND HANDLING....................................................................................................................... 1.7

P

PERSONAL PROTECTIVE EQUIPMENT................................................................................................................. 1.3 PNEUMATIC GREASE GUNS.................................................................................................................................... 1.7

R

READ THIS MANUAL FIRST...................................................................................................................................... 1.3 REQUIRED TOOLS..................................................................................................................................................... 1.8 GUIDE PINS........................................................................................................................................................... 1.11

S

SAFE LIFTING AND CARRYING............................................................................................................................... 1.7 SAFETY........................................................................................................................................................................ 1.3 GENERAL SAFETY PRECAUTIONS..................................................................................................................... 1.3 SAFETY SYMBOLS..................................................................................................................................................... 1.3 UNDERSTANDING SAFETY WORDS................................................................................................................... 1.3 SERIAL NUMBERS, LOCATION OF........................................................................................................................ 1.13 BARREL STYLE SERIAL NUMBER LOCATION................................................................................................. 1.13 FLANGE STYLE SERIAL NUMBER LOCATION................................................................................................. 1.13

Safety

Tigercat Differentials

SHIPPING COMPONENTS........................................................................................................................................ 1.8 T

THREAD LOCKING COMPOUNDS AND SEALANTS........................................................................................... 1.12 GASKET FORMING/SEALANT PRODUCTS....................................................................................................... 1.12 REMOVE FASTENERS SECURED WITH LOCTITE THREAD LOCKER COMPOUNDS............................... 1.12 REMOVE LOCTITE FLANGE SEALANT............................................................................................................. 1.12 THREAD LOCKER AND PRIMER PRODUCTS.................................................................................................. 1.12 TORQUE SPECIFICATIONS, GENERAL................................................................................................................ 1.15 IMPERIAL TORQUE SPECIFICATIONS.............................................................................................................. 1.15 METRIC TORQUE SPECIFICATIONS................................................................................................................. 1.16

W

WARNING.................................................................................................................................................................... 1.3

1.2

Tigercat Differentials

Safety

READ THIS MANUAL FIRST

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

NOTICE

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

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

The information contained in this manual is current at the time of printing. Tigercat reserves the right to make changes to the differentials 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.

SAFETY GENERAL SAFETY PRECAUTIONS Remember, safety is a prime responsibility of all.

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.

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

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

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

SAFETY SYMBOLS

PERSONAL PROTECTIVE EQUIPMENT (PPE)

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.

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

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.

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

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

1.3

Safety

Tigercat Differentials

HAZARDS

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

FLAMMABILITY

COMPETENT PERSON

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

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.

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

HAZARDOUS MATERIALS

LIQUID NITROGEN

WARNING

WARNING

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

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.

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

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

• 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.

VENTILATION WARNING

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

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

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

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.

1.4

Tigercat Differentials

Safety

WORKING WITH OIL

VITON SEALS

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

WARNING

Other safety advice includes:

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

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

• Avoid contact with oil, particularly heated oil.

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

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).

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

• Do not put oily rags in your pockets.

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

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

• Keep an extra change of work cloths nearby.

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

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

• Avoid breathing in oil fumes.

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

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

If these are found, do not touch.

COMPRESSED AIR

• 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.

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

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

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

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).

Follow acceptable Health and Safety protocols for using compressed air.

• Do not clean clothing or skin using compressed air.

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

1.5

Safety

Tigercat Differentials

HIGH PRESSURE INJECTION INJURIES

WARNING

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.

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

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

• Seek professional medical attention immediately.

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

When searching for possible fluid leaks:

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.

• Do not search for leaks with your bare hands. Wear thick protective gloves.

• Wear safety goggles for eye protection.

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.

• 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.

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

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.

• 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.

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.

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.

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

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.

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

WARNING

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

Do not use any hydraulic equipment suspected of being defective.

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 Differentials

Safety

PNEUMATIC GREASE GUN INJECTION INJURY HAZARDS

MATERIAL LIFTING AND HANDLING WARNING

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.

Only competent personnel are permitted to operate cranes or hoists.

Seek professional medical treatment immediately after any type of injection injury.

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.

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

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

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.

• Do not exceed working load limits.

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

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

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

• All operators of high pressure pneumatic grease guns must be trained in the hazards of its operations and the treatment for such injuries.

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

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

PERSONAL SAFE LIFTING AND CARRYING 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.

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

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

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

When manually lifting components: • Wear appropriate PPE

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

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

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

• Consider if a lifting device can be used

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

• Determine if the load weight is within your safe lifting capacity • Verify the route and destination used to move and place the load is clear of obstructions To safely lift a load, • Assume a stable lifting stance • Keep feet hip width apart with one foot slightly ahead of the other for stability • Get a good grip on load. If the grip needs to be adjusted, put the load down, then adjust the grip.

• Keep your back straight • Lift with legs • Keep load close to waist • Do not twist your torso. Move your feet.

• Keep your head up and watch your route.

1.7

Safety

Tigercat Differentials

SAFE SUPPORT OF COMPONENTS

WARNING

Differentials are heavy and represent a 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 verify that both components are adequately supported.

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.

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

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.

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

SHIPPING COMPONENTS

CALIBRATION

Depending upon location of the machine and the destination site, a differential may or may not be filled with oil prior to shipping/delivery. Be aware of local, regional, state or federal laws and regulations. Clearly mark differentials to show whether or not they contain oil.

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

REQUIRED TOOLS AND MATERIALS To remove a differential requires the following tools, equipment and materials:

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.

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

Tools must be calibrated when:

• Bearing Puller

• New

• Isopropyl alcohol or equivalent solvent

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

• Clean rags

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

• PPE

• Marking pen or other marking method • Support Stands

• Observations indicate incorrect readings

• Wooden support blocks

WORK CONDITIONS AND TOOLS

• Torque multiplier wrench capable of 1360N-m (1000 lbf-ft)

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.

• Snap ring installation tool • 600 lbf-ft torque wrench • 100 lbf-ft torque wrench

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

• Lifting eyes M16‑2.0 • Lifting eyes M8‑1.25 • 120 grit emery cloth • Loctite solvent or equivalent • Loctite 262 - SSA001 • Loctite 648- SSA244 • Loctite Primer 7649 - SS93996

1.8

• Guide Pins (as required). See, GUIDE PINS on page 1.11.

Tigercat Differentials

B

Safety

A

A

C000003

C00006

A Manifold Inner Seal Press Tool (B7785000)

A Adjustment Nut Torque Tool (53908B) 1/2 inch drive B Crown Nut Adjustment Tool (75813B) 3/4 inch drive

A

A C00237

A Manifold Outer Seal Press Tool (51482B) C00004

A Diff-Lock Restrictor

For the following differentials use the appropriate tool: • B17/F17

52804B

• B15

B7709000

• B20

B7865000

A C00008

A Diff-Lock Sleeve Press Tool (53658B)

A

C00005

A Pinion Seal Press Tool (51480B)

C00728

A Seal Cartridge Driver Tool (B9082000)

1.9

A

Safety

Tigercat Differentials

A

A C00009

A Diff-Lock Torque Tool B17/F17/B20 (A7508000) B15 (A7604000)

C00602

A Differential Case Bearing Press Fitting Tool (B8211000)

A C00537

A Pinion Bearing Press Fitting Tool B15,B17,F17 (B8212000) Pinion Bearing Press Fitting Tool B20 (B8213000)

A

C00743

A

A 3 inch Washer Press Tool (A8764000)

C00578

A Diff-Case Torque Fixture B17/F17 (B7437000) B15 (B7711000) B20 (B7862000)

A

C00602

A Differential Case Bearing Press Fitting Tool (B8211000)

1.10

Tigercat Differentials

Safety

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.

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 differential, clean and inspect the assembly carefully. Observe and record findings while disassembling the unit: 1. Have required tools, solvents, lint free cloths, rags, tools and other items at hand.

B

2. Read accompanying reports.

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

A

b. Rinse components after cleaning. c.

C00498

A Guide Pin B Grind fastener head down. Do not cut off.

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 an additional half turn.

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

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

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

6. Clean and inspect each component for obvious signs of wear, misalignment or failure, as it is removed from the assembly.

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

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

Worn components must be replaced.

9. Remove seals, gaskets, sensors and hoses. Inspect and note wear or damage. Gaskets, seals, O-rings and other components of this nature are replaced during the reassembly procedure. Do not reuse.

10. Remove bearings carefully to avoid damage to associated parts. Replace bearings. Do not reuse bearings removed from the unit for any purpose.

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.

1.11

Safety

Tigercat Differentials

DURING DISASSEMBLY Observe and record findings during disassembly: 1. Inspect for obvious misalignment of parts.

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. Inspect gears for roughness, damaged edges, wear patterns and foreign material.

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

3. Inspect seals, gaskets, sensors and hoses for wear or damage.

THREAD LOCKER AND PRIMER PRODUCTS

4. Record your findings providing as much information as possible.

5. Clean and inspect each component as it is removed from the assembly and retain.

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

6. Organize removed parts in a logical order on the workbench.

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

THREAD LOCKING COMPOUNDS AND SEALANTS

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

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

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

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

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

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

7. Wipe excess Loctite from the site.

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

GASKET FORMING/SEALANT PRODUCTS CAUTION

1. Remove the fastener.

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

a. Apply Bonderite C-SO Paint 200 Solvent Paint Line Cleaner or equivalent. b. Apply localized heat (250°C/480°F) if required.

Remove while hot. c.

Clean threads with a wire brush.

d. Wipe excess material from screw.

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

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

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

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

3. Apply the mating part.

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

5. Wipe excess gasket forming product from the site.

1.12

Tigercat Differentials

Safety

COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING

FLANGE STYLE SERIAL NUMBER LOCATION

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.

A

LOCATION OF SERIAL NUMBERS

xxxxxxxx

Serial numbers, eight numeric characters long, are stamped into each differential during manufacturing.

BARREL STYLE SERIAL NUMBER LOCATION

xxxxxxxx

B

B

C00748

A Original Manufacturing Serial Number Location B Rebuilt Serial Number Locations (May Vary)

A B

The serial number is located on the flat to the right of the Tigercat brand name cast in the differential carrier housing. If the differential has been rebuilt, look for the serial number on the bottom left half on the housing.

C

C00747

A Rebuilt Serial Number Location B Original Manufacturing Serial Number Location C Machined Area for the Trunnion Sleeve

The serial number is located on top of the casting adjacent the machined area for the trunnion sleeve.

If the differential has been rebuilt, look for the serial number on the upper right quadrant on the housing casting.

1.13

Safety

Tigercat Differentials

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

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

BOLTS Bolts join components in a way that provides 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.

may stretch. If that bolt is reused there is a risk the bolt 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. Follow the guidelines below to indicate which bolts may be reused or not. Clean/chase fasteners before determining suitability for reuse or replacement.

UNLESS OTHERWISE SPECIFIED 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 used to tighten the bolt(s) exceeded 90% of proof strength. The bolt(s) is/are not safe for reuse.

LOAD

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. Once a bolt has been torqued, it

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

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

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

1.14

Tigercat Differentials

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

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

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

METRIC

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

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

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

1.15

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 Differentials

1.16

DISASSEMBLY....................................................................................................................................................

