Tigercat EHS TRANSMISSION SERVICE AND REPAIR MANUAL - PDF DOWNLOAD

EHS TRANSMISSION

SERVICE AND REPAIR MANUAL

ISSUE 3.1, AUGUST 2019 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat EHS