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

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

CONTENTS – SECTION 2

ISSUE 4.0, AUGUST 2020

Symbols

30MM PINION NUT WEAR CONDITION................................................................................................................. 2.10 B

BEARING REMOVAL.................................................................................................................................................. 2.3

D

DIFFERENTIAL CASE.............................................................................................................................................. 2.12 BEARING CUPS, REMOVE FROM HOUSING.................................................................................................... 2.11 DISASSEMBLE DIFFERENTIAL LOCK............................................................................................................... 2.14 DISASSEMBLE THE DIFFERENTIAL CASE....................................................................................................... 2.12 SPIDER WASHER CONFIGURATIONS........................................................................................................... 2.13

M

MACHINE ORIENTATION........................................................................................................................................... 2.3 MOVING DIFFERENTIALS/COMPONENTS............................................................................................................ 2.3

O

OIL, REMOVE.............................................................................................................................................................. 2.4

P

PINION......................................................................................................................................................................... 2.7

S

SAFETY........................................................................................................................................................................ 2.3 SPIRAL BEVEL GEAR, REMOVE............................................................................................................................ 2.12

Disassembly

Tigercat Differentials

2.2

Tigercat Differentials

Disassembly

SAFETY

MOVING DIFFERENTIALS/ COMPONENTS

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

Use lifting rings to move differentials and differential components.

MACHINE ORIENTATION

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

1. Refer to the bearing manufacturer's literature for bearing installation and removal specifications.

2. Direct flame or localized heat applied to a bearing cone or cup may raise temperatures unevenly, resulting in race hardness reduction. This increases the risk of damage to gears and other components.

C00023

Direction of View

3. Do not heat standard product bearing cones, cups gears or steel sleeves above 120°C (250°F). If heated above this temperature, the metallurgical structure may soften, rendering them unsuitable for use.

Positional references for the differential are based on viewing the differential with the yoke facing the observer.

WARNING

4. Drive bearing components only on parts of the assembly that do not directly impact bearing separators, bearing pullers, chisels or punches to remove bearing components.

Differential components are heavy. Use appropriate lifting devices. Support and brace major components so they Do not fall or roll.

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

5. Welding a bead on the thick part of a bearing cup and allowing it to cool will often free a bearing from a blind hole or where no purchase is to be had on the bearing edge. Do not use oxyacetylene welding equipment for welding a bead on a bearing cup. Too much heat is applied to surrounding materials to make the bead effective.

This procedure is used to service and repair Tigercat differentials. Carefully inspect the machine to determine the extent of repairs required.

6. Cut the bearing race from a housing or component only as a last resort. There is a high risk of damaging the housing or component.

There are different sizes of differentials and housings used in building fixed axles, oscillating axles and bogie axles.

See PERSONAL SAFE LIFTING AND CARRYING on page 1.7.

See SAFE SUPPORT OF COMPONENTS on page 1.8.

Service the differential on a clean, robust work surface.

The work area: • Must be level • Must be clean • Must be blocked to eliminate movement.

2.3

Disassembly

Tigercat Differentials

REMOVE DIFFERENTIAL CASE

REMOVE OIL WARNING 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.

Oil was drained from the differential prior to shipping.

Residual oil may remain and be removed during disassembly.

1. Remove the magnetic drain plug from the differential. Inspect for metal particles. Some residual oil may drain from the differential.

C00132

1. Place the differential on a sturdy work surface. Use a robust support to position the differential as shown.

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

3. Clean all magnetic drain plugs of oil and debris.

4. Reinstall drain plugs once clean.

C00133

2. Remove the bleeder screw and bleeder seat (one each side) from the differential housing. Clean bleeder screws and seats and inspect for damage.

2.4

Tigercat Differentials

Disassembly

C00134

3. Remove the magnetic plug and O-ring from the side of the differential housing. Inspect for metal filings and record findings. Clean magnetic plug and O-ring of oil and debris.

C00165

5. Remove four bolts securing the rotary manifold, then remove the manifold from the differential.

6. Remove the rotary manifold oil seals, O-rings and internal retaining rings from the rotary manifold housing.

A

C00136

A Securing Bolts

C00139

4. Remove two bolts securing the adjusting nut lock and remove the lock. Clean and inspect the lock.

7. Remove the split rings (2) from the differential lock flange.

8. Insert M8-1.25 lifting rings on opposite sides of the differential retainer. See image for step 13.

9. Lift and turn the differential so the differential retainer faces up, if not already in position.

2.5

Disassembly

Tigercat Differentials NOTICE

A

Do not damage the screw threads on the pinion.

B

C D

C00577

A B C D

M30 Nut Yoke Torque multiplier wrench Block

10. Loosen the M30 nut on the end of the pinion prior to removing the differential retainer. The weight of the total differential unit aids in applying the necessary force of 1356 N-m (1000 lbf-ft) to loosen the nut, as required in a subsequent step. a. Block the yoke from turning by placing a sturdy block of hardwood or steel beneath the edge of the yoke. b. Carefully apply localized heat to the pinion nut to release the Loctite. Do not heat above 250°C (480°F). c.

C00141

13. Lift the differential retainer from the differential housing using the lifting rings installed in step 8. The tapered bearing cup from the flange case may move with the retainer.

Apply a 30 mm socket to a torque multiplier wrench with extension, and manually loosen the pinion nut.

14. Remove the O-ring from the bottom surface of the differential retainer then set the retainer aside.

NOTICE The B17 and B20 differential cases lift straight up and out of the housing.

The top edge of the B15 differential case may interfere with the housing and must be tilted to clear the pinion gear.

C00086

11. Remove the adjusting nut from the differential retainer. Use tool 53908B. The adjacent illustration is representative of the adjusting nuts on each side of the differential.

12. Remove four bolts securing the differential housing to the differential.

2.6

Tigercat Differentials

Disassembly REMOVE PINION (USE PROCEDURE FOR ALL, EXCEPT MULTIPLE SHIM CONFIGURATION OF B20 ) To remove the pinion from the differential: 1. Remove the nut. See, Step 10, Page 2.6.

A

C00138

B

C

D

E

C00238

B17 and B20 differential cases

A B C D E

Lift the differential case straight up.

Yoke O-ring O-ring Spacer Pinion Spacer M30 Nut

2. Remove the yoke, O-ring, O-Ring spacer and pinion spacer. Temporarily retain the parts for shim calculations found in, BACKLASH MEASUREMENT on page 3.28.

A

B

C00143

B15 differential cases

Tilt the top edge of the differential case toward the pinion if the differential case binds on the differential housing.

C00166

A V-ring B Yoke

15. Lift the differential case carefully from the differential housing.

3. Remove the V-ring from the yoke.

NOTICE Do not damage the screw threads on the pinion.

2.7

Disassembly

Tigercat Differentials (B20 DIFFERENTIALS) Service technicians may encounter one of two configurations of shims/spacers with the Tigercat B20 differential pinion gear; a multiple shim configuration and a single pinion spacer shim configuration.

A

The assemblies differ in the depth of the yoke, the thickness and number of shim(s) and spacers and how backlash is calculated.

B I C00197

A Pinion Spacers B M30 Nut

F

E

H G

4. Place the yoke back onto the pinion.

5. Install several spacers over the threaded end of the pinion. The spacers rest on the shoulder of the yoke, above the splines, so the pinion threads are protected when the M30 nut is applied.

6. Install and hand tighten an M30 nut (not the one removed to free the pinion) to hold the spacers in place.

A

B C

C00762

A B C D E F G H I ^

C00146

7. Strike the nut firmly to dislodge the pinion from the differential housing.

8. Remove the pinion.

D

B20 Multiple Shim Configuration (Obsolete)

Yoke ^ O-ring (do not reuse) O-ring Spacer (do not reuse) M30 Nut ^ Shim ^ Shim ^ Shim ^ Shim ^ Pinion Spacer ^ Identifies obsolete parts

NOTICE Configurations using multiple shims are obsolete. Parts are not interchangeable with single pinion spacer shim configuration parts.

2.8

Tigercat Differentials

Disassembly A C

E

B A

B C

C00762

A B C D E

D

B20 Single Pinion Spacer Shim Configuration

Yoke O-ring O-ring Spacer M30 Nut Pinion Spacer Shim

C00147

A Lube Fitting B Seal Retaining Cartridge C Bolt

Replace multiple shim configuration parts with parts for a single pinion spacer shim configuration if servicing/ repair is required. Contact the Tigercat Parts and Service Department for further information.

9. Install an M8X1.25 - 2B bolt in each side of the seal retaining cartridge to assist in removal.

10. Remove the seal retaining cartridge. Use the bolts and a bar or lock-grip pliers and alternately tap the bolts to remove the cartridge from the housing.

11. Remove the lube fitting from the seal retaining cartridge.

2.9

Disassembly

Tigercat Differentials 14. Apply downward force on the shaft of the pinion using a press, if available. If a press is not available, apply the spacers and nut as described in steps 4 – 6 and use a hammer to drive the pinion from the bearing. If necessary, heat the bearing as described in, BEARING REMOVAL on page 2.3.

A

NOTICE B

Extract the bearing carefully, using a bearing separator, if the bearing preload is lost or if the bearing is destroyed or pitted. Do not cut the sleeve from the pinion.

E

C D

30MM PINION NUT WEAR CONDITION 1. Clean the M30 nut of grease and dirt.

C00162

A B C D E

Oil Seal Grease Seal Lube Fitting Thrust Washer Seal Retaining Cartridge

2. Inspect the contact surface of the pinion nut for excessive wear.

A

12. Remove the thrust washer, grease seal, oil seal and O-ring from the seal retaining cartridge.

A

B

B C

D

C

C00163

A B C D

Pinion Bearing Cone Bearing Puller Block

13. Remove the tapered bearing from the pinion. a. Apply a bearing puller to the pinion/bearing. b. Set the pinion/bearing on two blocks. The bearing race must be on the blocks.

C00694

A New Contact Surface B Lightly Worn Contact Surface C Heavily Worn Contact Surface

3. Reuse nuts exhibiting light to moderate wear (light scoring, black oxide finish worn evenly) providing there are no embedded particles in the contact surface. Images of new, lightly worn and heavily worn contact surfaces of an M30 nut are shown in illustration C00694.

4. Replace nuts exhibiting excessive wear, galling and embedded particles.

2.10

Tigercat Differentials

Disassembly

REMOVE BEARING CUPS FROM HOUSING

A

A B B

D

C C

C00240

A Differential Housing B Metal Punch C Bearing Cup

C00241

A B C D

Differential Housing Metal Punch Bearing Cup Lubrication Slot

2. Place a punch against the edge of the bearing cup in the differential housing located behind the seal retaining cartridge. a. Work from the inside of the housing.

1. Place a punch against the edge of the bearing cup in the differential housing that receives the pinion bearing.

b. Place the punch on the exposed edge of the cup.

a. Work from the outside of the housing.

c.

b. Place the punch on the edge of the cup exposed by the lubrication slots. c.

Tap the pinion bearing cup towards the inside of the housing using a hammer and cold chisel.

2.11

Tap the bearing cup nearest the seal retaining cartridge towards the outside of the housing.

Disassembly

REMOVE SPIRAL BEVEL GEAR

Tigercat Differentials

DIFFERENTIAL CASE DISASSEMBLE THE DIFFERENTIAL CASE

C00148

1. Place support blocks on either side of the housing to protect the spiral bevel gear teeth when the gear releases from the housing.

2. Remove the *bolts securing the spiral bevel gear to the housing using a pneumatic impact gun. See, FASTENER TORQUE AND REUSE on page 1.14.

C00150

1. Remove the *bolts securing the differential case cover to the diff-lock case housing. See, FASTENER TORQUE AND REUSE on page 1.14.

C00149

3. Strike the edge of the gear using a hammer and a soft punch.

4. Rotate the flange to strike evenly around the gear.

C00151

5. Clean and inspect the gear carefully.

6. Turn the housing over.

Thrust Washers With Tabs Shown

2. Pull up on the bearing to separate the halves of the differential case.

3. Inspect the condition of the differential case cover and thrust washers. Inspect for filings or missing tabs from the spider gear washers. Refer to, SPIDER WASHER CONFIGURATIONS on page 2.13. Record the findings.

2.12

Tigercat Differentials

Disassembly

C00195 C00152

4. Remove the thrust washer from the top of the side gear.

7. Remove the diff-lock side gear.

SPIDER WASHER CONFIGURATIONS 1. Clean and inspect washer.

A

C B

C00692

A Semi-spherical Spider Gear Washer (2 per Diff-Lock) B Spider Gear Washer (Without Tabs, 4 per Diff-Lock) C Spider Gear Washer (Bimetallic With Tabs, 4 per Diff-Lock)

C00153

5. Remove the differential case cover side gear.

When servicing a differential case, one of three configurations of spider gear washer will be present: a. Two bronze semi-spherical spider gear washers. b. Four bronze spider gear washers without tabs. c.

Four bimetallic spider gear washers with two locking tabs.

Replace four washer configurations with two semispherical spider gear washers if: • Spider gear washers have scored the inside of the case housing or case cover.

• Spider gear washers are worn thin. On the tabbed spider gear washers, the bronze coating is worn through exposing steel.

• Spider gear washers have broken tabs.

C00154

• Spider gear washers have fragments embedded in the contact surfaces.

6. Remove the spider gears and spider.

2.13

Disassembly

Tigercat Differentials

• The inside of the case/cover contains metal filings or fragments.

• Spider, spider gears, side gears and side thrust washers are damaged.

If the four existing washers are in good working condition when inspected, they may be reused. If thrust washers do require replacement, Tigercat recommends replacing them with the semi-spherical two washer configuration. If the differential case cover is worn, it must be replaced.

DISASSEMBLE DIFFERENTIAL LOCK C00157

3. Insert a small pry tool in the hole and leverage the flange from the housing.

C00155

1. Turn the flange/housing so the flange is facing up, then remove bolts securing the flange.

C00158

4. When a gap is established between the flange and the housing, insert a tool, for example, hardwood wedges or pry bars, and continue to work the flange from the housing in a circular direction. Do not damage the machined surfaces.

A

B

C C00156

2. Strike the flange using a soft punch at a 45° angle on the edge of a bolt recess until the holes of the flange overlap the holes of the housing by approximately one half a hole diameter.

C00234

A Diff-Lock Piston B Flange C Housing, Diff-Lock Case

2.14

Tigercat Differentials

Disassembly E

A

A B

B

C

C

C00159

A Air Nozzle B Sleeve C Flange

C00164

A B C D E

WARNING Protect yourself from compressed air injuries.

Use a rag or other barrier to stop the hole.

5. Remove the differential lock piston from the flange. a. Insert an air nozzle in the oil hole in the sleeve on the top of the flange.

D

Inner Backup Ring Inner O-ring Outer Backup Ring Outer O-ring Diff-Lock Piston

6. Remove the piston from the cavity, then remove the backup ring and O-ring from the inner diameter of the piston. Discard these rings.

7. Remove the backup ring and O-ring from the outer diameter of the diff-lock piston. Discard these rings.

b. Stop the oil hole directly opposite the first hole.

(This step is shown without a barrier to stop the hole, for clarity.) c.

Apply air to push the diff-lock piston from the cavity in the flange.

WARNING There may be oil spray from the compressed air displacing the oil in the cavity.

C00160

8. Remove the friction plates and reaction plates from the differential lock housing. Inspect each carefully for wear, scoring and flatness.

2.15

Disassembly

Tigercat Differentials

C00161

9. Remove the tapered bearing from the flange using a bearing puller. Place a piece of metal stock under the bolts used to raise the bearing puller to avoid marring the casting.

NOTICE If the sleeve is damaged and needs to be removed, use a bearing puller and heat as required. Do not cut the sleeve from the casting.

10. Remove the sleeve, using a bearing puller, only if it is damaged. Place a piece of metal stock under the bolts used to raise the bearing puller to avoid marring the casting.

Do not cut the sleeve from the casting. Cutting may damage the flange casting.

2.16

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

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

CONTENTS – SECTION 3

ISSUE 4.0, AUGUST 2020

A

ASSEMBLY, PRIOR TO............................................................................................................................................... 3.4

B

BEARING INSTALLATION INSTRUCTIONS............................................................................................................ 3.3 BEARING INDUCTION HEATER............................................................................................................................ 3.3 COOLING BEARINGS............................................................................................................................................. 3.4 HEATING BEARINGS.............................................................................................................................................. 3.3

C

CLEANING AND INSPECTION.................................................................................................................................. 3.3 CONTACT PATTERN................................................................................................................................................ 3.31 CONTACT PATTERN RUN PATTERN TEST............................................................................................................................................ 3.32

D

DIFFERENTIAL CASE................................................................................................................................................ 3.4 B-BARREL DIFFERENTIAL................................................................................................................................... 3.24 DIFFERENTIAL CASE COVER TO THE DIFF-LOCK HOUSING...................................................................... 3.13 DIFFERENTIAL LOCK........................................................................................................................................... 3.15 DIFF-LOCK HOUSING............................................................................................................................................. 3.9 F-FLANGE DIFFERENTIAL................................................................................................................................... 3.25 FLANGE.................................................................................................................................................................... 3.4 FOUR THRUST WASHER CONFIGURATION...................................................................................................... 3.9 INSTALL PINION GREASE................................................................................................................................... 3.35 INSTALL SPIRAL BEVEL GEAR........................................................................................................................... 3.16 MANIFOLD, INSTALL............................................................................................................................................. 3.33 SEAL RETAINING CARTRIDGE, INSTALL SEALS............................................................................................... 3.8 TWO SPIDER GEAR WASHER CONFIGURATION............................................................................................ 3.11 DIFFERENTIAL CASE HOUSING.............................................................................................................................. 3.9 DIFF-LOCK HOUSING CONFIGURATIONS......................................................................................................... 3.9 DIFFERENTIAL HOUSING....................................................................................................................................... 3.18 BLEEDER AND MAGNETIC PLUG, INSTALL..................................................................................................... 3.18 DIFFERENTIAL SLEEVE (OSCILLATING DIFFERENTIAL ONLY), ASSEMBLE............................................. 3.18 PINION BEARING PRELOAD AND ROLLING TORQUE TEST......................................................................... 3.21 PINION BEARINGS, INSTALL.............................................................................................................................. 3.19 SET PINION MOUNTING DISTANCE.................................................................................................................. 3.19 DIFFERENTIAL LOCK LEAK TEST......................................................................................................................... 3.34 HIGH PRESSURE LEAK TEST............................................................................................................................. 3.34 LOW PRESSURE LEAK TEST.............................................................................................................................. 3.34 DIFFERENTIAL LOCK MANIFOLD............................................................................................................................ 3.7 EXPANDER PLUGS................................................................................................................................................. 3.7 LOW AND HIGH PRESSURE SEALS.................................................................................................................... 3.7

F

F17 DIFFERENTIAL BEARING CAP MEASUREMENT......................................................................................... 3.31

L

LOCK ADJUSTMENT NUTS..................................................................................................................................... 3.30 LOCKING TAB/BOLT.............................................................................................................................................. 3.30 B - BARREL DIFFERENTIAL............................................................................................................................. 3.30 F - FLANGE DIFFERENTIAL............................................................................................................................. 3.30

Assembly

Tigercat Differentials

M

MEASURE BACKLASH............................................................................................................................................. 3.28 BACKLASH MEASUREMENT............................................................................................................................... 3.28 BACKLASH SETTING (S) = MINIMUM MEASUREMENT.................................................................................. 3.29 BACKLASH VARIATION (V) = MAXIMUM MEASUREMENT - MINIMUM MEASUREMENT........................... 3.29 MEASURE RUNOUT................................................................................................................................................. 3.27

P

PINION, GREASE...................................................................................................................................................... 3.35

S

SAFETY........................................................................................................................................................................ 3.3 SEAL RETAINER CARTRIDGE WITHOUT SEAL CARTRIDGE DRIVER TOOL................................................................................................... 3.23 WITH SEAL CARTRIDGE DRIVER TOOL........................................................................................................... 3.23

3.2

Tigercat Differentials

Assembly

SAFETY

HEATING BEARINGS

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

WARNING

CLEANING AND INSPECTION

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

Clean and inspect components carefully before assembling the differential.

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

1. Have required tools, solvents, lint free cloths, rags and other items at hand. Verify tools and instruments have current calibration.

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

2. Read accompanying reports.

3. Clean all surfaces of grease, oil and dirt using appropriate cleaning solutions or solvents to remove contaminants. Rinse components after cleaning. Use cleaning methods in keeping with materials used and surface finishes.

3. Do not heat standard product bearings, gears, or steel sleeves above 120°C (250°F). If bearings, gears, or steel sleeves are heated above this temperature, the metallurgical structure may soften, rendering them unsuitable for use.

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

4. Heat and cool bearing components gradually.

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

WARNING

BEARING INDUCTION HEATER

Hazardous liquids and materials are used. Read and understand MSDS/PSDS literature.

WARNING

5. Protect machined surfaces from damage.

Only workers trained in the correct use of induction heaters may use them. Workers with pacemakers must not use induction heaters or come within 4m/15 ft of an induction heater.

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

7. Inspect all port and hole geometry and dimensions.

8. Clear recesses and holes with compressed air.

BEARING INSTALLATION INSTRUCTIONS

Induction heat is used to expand bearings, sleeves, and gears to provide the tightest fit possible between the bearing and the surface it is mounted to during assembly.

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:

Induction heating uses high current AC electricity to generate strong magnetic fields which heat an object from within. Magnetic fields are capable of disrupting or damaging electrical instruments. Observe industry standards for electrical hazards and magnetic field hazards.

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

2. Leave bearings in packages until ready for assembly.

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

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

5. Allow sufficient time for bearings to fully heat and cool. Larger bearings, take more time to heat up and cool down.

3.3

Assembly

Tigercat Differentials

COOLING BEARINGS

DIFFERENTIAL CASE ASSEMBLE THE FLANGE

WARNING

1. Lightly scuff the bonding surfaces of the flange and manifold sleeve using 120 grit emery cloth.

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

Cooling shrinks components and/or bearings and sleeves to allow them to be fitted to machine features to provide the tightest fit possible between mating surfaces.

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

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

C00043

2. Wipe the flange and manifold sleeve with an appropriate solvent and a clean rag to remove any grease, grit or oil residue.

3. Dry the flange case thoroughly. See, COMPRESSED AIR on page 1.5.

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

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

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

PRIOR TO ASSEMBLY Prior to assembling the differential: 1. Have all required parts readily available.

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

C00044

3. Verify part numbers, dimensions and orientation of parts to be assembled or replaced.

4. Press fit a bearing cone onto the flange case using tool B8211000 to seat the bearing completely.

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

If the tool is unavailable, use the inner race of the removed bearing to seat the bearing. a. Orient the bearing cone with the larger outer diameter towards the diff-lock case. b. Verify the bearing is seated using a 0.038 mm (0.0015 in) feeler gauge. c.

3.4

Protect bearings from contaminants by covering with a clean cloth or barrier.

Tigercat Differentials

Assembly

CAUTION Loctite products present conditions for eye, skin and lung irritation. Product vapours may be harmful and are highly fla mmable. Products may adhere skin and objects together. Follow MSDS conditions and reco mmendations for handling and using Loctite products.

C00047

7.

Press the manifold sleeve evenly onto the flange using sleeve press tool 53658B. The press must be centred and straight. Allow 5 minutes for the Loctite to start to cure.

A

C00045

A Flange Sleeve Location

5. Apply a thin, even coat of Loctite 648 to the entire manifold sleeve location on the flange. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.12. Unprotected fingers in illustrations show surface location only.

C00048

8. Blow out any debris and excess Loctite from the set screw hole and the side oil holes using compressed air.

9. Wipe away any excess Loctite that may emerge.

C00046

6. Apply a thin, even coat of Loctite 648 onto the entire inner surface of the manifold sleeve as shown.

C00049

10. Apply a thin, even coat of Loctite 648 to the set screw and install the set screw into the oil hole until it bottoms out in tapped hole.

3.5

Assembly

Tigercat Differentials

11. Wait a minimum of 12 hours for the Loctite to fully cure before applying hydraulic pressure to the differential lock.

C

E D

A

B

C00723

Press Piston In Place

C00050

A

B

E C00164

A B C D E

C

C00168

D

Tap Piston In Place

Inner O-ring Inner Backup Ring (Nearest Machined Surface) Outer O-ring Machined Surface of Piston Outer Backup Ring (Nearest Machined Surface)

14. Install the piston evenly into the flange using a press. If a press is unavailable, install the piston evenly into the flange, then carefully tap around the perimeter of the piston using a soft hammer or mallet to seat the piston.

12. Install the O-rings and backup rings on the differential lock piston. The thin inner and outer backup rings are installed nearest the machined surface. The thicker inner and outer O-rings are installed furthest from the machined surface.

15. Inspect the O-rings for damage. If damaged replace.

NOTICE Do not pinch square O-rings in the flange.

13. Lubricate the inner and outer surfaces of the piston groove on the flange and seals using oil. Do not use grease.

3.6

Tigercat Differentials

Assembly

DIFFERENTIAL LOCK MANIFOLD

7. Wipe away any excess Loctite that may emerge.

EXPANDER PLUGS

C00101

8. Install the retaining rings in the grooves in the manifold.

C00096

A

1. Clean manifold with alcohol and a clean rag to remove any grease or oil residue. See. CLEAN AND INSPECT on page 1.11.

2. Clean the cartridge using warm soapy water to remove surface contaminants or nitrite deposits.

3. Install the large and small expander plugs with a pop rivet gun.

LOW AND HIGH PRESSURE SEALS 1. Clean both seals with alcohol and a clean rag to remove any grease or oil residue.

B

2. Clean the seals and cartridge using warm soapy water to remove surface contaminants or nitrite deposits.

3. Scuff the bonding surfaces of each part lightly, using a strip of 120 grit emery clot.

4. Dry the surface with a clean rag.

C00239

5. Apply a thin, even coat of Loctite 648 to the outer circumference of the seals as well as the inner surface of the manifold.

A There Must Be a Gap to Allow Fluid Transfer.

B Arrow Represents Path of Fluid Transfer.

9. Visually check that there is a gap between the inside of the seals and the diff-lock manifold.

10. Clear oil passages of residual Loctite using compressed air.

11. Wait a minimum of 12 hours before applying hydraulic pressure to the differential lock to allow the Loctite to fully cure.

C00098

6. Press the seals into the manifold using tools B7785000 and 51482B. 3.7

Assembly

Tigercat Differentials

INSTALL SEALS IN SEAL RETAINING CARTRIDGE

8. Install the expander plug (high pressure rivet) into the cartridge as required. The expander plug must be flush with the surface of the retainer before applying pressure.

1. Lightly scuff the outer bonding circumference surfaces of each part using a strip of 120 grit emery cloth.

A

2. Clean the cartridge, oil seal, and grease seal with alcohol or suitable degreaser and a clean rag to remove any grit, grease or oil residue.

B

3. Dry the surface with a clean rag and compressed air.

4. Apply a thin, even coat of Loctite 648 to the outer circumference of the oil seal, grease seal, and the inner surfaces of the pinion seal.

F

A

A B C D E F

B F

C D

A B C D E F

O-ring Thrust Washer Grease Seal Oil Seal Press Tool 51480B Direction of Press

Grease Nipple Expander Plug Grease Fitting Fitting Cap Remote Lube Seal Retainer Cartridge Standard Lube Seal Retainer Cartridge

10. Install the appropriate grease fitting, either a grease nipple in a standard grease cartridge, or a grease connector in a remote grease cartridge.

5. Press the grease and oil seals into the cartridge using tool 51480B. 6. Press the thrust washer into the cartridge using tool A8764000.

7. Clear the grease channel of residual Loctite using compressed air.

A

C00179

D C

9. Clean the bonding surfaces with alcohol or suitable degreaser and a clean rag to remove any grit, grease or oil residue.

E

C00178

E

C00725

B

A Differential Case B Tapered Bearing Cone

3.8

Tigercat Differentials

Assembly

DIFFERENTIAL CASE HOUSING

ASSEMBLE A DIFF-LOCK HOUSING

1. Remove two bolts securing the cap case to the difflock case housing, if present.

2. Wipe the cap case and the diff-lock case housing with an appropriate solvent and a clean rag to remove any grease, grit or oil residue. See, CLEAN AND INSPECT on page 1.11.

3. Dry the case cap and the diff-lock case housing, thoroughly. See, COMPRESSED AIR on page 1.5.

A

C00635

1. Place the diff-lock housing, flange down, on the work surface.

B

2. Wipe surfaces clean using isopropyl alcohol and clean rags. Verify there are no particles in the interior of the housing.

3. Grease the bottom of the diff-lock housing.

C00042

A Differential Case B Tapered Bearing Cone

FOUR SPIDER GEAR WASHER CONFIGURATION

4. Press fit a bearing cone onto the case cap using tool B8211000 to seat the bearing completely.

A

If the tool is unavailable, use the inner race of the removed bearing to seat the bearing. a. Orient the bearing cone with the larger outer diameter towards the diff-lock case.

B

b. Verify the bearing is seated using feeler gauges. c.

Cover bearings with a clean cloth or barrier to protect from contaminants.

C

DIFF-LOCK HOUSING CONFIGURATIONS The diff-lock (differential lock) housing contains the spider gear components and one of three configurations of spider gear washers: a four washer without tabs configuration, a four washer with tabs configuration, or a two washer without tabs configuration. Tigercat recommends using the two spider gear washer configuration based on improved performance data.

C00053

A Spider B Spider Gear C Spider Gear Washer

4. Record the lot/serial numbers from the side gear and spider gear and store this information for future use.

5. Grease the bore and spherical face of the spider gears and thrust washers.

Refer to, SPIDER WASHER CONFIGURATIONS on page 2.13.

6. Install the spider gears onto the spider, then install the spider gear washers onto the spider gears.

The convex side of the gears and washers face outwards.

Contact the Tigercat Service Department for information regarding spider gear washer configurations.

3.9

Assembly

Tigercat Differentials A

A

B

B

C00619

A Side Gear B Spider Gear Components

C00618

A Spider Gear Components B Diff-Lock Housing

8. Grease the side gear and install onto the spider gear components.

NOTICE

A

Do not pin or crush the tabs of the thrust washers between the gears and the diff-lock case. Pinned or crushed washers may prevent the gears from turning.

A

B C00620

A Thrust Washer C D

9. Grease the thrust face of the side gear and install thrust washer on top of the side gear.

10. Grease the top of the thrust washer.

C00617

A B C D

Spider Gear Assembly Thrust Washer Diff-lock Housing Notch

7. Seat the spider gear components onto the diff-lock housing. The tabs on the thrust washers must be aligned with the notches in the diff-lock housing.

3.10

Tigercat Differentials

Assembly

TWO SPIDER GEAR WASHER CONFIGURATION The two spider gear washer configuration uses two hemispherical pieces positioned between the spider gears and the assembled diff-lock housing/differential case cover.

5. Seat the spider gear washer in the housing by tapping firmly, using a deadblow mallet, on the spider where each spider shaft meets the centre ring of the spider.

A

B

C00744

Spider Gear Washer

1. Clean parts using isopropyl alcohol and allow to dry.

Parts must be free of grease and particulates.

C00679

2. Do not grease the outer surface of the spider gear washers. Do not grease the inner surfaces of the differential case cover, or the diff-lock housing.

C

A Feeler Gauge B Thrust Washer C Diff-Lock Housing

6. Verify the gap between the top outer edge of the spider gear washer and the top inner edge of the housing does not exceed 0.05 mm (0.002 in).

VERIFY FIT

a. Use a feeler gauge, in four locations located 90° apart to measure the gap. b. If the gap exceeds the recommended value, contact the Tigercat Service Department.

A

C C

B

A

B C00687

A Spider Gear Washer B Spider C Diff-Lock Housing

C00680

A Feeler Gauge B Diff-Lock Housing C Spider Gear Washer

3. Install a spider gear washer into the diff-lock housing.

4. Align the spider gear washer in the diff-lock housing, then lay the gear spider on top of the washer.

3.11

Assembly

Tigercat Differentials

7. Verify the gap between the bottom edge of the spider gear washer and the thrust washer shoulder in the diff-lock housing. Follow the gap criteria in step 6.

A

A D

B

C

C

B

C00681

A B C D

C00688

A Differential Case Cover B Spider Gear Washer C Spider

8. Install a spider gear washer into the differential case cover. Use the gear spider to align and seat the spider gear washer in the housing.

Dead Blow Mallet Spider Gear With Grease Spider Thrust Washer

11. Install the spider gears onto the spider, with the convex side of the gears facing outwards.

12. Install the spider gear components into the difflock housing, then seat the components using the deadblow mallet as in step 5.

9. Verify the gap between the spider gear washer and the cover does not exceed 0.05 mm (0.002 in), in four locations located 90° apart. If the gap exceeds the recommended value replace the housing. If the gap still exceeds the recommended value, contact the Tigercat Service Department.

10. Grease the bore and spherical face of the spider gears.

3.12

Tigercat Differentials

Assembly DIFFERENTIAL CASE COVER TO THE DIFF-LOCK HOUSING

A E

1. Install the differential case cover onto the assembled spider gear components seated in the diff-lock housing.

D

A

C

E

B

Side Gear Spider Differential Case Cover Spider Gear Washer Thrust Washer

13. Install a side gear on top of the spider gear components.

A B C D E C00055 inverted

14. Apply assembly grease to the top of the side gear.

C

D

C00592

C00681

A B C D E

B

4 Thrust Washer Configuration Shown

Differential Case Cover Spring Pin Diff-Lock Housing Thrust Washer Tab on Each Side of Thrust Washer

2. Align the spring pin in the differential case cover with the alignment hole in the diff-lock housing.

3. Orient the washers so the chamfered edge faces the head of the differential case cover *bolts, as shown.

15. Install a side gear thrust washer on top of the side gear.

16. Apply white assembly grease to the top of the side gear thrust washer.

A

17. Turn the differential case cover so the flange faces down. If the thrust washer falls out of the cover, place the thrust washer over the posts of the gear spider in the diff-lock.

B

18. Lift the differential case cover onto the diff-lock housing.

C

C00056

A *Bolt B Chamfer on Washer C Washer See, FASTENER TORQUE AND REUSE on page * INSPECT. 3.13.

3.13

Assembly

Tigercat Differentials

A

C00683

C00745

4. Apply Loctite Primer 7649 and Loctite 262 threadlocker to the *bolts and bolt holes, then torque the *bolts following a star-pattern torque sequence, to: a. For B17/F17/B20, 312 N-m (230 lbf-ft) b. For B15, 203 N-m (150 lbf-ft) A

A Diff-Lock Housing B Diff-Lock Side Gear C Grease

FOR TWO SPIDER GEAR WASHER CONFIGURATION 5. Inspect for gaps greater than 0.0127 mm (0.0005 in) between the split faces of the assembled differential case using a feeler gauge. If there is a gap greater than that, contact the Tigercat Service Department.

6. Turn the assembled components over.

B

C

D C00591

A B C D

*

*Bolt Washer Differential Case Cover Diff-Lock Housing INSPECT. See, FASTENER TORQUE AND REUSE on page 3.14.

3.14

Tigercat Differentials

Assembly

ASSEMBLE DIFFERENTIAL LOCK A

4. Install the flange/piston on top of the diff-lock housing.

A

B

C

B

A

C00622

A Diff-Lock Housing B Diff-Lock Side Gear C Grease Surfaces

C00131

1. Place the diff-lock side gear, splines up, onto the spider gears visible through the opening in diff-lock housing.

2. Grease the top of the diff-lock side gear and the bottom surface of the inside of the diff-lock housing.

A Location of M8 Lifting Rings B Paint Mark

5. Insert two M8 lifting rings on opposing sides of the flange/piston assembly and hand tighten. Do not apply Loctite or torque these bolts.

6. Test the breakaway torque of the differential lock plates using tool A7508000 or A7604000.

NOTICE

NOTICE

Align the reaction plates and friction plates so there is a channel for oil to travel through.

A

Verify the breakaway torque is less than 34 N-m (25 lbf-ft).

7. Turn the assembled flange piston/differential case over.

B

C

C00058

A Side Gear Thrust Washer B Reaction Plate Oil Path C Friction Plate Oil Path

3. Install the reaction and friction plates (collectively known as diff-lock plates or diff-lock clutch pack). a. Apply gear oil between each plate. b. Alternate between reaction and friction plates, starting with a reaction plate. c.

Align the friction and reaction plates to provide a clear channel for oil passage.

3.15

Assembly

Tigercat Differentials

INSTALL SPIRAL BEVEL GEAR

9. If any space is present remove, then reinstall the gear. Repeat step 4 to step 12. See, REMOVE SPIRAL BEVEL GEAR on page 2.12.

WARNING

NOTICE

The spiral bevel gear is hot. Wear PPE and lift the gear carefully.

NOTICE Verify the serial numbers of the pinion gear and the spiral bevel ring gear match.

1. Verify pinion and spiral bevel gear part numbers and serial numbers. Parts must be part number and serial number matched.

The spiral bevel gear must cool to room temperature before proceeding 10. Turn the assembly over and remove four bolts used to align the spiral bevel gear once it has cooled to room temperature. If the gear moves or does not remain on the housing, contact the Tigercat Service Department.

A

2. Clean the spiral bevel gear with an appropriate cleanser prior to inspection and installation.

B

3. Visually inspect each tooth of the spiral bevel gear for nicks, cracks, chips, or any other defects.

If a defect is found, contact the Tigercat Service Department.

C C00056

A

A *Bolt B Chamfer on Washer C Washer

A F E B B

C00129

Insert Bolts (Shown Without Lifting Rings for Clarity)

A Spiral Bevel Gear B M16 Bolts (Four Equally Spaced)

D

4. Heat the spiral bevel gear. See, HEATING BEARINGS on page 3.3.

5. Carefully lower the gear onto the differential case.

C00540

C

Torque Bolts With Fixture (Without Lifting Rings)

6. Install and hand tighten four bolts on the differential case to align the gear as shown.

A M8 x 1.25 in Lifting Ring B Torque Wrench C Diff-Case Torque Fixture B20-B7862000, B15-B7711000, B17/F17- B7437000 D Diff-Lock Case E *Bolt E Washer

7. Cool the spiral bevel gear to room temperature.

8. Verify the spiral bevel gear is seated using a 0.38 mm (0.015 in) feeler gauge. If there is a gap, remove the spiral bevel gear and repeat steps 1 – 5.

* 3.16

INSPECT. See, FASTENER TORQUE AND REUSE on page 3.16.

Tigercat Differentials

Assembly

11. Apply Loctite Primer 7649 and Loctite 262 threadlocker to *bolts and bolt holes used to secure the diff-lock case. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.12. Do not get primer or thread locker in the M8 threaded holes.

12. Install M8 x 1.25 lifting rings in two holes opposite each other. See illustration C00131.

13. Place the assembly in the diff-case torque fixture if available, using a lifting device. See, REQUIRED TOOLS AND MATERIALS on page 1.8.

1

14. For B15, B17and F17 spiral bevel gears, install and torque 16 *bolts to 81 N-m (60 lbf-ft.) using the 16 bolt torque pattern for B15 and B17.

15. For the B20 B20 spiral bevel gear install and torque 20 bolts to 81 N-m (60 lbf-ft.) using the 20 bolt torque pattern.

16. Torque *bolts using the same torque pattern to 312 N-m (230 lbf-ft). After each bolt is torqued, mark the top with a paint marker.

A

9

16

5 0°

8

12

11°15'

13

22°30'

3

292.5°

A

112.5°

4

11 14

A Location of M8 Lifting Rings B Paint Mark

7

202.5°

If diff-case torque fixture is unavailable,

6

17. Secure the diff-lock case:

15 10

C00131

a. Install the diff-lock assembly into the differential with the pinion installed. Orient the differential on the side with the diff-lock facing up.

2

C00427

16 Bolt Torque Pattern

12 20

1

13

0°

A

5 17

18° 9°

8 16

9 3

288° 108°

4

C00579

15

Torque *Bolts Without Fixture, Differential Shown With Pinion Installed

A Torque Wrench B Extension Bar with M30 Socket

7

10 198°

18 6 C00426

B

14

*

19 2

11

INSPECT. See, FASTENER TORQUE AND REUSE on page 3.17.

b. Remove M8 lifting rings. c.

20 Bolt Torque Pattern

3.17

Hold the pinion nut stationary using an extension bar and M30 socket while torquing the *bolts with washers.

Assembly

Tigercat Differentials

DIFFERENTIAL HOUSING INSTALL THE BLEEDER AND MAGNETIC PLUG Verify there is an O-ring on the magnetic drain plug and the plug is free of dirt.

NOTICE The magnetic drain plug and bleeder screws are brass. Do not over-torque the parts.

ASSEMBLE DIFFERENTIAL SLEEVE (OSCILLATING DIFFERENTIAL ONLY) To install an oscillating differential sleeve follow these steps.

For a fixed differential, proceed to SET PINION MOUNTING DISTANCE on page 3.19.

1. Heat the sleeve. See, HEATING BEARINGS on page 3.3.

C00170

1. Install and finger tighten the magnetic drain plug into the housing.

2. Tighten the magnetic drain plug using a wrench, and torque to 67 N-m (50 lbf-ft).

C00171

1. Slide the sleeve onto the housing. Verify the sleeve sits flush with the seat on the housing for a proper fit.

2. Allow the sleeve to cool.

A

B C00064

A Housing B Bleeder Screw Components

3. Install and finger tighten the bleeder insert and insert seat in the housing.

4. Torque the bleeder screw to 27 N-m (20 lbf-ft).

NOTICE Orient the seat with the chamfer on the seat facing the bleeder insert.

3.18

Tigercat Differentials

Assembly INSTALL PINION BEARINGS

SET PINION MOUNTING DISTANCE

NOTICE

WARNING

Verify the serial numbers of the pinion gear and the spiral bevel ring gear match.

Nitrogen or freezer cooled parts can damage unprotected skin. Wear appropriate PPE. Only properly trained workers may use liquid nitrogen.

WARNING

1. Calculate the thickness of the shims required using the formula found in APPENDIX A - SHIM PACK CALCULATION, PINION MOUNT on page 4.3.

Wear appropriate PPE when handling components that will or have been heated or chilled.

A

1. Heat the bearing cone. See, HEATING BEARINGS on page 3.3.

2. Cool the pinion using liquid nitrogen or in a freezer overnight.

A

B C00235

A Housing B Shim Pack

2. Install the shim pack from the inside of the housing prior to installing the bearing cup.

3. Cool the pinion bearing cups using liquid nitrogen or place parts in a freezer over-night.

B

A C00201

B

C00172

A Housing B Bearing Cone

A Pinion B Bearing Cone

3. Place the heated bearing cone onto the pinion.

See, BEARING INSTALLATION INSTRUCTIONS on page 3.3.

4. Insert the cooled pinion bearing cups into the housing so the shims and bearing cups are fully seated against the housing. Tap the perimeter of the bearing cup in a star shaped pattern to fully seat the bearing cone and the shims.

5. Allow cups to warm to room temperature before proceeding.

3.19

Assembly

Tigercat Differentials

A

B

C

C00173

D E

6. Insert the pinion/bearing cone into the housing from the inside and support it using a bottle jack to seat the bearing firmly in the cup.

D C00539

A Press B Pinion Bearing Press Fit Tool-B8213000 (B20) B8212000 (B15, B17, F17) C Bearing Cone D Pinion E NO GAP. Bearing Must Be Fully Seated.

4. Press the bearing into position. a. Orient the bearing cone with the larger diameter towards the pinion gear. b. Maintain the force applied to seat the bearing until the bearing has returned to room temperature. c.

Verify the bearing is seated using a background light. There must not be any light showing between the bearing and the pinion bearing shoulder.

C00174

7. Heat the second bearing cone and install it onto the pinion. See, HEATING BEARINGS on page 3.3.

d. Protect bearings from contaminants by covering with a clean cloth or barrier.

5. Grease the bearing cup in the housing lightly with assembly grease.

3.20

Tigercat Differentials

Assembly

PINION BEARING PRELOAD AND ROLLING TORQUE TEST

9. Install the driver spacer tool A7621000 on the pinion.

The pinion threads must not be exposed when the pinion is shocked or they will be damaged.

1. Install the yoke on the pinion.

2. Apply a light coat of extra pressure assembly grease or equivalent to the contact surface on top of the yoke.

10. Install the pinion nut and hand tighten against the driver spacer tool.

3. Install a bronze washer onto the yoke.

4. Apply a light coat of extra pressure assembly grease or equivalent to the top of the bronze washer.

A

5. Install the pinion nut, then torque to 1365 N-m (1000 lbf-ft), using a torque multiplier, while the bearing is hot.

B

a. Carefully inspect the 30 mm pinion nut. See, 30MM PINION NUT WEAR CONDITION on page 2.10.

C

b. Verify the pinion is locked and that it does not rotate freely. No free play is permitted with the yoke. c.

C00197

A Pinion Nut Spacer B Yoke C Pinion Nut

Use torque tools: 54934B (6C yoke), 52720B (7C yoke), or B7866000 (8.5C yoke).

6. Allow the second bearing to cool to room temperature before proceeding to the next step.

7. Retorque the bearing to 1365 N-m (1000 lbf ft), using a torque multiplier, when the bearing has cooled.

A B C00189

11. Shock the pinion by striking the end of the spacer tool with a hammer so the pinion moves freely.

C D

C00577

A Pinion Nut B Yoke C Torque Multiplier Wrench D Block to Support Yoke

8. Remove the pinion nut and bronze washer from the pinion. Discard the bronze washer.

NOTICE Use additional pinion nut spacers if the driver spacer tool is not available. Do not damage the threads on the pinion.

C00175

12. Rotate the pinion 10 – 15 turns in both directions to verify the pinion turns freely with a rolling torque of approximately 0 in-lb.

13. Remove the pinion nut and driver spacer tool. Clean any grease from the nut and apply fresh extra pressure assembly grease or equivalent.

3.21

Assembly

Tigercat Differentials 16. Measure the rolling torque and record the value. The target rolling torque value is between 1.1 N-m (10 in-lb) and 4.5 N-m (40 in-lb).

A

NOTICE If adjustment is necessary, shock the pinion so the rolling torque is 0 in-lb before proceeding to install a different pinion nut spacer. If the adjustment is made without shocking the pinion, the measurement may be inaccurate

C00177

A

Pinion Spacer

17. Repeat step 8 – 16 to adjust spacer thickness as required to achieve the desired rolling torque value.

Thicker spacers decrease rolling torque. Thinner spacers increase rolling torque.

NOTICE The rolling torque must measure between 1.75-70.0 N-m (10-40 lb-in.)

E

18. Measure the final rolling torque and record for future use.

A

B C

D

C00762

A B C D E

B20 One Pinion Spacer Configuration

Yoke O-ring O-ring Spacer M30 Nut Pinion Spacer

14. Install a pinion nut spacer. Spacer selection varies depending upon the differential. Start the shim selection process by using: a. Select a 3.56 mm (0.140 in) thick shim as a starting thickness for a B15 differential. b. Select a 3.86 mm (0.152 in) thick shim as a starting thickness for a B17 differential. c.

Select a 3.91 mm (0.154 in) thick shim as a starting thickness for a B20 differential.

15. Install and torque the pinion nut to 1356 N-m (1000 lbf-ft).

3.22

Tigercat Differentials

Assembly

SEAL RETAINER CARTRIDGE 1. Remove the pinion nut, pinion nut spacer and yoke.

NOTICE

6. Install a lightly greased bronze washer and thread the pinion nut onto the end of the pinion, then tighten the nut to seat the seal retainer cartridge in the housing.

7. Remove the pinion nut and bronze washer.

Shims may adhere to the yoke and/or fall from the differential housing. Verify shims are accounted for and installed correctly.

2. Lightly grease the seal retainer cartridge housing seat in the differential housing.

WITHOUT SEAL CARTRIDGE DRIVER TOOL 8. Orient the seal retainer cartridge with the grease fitting in the clearance gap in the differential housing.

Align the cartridge as evenly as possible with the opening, then tap the seal into place using a ha mmer and wooden block to protect the cartridge.

WITH SEAL CARTRIDGE DRIVER TOOL A

B

C00729

C00730

A Seal Retainer Cartridge B MD3 Computer and Display

3. Apply assembly grease to O-ring on seal retainer cartridge.

4. Place the assembled seal retainer cartridge on the work surface with the manufacturer's serial number and part information facing up, then insert the seal cartridge driver tool B9082000 into the cartridge.

A

C00078

9. Apply white grease to the V-ring and install the V-ring onto the yoke. Note the orientation of the V-ring.

A

B

E

C

B

C

D

D C00180

A B C D E

C00730

A B C D

Seal Retainer Cartridge Assembly Grease on O-ring Gap in Pinion Housing Grease Fitting

5. Align the seal cartridge tool/cartridge onto the pinion spline. The grease nipple/threaded grease fitting hole must align with the clearance gap in the housing.

Pinion O-ring O-ring Spacer Pinion Nut Spacer Yoke

10. Clean the yoke and nut with alcohol and a clean rag to remove any particulates, grease or oil residue.

3.23

Assembly

Tigercat Differentials

11. Install the yoke, O-ring, O-ring spacer, pinion nut spacer and 30 mm nut onto the pinion. Apply a light coat of extra pressure assembly grease or equivalent to the contact surface of the pinion nut 12. Apply Loctite Primer 7649 and Loctite 262 threadlocker to pinion threads and pinion nut, then install and torque the pinion nut to 1365 N-m (1000 lbf ft) using a torque multiplier. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.12.

B-BARREL DIFFERENTIAL NOTICE Do not cross thread the adjustment nut.

1. Install the adjustment nut: a. Thread the adjustment nut from outside of the non-retainer side of the differential housing until it bottoms out in the threaded hole. b. Turn the adjustment nut back two complete turns.

A

C00138

B17 and B20 Differential Cases

Lower the differential case straight down.

4. Lift, then lower the differential case into the differential housing.

B

C

C00181

A Bearing Cup B Adjustment Nut C Inside of Differential Casting

2. Install the bearing cup to the inside bearing seat of the non-retainer side of the differential housing. Tap the bearing until fully seated.

NOTICE The B17 and B20 differential case assemblies lift straight up and out of the housing. B15 assemblies must be tilted to clear the pinion gear.

C00143

B15 differential case shown with differential case

Tilt the top edge of the differential case toward the pinion to provide additional clearance between the outside diameter of the crown gear and the housing.

3. Install M8-2.0 lifting rings in opposing open bolt holes on the top of the differential assembly.

3.24

Tigercat Differentials NOTICE If there is an X marked on the pinion, and two marked on the gear, verify the marked tooth on the pinion is aligned between the two marks on the gear.

Assembly F-FLANGE DIFFERENTIAL 1. Arrange adjustment nuts, bearing cups and the differential on a lift rod. The lifting mechanisms may vary. Use a robust rod with secure fittings to lift the components.

C00208 C00082

2. Lower the components and differential case onto the flange housing.

3. Align the pinion to the gear. If there is an X marked on the pinion, and two marked on the gear, verify the mark on the pinion is aligned between the two marks on the gear. See, B-BARREL DIFFERENTIAL on page 3.30.

A

C00083

5. Install the retainer onto the flange assembly.

6. Apply Loctite Primer 7649 and Loctite 262 threadlocker, then install and torque the retaining bolts to 27 N-m (20 lbf-ft).

B C00182

A Bearing Cup B Adjustment Nut

4. Place and secure the flange end of the differential case in the differential housing. Fit the bearing cup into the housing so it is clear of the adjustment nut threads.

5. Install the housing clamps on the assembly.

3.25

Assembly 6. Apply Loctite Primer 7649 and Loctite 262 threadlocker to each bolt and bolt hole.

Install each bolt finger tight, then torque the housing clamp bolts to 533 N-m (393 lbf-ft) to secure the clamp. See,REQUIRED TOOLS AND MATERIALS on page 1.8.

Tigercat Differentials

DIFFERENTIAL CASE/HOUSING SETUP SET INITIAL BACKLASH

7. Align and thread the adjustment nut into the housing clamps. The adjustment nut must move freely, without interference.

8. Fit the bearing cup on the other end of the differential case into the housing so it is clear of the adjustment nut threads in the housing.

9. Install the housing clamps on the assembly.

10. Apply Loctite Primer 7649 and Loctite 262 threadlocker to each bolt and bolt hole. Install each bolt finger tight, then torque the housing clamp bolts to 533 N-m (393 lbf-ft) to secure the clamp.

See,THREAD LOCKER AND PRIMER PRODUCTS on page 1.12.

C00643

Output Axis Horizontal

1. Position the differential with output axis horizontal to the work surface.

2. Torque adjustment nut to 135 N-m (100 ft-lb) to remove output bearing endplay using Adjustment Nut Torque tool, 53908B. A C

B

C00746

Output Axis Horizontal

3. Install backlash tool to the yoke using two bolts.

• 6C Tool: A7510000 • 7C Tool: A7510001 • 8.5C Tool: A7510002 If the tool is not available, install two bolts into diagonally opposed holes. Leave a gap between the bolt head and yoke to insert the measuring rod of the dial indicator onto the bolt shank. See, Backlash Measurement on page 3.28.

3.26

Tigercat Differentials

Assembly

MEASURE RUNOUT

4. Attach the dial indicator to housing and set measurement rod perpendicular to the measuring surface.

5. Lock the spiral bevel gear from rotating using a pry bar.

A

6. Set the dial indicator to zero (0). This is the starting point of the measurement.

B

7. Manually turn the yoke forward, then back and record the amount of backlash (movement/clearance between the teeth on the bevel gear and the teeth on the pinion). When the yoke is turned back the dial indicator must read zero (0). If the indicator does not read zero (0) repeat the step.

C

8. Tighten and loosen the adjustment nut, using tool 53908B to increase and decrease the backlash, to be within the upper range of the settings specified in the, BACKLASH RANGE CHART on page 3.29.

SEAT OUTPUT BEARINGS C00204

A

F17 Runout Measurement

A Spiral Bevel Gear B Back Face of Gear C Measurement Rod B

A

B

C

C C00645

B15, B17, B20 Backlash Measurement

A Torque Multiplier B Crown Nut Attachment Tool C Differential Housing

C00190

B15, B17, B20 Runout Measurement (View Rotated 90°)

A Dial Indicator B Measurement Rod C Back Face of Spiral Bevel Gear (hidden)

1. Rotate the housing so the output axis is vertical.

2. Tighten the adjustment nut to 340-678 N-m (250-500 lbf-ft) using the crown nut attachment tool, to seat the bearings. See, REQUIRED TOOLS AND MATERIALS on page 1.8.

3. Loosen the adjustment nut.

4. Tighten the adjustment nut and torque to 41 N-m (30 lbf-ft) to set preload.

5. Spin the yoke forward and backwards and observe the adjustment nut. If the nut moves, continue to spin and tighten the adjustment nut to 41 N-m (30 lbf-ft) until it no longer moves.

Measure the runout on the spiral bevel gear: 1. Attach dial indicator to the housing and slide the measurement rod into the housing slot until it rests against the back face of the spiral bevel gear.

2. Turn the gear using the yoke and record the runout.

If the runout is over 0.15 mm (0.006 in) contact the Tigercat Service Department.

3.27

Assembly

Tigercat Differentials A

See, SET INITIAL BACKLASH on page 3.26 for details about backlash tool setup.

B

2. Mark one bolt with a coloured marker to assist in determining the number of rotations of the yoke.

3. Place a dial indicator on the top of the pinion sleeve of the differential housing.

4. Place the tip of the dial indicator measuring rod perpendicular to and centred on the highest point of the bolt shank in the gap between the bolt head and yoke.

C

5. Lock the spiral bevel gear from rotating using a pry bar.

C00596

Manifold Measurement

6. Set the dial indicator to zero (0). This is the starting point of the measurement.

A Dial Indicator B Measurement Rod C Manifold Sleeve

H

3. Attach the dial indicator to the housing and position the measurement rod on the manifold sleeve. Turn the yoke so the sleeve turns one full revolution and record the runout. If the runout is over 0.127 mm (0.005 in.), contact the Tigercat Service Department.

A

B G

MEASURE BACKLASH Position the differential with the output axis horizontal to the work surface.

BACKLASH MEASUREMENT E

F

D

E C00584

A B C D E F G H

C00582

A B C D E

C

B

C

D

Backlash Measurement

Dial Indicator Base Housing Yoke Bolt Alternate Colour Marking to Differentiate Yoke Rotation 540° of Rotation for Each of 7 Readings Measuring Rod, Perpendicular to Centreline of Bolts Dial Indicator

7. Manually turn the yoke forward, then back and record the amount of backlash (clearance between the teeth on the bevel gear and the teeth on the pinion). When the yoke is turned back the dial indicator must read zero (0). If the indicator does not read zero (0) repeat the step.

A

Backlash Measurement Gap

Housing Yoke Bolts Alignment Mark Gap

1. Install two bolts in the threaded holes of the yoke in opposing corners. Leave a gap between the bolt head and yoke to insert the measuring rod of the dial indicator onto the bolt shank.

8. Retract the tip of the measuring rod to clear the yoke when it is rotated, then reset the dial indicator to zero (0).

9. Rotate the yoke 540° (1 1/2 turns, 360°+180°), then record the backlash measurement.

3.28

Tigercat Differentials

Assembly

10. Repeat step 4 – 9, seven times in total. Record the backlash each time.

11. Fine tune the backlash by turning the adjustment nuts using tool 53908 to increase or decrease the back lash so the smallest value is within the specified backlash range chart.

Setting (S)

Variation (V)

B20-5.444:1 @ 8.5C YOKE

Differential

0.686-0.914 mm (0.027-0.036 in)

0.279 mm (0.011 in)

B17-5.429:1 @ 8.5C YOKE

0.787-1.067 mm (0.031-0.042 in)

0.305 mm (0.012 in)

B17-5.429:1 @ 7C YOKE

0.711-0.940 mm (0.028-0.037 in)

0.279 mm (0.011 in)

B17-5.125:1 @ 7C YOKE

0.660-0.889 mm (0.026-0.035 in)

0.254 mm (0.010 in)

B17-3.250:1 @ 8.5C YOKE

1.067-1.219 mm (0.042-0.048 in)

0.305 mm (0.012 in)

B17-3.250:1 @ 7C YOKE

0.940-1.092 mm (0.037-0.043 in)

0.279 mm (0.011 in)

B17-2.786:1 @ 8.5C YOKE

0.559-0.686 mm (0.022-0.027 in)

0.0254 mm (0.011 in)

B17-2.786:1 @ 7C YOKE

0.483-0.610 mm (0.019-0.024 in)

0.279 mm (0.009 in)

B17-2.714:1 @ 8.5C YOKE

0.914-1.041 mm (0.036-0.041 in)

0.229 mm (0.010 in)

B17-2.714:1 @ 7C YOKE

0.787-0.914 mm (0.031-0.036 in)

0.229 mm (0.009 in)

F17-3.250:1 @ HEEL

0.686 -0.406 mm (0.027-0.031 in)

0.203 mm (0.008 in)

F17-2.714:1 @ HEEL

0.686-0.406 mm (0.027-0.031 in)

0.203 mm (0.008 in)

F17-2.786:1 @ HEEL

0.406-0.508 mm (0.016-0.020 in)

0.203 mm (0.008 in)

B14.5-5.125:1 @ 7C YOKE

0.660-0.838 mm (0.026-0.033 in)

0.0254 mm (0.010 in)

B14.5-5.125:1 @ 6C YOKE

0.635-0.813 mm (0.025-0.032 in)

0.0254 mm (0.010 in)

B14.5-2.929:1 @ 8.5C YOKE

0.432-0.559 mm (0.017-0.022 in)

0.178 mm (0.007 in)

BACKLASH RANGE CHART

BACKLASH SETTING (S) = MINIMUM MEASUREMENT Backlash Setting value is the lowest measured value and must be within setting (S) range values listed in the Backlash Range Chart.

BACKLASH VARIATION (V) = MAXIMUM MEASUREMENT-MINIMUM MEASUREMENT The backlash variation must be equal to or less than the variation measurement in the Backlash Range Chart.

EXAMPLE 2: B14.5-2.929@8.5C YOKE Readings taken: 0.014, 0.019, 0.017, 0.019, 0.017, 0.018, 0.015.

S Min (from chart) = 0.014 in Not Acceptable Setting range from table = 0.017 – 0.022 in V Max– Min (from chart) = 0.019 – 0.015 = 0.004 in Acceptable Adjust backlash to bring setting within range.

EXAMPLE 1: B14.5-2.929@8.5C YOKE Measurements: 0.024, 0.021, 0.017, 0.024, 0.021, 0.028, 0.021 S Min (from chart) = 0.017 in Acceptable V Max– Min (from chart) = 0.028 – 0.017 = 0.011 in Not Acceptable Max Variation from table = 0.007 in.

Variation is out of range, contact the Tigercat Service Department.

3.29

Assembly

Tigercat Differentials

LOCK ADJUSTMENT NUTS

F-FLANGE DIFFERENTIAL

NOTICE Do not loosen the nut to align the locking mechanism. Tighten the nut only.

LOCKING TAB/BOLT Verify each locking mechanisms aligns with the respective adjustment nut. There are locking mechanisms on the lock nut and the rotary manifold.

A B C00639

C00087

A Rotary Manifold Locking Bolt B Differential Housing Adjustment Nut Lock

To align locking mechanisms tighten the adjustment nut only. Do not loosen the adjustment nut.

Apply Loctite Primer 7649 and Loctite 262 threadlocker to bolts with washers and bolt holes, then install and torque the bolt holding the adjustment nut lock onto the retainer to 27 N-m (20 lbf-ft) . See,THREAD LOCKER AND PRIMER PRODUCTS on page 1.12.

B-BARREL DIFFERENTIAL

C B

A

C00183

A Bolts B Adjustment Nut Lock E Adjustment Nut

1. Align the adjustment nut lock tabs with the adjustment nut and the openings in the differential housing.

2. Apply Loctite Primer 7649 and Loctite 262 threadlocker to bolts with washers and bolt holes, then install and torque the bolts holding the adjustment nut lock onto the retainer to 27 N-m (20 lbf-ft) . See,THREAD LOCKER AND PRIMER PRODUCTS on page 1.12.

3.30

Tigercat Differentials

Assembly

F17 DIFFERENTIAL BEAR G CAP MEASUREMENT

CONTACT PATTERN The contact pattern indicates how gear teeth are meshing. See, Appendices B and C in Section 4 for more information.

1. B15/B17/B20 ONLY: Remove the retaining bolts and lift the retainer, differential case and spiral bevel gear out of the differential housing. Use M8 lift rings for the retainer and M16 lift rings for the differential case.

d A

2. Paint three consecutive gear teeth on both the drive and coast sides of the spiral bevel gear using the gear marking compound.

d C00186

B

A Bolts d Dimension Across Diagonal Axis.

1. Measure diameter across bearing caps in two diagonal axes. Both measurements (D) must be between 422.15 mm-422.53 mm (16.620 – 16.635 in). If the measurement is outside this range, reduce torque to a minimum of 41 N-m (30 lbf-ft) to meet tolerance.

A

C00093

2. If the measurement is outside the specified range, after torque reduction, contact the Tigercat Service Department.

A Coast Side (concave) B Drive Side (convex)

3. Repeat step two by marking three teeth 180° away from the first three teeth.

4. Install the differential case, spiral bevel gear and retainer into the differential housing.

5. Install the bolts securing the retainer to the differential housing and torque them to 27 N-m (20 lbf-ft).

3.31

Assembly

Tigercat Differentials

RUN PATTERN TEST

11. B15/B17/B20 ONLY: Re-install the differential case, a. Remove two M8 lift rings. b. Apply Loctite Primer 7649 and Loctite 262 threadlocker to bolts with washers and bolt holes. See, COMPRESSED AIR on page 1.5. c.

Install the bolts with washers that replace the M16 lift rings and manually torque each to 312 N-m (230 lbf-ft).

C

A

C00207

6. Spin the yoke 50 revolutions forward, and 50 revolutions in reverse. Verify the adjustment nut is tight by periodically checking, using a torque wrench set to 40 N-m (30 lbf-ft).

7. B15/B17/B20 ONLY: Remove the retaining bolts and lift the retainer, differential case and spiral bevel gear out of the differential housing. Use M8 lift rings in the retainer.

8. Observe and record the contact pattern of both the drive, and coast sides of the gear,and the drive and coast sides of the pinion.

B C00579

A Torque Wrench B Extension Bar with M30 Socket C Bolts with Washers (replacing M16 lift rings)

12. Hold the pinion nut stationary using an extension bar and M30 socket while torquing the bolts with washers.

Use pictures to compare the wear pattern with the Tooth Contact Pattern requirements found in Appendix C. 9. Make any necessary adjustments to obtain a desired tooth contact pattern as directed in Appendix C.

13. After each bolt is torqued, mark the top with a paint marker.

A

B C00187

A Retainer B Retainer O-ring

10. B15/B17/B20 ONLY: Apply a coat of white assembly grease to the bottom half of the retainer, then install the retainer O-ring.

C00205

14. B15/B17/B20 ONLY: Attach M8– 1.25 lifting rings to the retainer, lift it and install onto the differential housing. Do not pin the O-ring.

15. B15/B17/B20 ONLY: Apply Loctite Primer 7649 and Loctite 262 threadlocker to bolts and bolt holes, then install and torque the bolts to 27 N-m (20 lbf-ft). See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.12.

3.32

Tigercat Differentials

Assembly

INSTALL MANIFOLD

16. Rotate the housing so the output axis is in the vertical position.

17. Spin the yoke 50 revolutions forward, and 50 revolutions in reverse. Torque the adjustment nuts with a torque wrench set to 41 N-m (30 lbf-ft).

18. Conduct the backlash measurement after this step to verify accuracy.

A

C00193

A Split Rings

1. Install two split rings on the sleeve of the differential case.

C00097

B

19. B15/B17/B20 ONLY: Install dowel pins on opposite sides of differential

A C00192

A Ejector Molding Marks B Retainer O-ring

a. Place the split rings with the injector molding marks facing towards each other.

A B

C00104

A O-rings B Manifold

2. Lubricate two manifold O-rings with gear oil, then install on the manifold.

3.33

Assembly

Tigercat Differentials

DIFFERENTIAL LOCK LEAK TEST A

D

The differential leak test may be completed one of two ways.

The low pressure test uses compressed air or oil at pressures no greater than 6.4 bar (100 psi).

The high pressure test uses compressed oil at pressures up to, but not exceeding 44 bar (635 psi).

C C00191

A B C D

NOTICE

B

Oil Passages Manifold Oil Passages Retainer Retainer Manifold

Do not exceed the recommended leak test pressures. Internal seals may be damaged.

LOW PRESSURE LEAK TEST

3. Install the manifold onto the housing, then align the oil passages on the manifold with the passages in the retainer.

4. Apply Loctite Primer 7649 and Loctite 262 threadlocker to bolts and holes, then install and torque the bolts to 27 N-m (20 lbf-ft). See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.12.

5. Lock the adjustment nut using the appropriate sized bolt inserted into one of the three available positions on the manifold. a. If required, tighten the adjustment nut to align to the next closest locking position. Tighten the adjustment nut clockwise, only. Do not loosen the adjustment nut.

1. Thread an M16 straight thread plug/fitting into the TANK port to seal it.

2. Attach a regulated airline or oil supply line to the PRESSURE port using an M14 straight thread O-ring fitting.

3. Charge the system to 6.4 bar (100 psi) maximum.

4. Monitor the pressure for five minutes and note any pressure drop, sounds of leaking air or oil leaks. If no leaks are found, the differential is ready for use.

HIGH PRESSURE LEAK TEST A

b. Apply Loctite Primer 7649 and Loctite 262 threadlocker to bolts and holes, then install and torque the bolts to 27 N-m (20 lbf-ft).

D

A C C00626 C00188

A B C D

A M8 locking bolt

3.34

To Pressure Port (P) To Tank Port (T) Clean Oil Container Manual/Electric Oil Pump to Produce 44 bar (635 psi)

B

Tigercat Differentials

Assembly

GREASE PINION

WARNING

1. Pump grease through the lube fitting in the seal retaining cartridge, while the yoke is being rotated, until grease purges around the yoke.

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

A

1. Thread a hose with an M16 straight thread fitting into the TANK port. Place the other end in a clean container.

2. Attach a hose with an M14 fitting to the PRESSURE port.

B

3. Attach the other end to a manual or electric hydraulic pump.

4. Charge the system to 44 bar (635 psi) maximum.

C

5. Monitor the pressure for 30 seconds and note any sudden pressure drop or oil leaks. If no leaks are found, the differential is ready for use.

C00077

During the high pressure test, the maximum allowable flow of oil that will pass to TANK is 2.84 lpm (0.75 gpm).

A Protective Cap B Grease Fitting C Seal Retainer Cartridge

2. Wipe excess grease from the front of the seal retaining cartridge.

C00206

NOTE: Remove the protective cap, then connect a grease nipple adaptor to the fitting. (2519A001 and AA006) when lubricating remote grease type cartridges.

BRAKES For information regarding brakes see, Axles SERVICE AND REPAIR Manual, 47731AENG.

3.35

Assembly

Tigercat Differentials

3.36

APPENDICES.......................................................................................................................................................4 APPENDICES .................................................................................................................................................... 4

Tigercat Differentials SECTION 4 – APPENDICES Read and understand the safety section in this manual prior to servicing any machine components.

ISSUE 4.0, AUGUST 2020

CONTENTS – SECTION 4 A

APPENDIX A - SHIM PACK CALCULATION, PINION MOUNT............................................................................... 4.3 APPENDIX B - TOOTH CONTACT PATTERN.......................................................................................................... 4.5 APPENDIX C - TOOTH CONTACT PATTERN IMAGES.......................................................................................... 4.8

C

CONTACT PATTERN PROFILE ERRORS AND CORRECTIVE ACTIONS............................................................ 4.7

G

GEAR TOOTH STRUCTURE..................................................................................................................................... 4.6

S

SPIRAL BEVEL GEAR SET TERMINOLOGY........................................................................................................... 4.5 BEVEL GEAR........................................................................................................................................................... 4.5 GEAR SETS.............................................................................................................................................................. 4.5 PINION GEAR.......................................................................................................................................................... 4.5

T

TOOTH CONTACT PATTERNS.................................................................................................................................. 4.6 BEVEL GEAR BACKLASH...................................................................................................................................... 4.6 PINION BACKLASH................................................................................................................................................. 4.6

Appendices

Tigercat Differentials

4.2

Tigercat Differentials

Appendices

APPENDIX A - SHIM PACK CALCULATION, PINION MOUNT A

C00109

Pinion Mounting Distance (MD) Vendor Applied on Bevel Gear B20, B17, F17 Example: 217.653 mm

B

C B

B C00585

Housing Dimension Locations, Vendor Applied A Differential Flange Housing B Stamped or Inscribed Housing Dimension C Differential Barrel Housing

A C00586

Pinion Mounting Distance (MD) Vendor Applied on Bevel Gear B20, B17, F17

A 15 inch Differential Pinion B Stamped or Inscribed Housing Dimension and Serial Number

C00108

Housing Dimension, Example

Example: 264.177 mm (10.041 in.)

C00110

Bearing Height Example: 0.464 mm (0.0183 in.)

4.3

Appendices

Tigercat Differentials

See example calculation.

EXAMPLE CALCULATION Example: 264.177 mm (10.041 in.) (Housing) Example: -217.653 mm (-8.569 in.) (Pinion MD) Example: - 46.060 mm (-1.813 in.) (Bearing Height) = 0.464 mm (0.0183 in.) (Calculated Shim Value) Shim Pack Used (value rounded down) 0.457 mm (0.018 in.)

This shim calculation is used in section, PINION BEARING PRELOAD AND ROLLING TORQUE TEST on page 3.21.

4.4

Tigercat Differentials

Appendices

APPENDIX B - TOOTH CONTACT PATTERNS

A right spiral bevel gear has gear teeth that turn clockwise from the toe of each gear tooth (inside gear radius) to the heel of each gear tooth (outside gear radius).

SPIRAL BEVEL GEAR SET TERMINOLOGY A

A left spiral bevel gear has gear teeth that turn counterclockwise from the toe of each gear tooth (inside gear radius) to the heel of each gear tooth (outside gear radius).

B

SPIRAL BEVEL PINION The spiral direction of a spiral pinion gear is described in the same manner as a bevel gear with left or right spiral directions.

D

SPIRAL BEVEL GEAR SETS

C

Spiral bevel gear sets consist of a gear and a pinion. If the bevel gear spiral direction is right, then the pinion gear spiral direction must be left. If the bevel gear spiral direction is left, the pinion gear spiral direction must be right.

The parts of a spiral bevel gear set are factory paired and marked with matching serial numbers, typically on the gear end of the pinion, and the outer shoulder of the bevel gear. Additional measurement values, etched into the gear parts adjacent the serial number, are used to calculate shim stack requirements. A matched gear set MUST remain together. They are not interchangeable with any other gear parts. See, APPENDIX A - SHIM PACK CALCULATION, PINION MOUNT on page 4.3 for a pictorial reference to serial number locations.

C00752

A B C D

Right Spiral Bevel Gear (Looking at Gear Face) Left Pinion Gear Right Pinion Gear Left Spiral Bevel Gear (Looking at Gear Face)

SPIRAL BEVEL GEAR The spiral direction of a bevel gear is described as left, (left-hand) or right, (right-hand), when looking at the gear face (tooth side of the gear).

A B

C C00756

A B C D

D

Pinion Gear Tooth Toe Tooth Heel Spiral Bevel Gear

4.5

Appendices

Tigercat Differentials

TOOTH CONTACT PATTERNS

GEAR BACKLASH To adjust gear backlash, turn the adjusting nuts to move the gear towards or away from the pinion axis. See, DIFFERENTIAL CASE COVER TO THE DIFF-LOCK HOUSING on page 3.13.

Tooth contact pattern positions are controlled by moving either the gear backlash or the pinion backlash.

PINION BACKLASH To adjust the axial backlash of the pinion, add or remove shims to alter the position of the pinion from the nominal mounting distance, until the pinion is in an acceptable location.

A

C

Remove shims to move the pinion away from the gear, causing the mounting distance to increase.

Add shims to move the pinion toward the gear, causing the mounting distance to decrease.

See, MEASURE BACKLASH on page 3.28.

A

B

E

C00755

B

A Pinion Gear B Spiral Bevel Gear C Bevel Gear Backlash Distance Error

D

GEAR TOOTH STRUCTURE

C00754

A B C D E

A B C D E F

C

Pinion Backlash Distance Error Pinion Gear Spiral Bevel Gear Pitch Apex (Bevel Gear) Pitch Apex (Pinion Gear)

Toe Inside Diameter of Gear Drive Side (Convex Side) Outside Diameter of Gear Heel Coast Side (Concave Side)

The drive side (convex side) of a pinion gear tooth is the primary pressure/contact side of the tooth. The drive side of the pinion gear tooth contacts the coast side (concave side) of the bevel gear.

4.6

Tigercat Differentials

Appendices

F A

E

B

D

C

C00111

A B C D E F

Addendum Dedendum Profile Toe Centre Heel

CONTACT PATTERN PROFILE ERRORS AND CORRECTIVE ACTIONS B A

C

G

D

E

F C00758

A B C D E F G

Pinion Too Far Advanced With Resulting Patterns - Solution, Increase Mounting Distance, Remove Shims

Profile Error (Pitch Apex of Pinion Gear Extends Beyond Pitch Apex of Bevel Gear) Pinion Convex Tooth Side,High Toe Contact Pinion Gear Pinion Concave Tooth Side, High Heel Contact Spiral Bevel Gear Concave Tooth Side, Low Toe Contact Spiral Bevel Gear Convex Tooth Side, Low Heel Contact Spiral Bevel Gear

4.7

Appendices

Tigercat Differentials

APPENDIX C - TOOTH CONTACT PATTERN IMAGES Drive

Ratio

Coast

5.429:1 (B17) R00 – R01

C00558

C00559

5.429:1 (B17) R02+

C00561

C00560

5.125:1 (B17) R00 – R01

C00562

C00563

4.8

Tigercat Differentials

Appendices

5.125:1 (B17) R02+

C00564

C00565

3.25:1 (B17 and F17)

3.25:1 (B17 and F17)

C00567

C00566

4.9

Appendices

Tigercat Differentials

2.71:1 (B17 and F17)

C00568

C00569

C00615

C00616

5.125:1 (B15)

C00570

C00571

2.929:1 (B15)

C00573

C00572

4.10

Tigercat Differentials

Appendices

5.444:1 (B20)

C00574

C00575

2.786:1 (B17)

C00751

C00750

4.11

Appendices

Tigercat Differentials

4.12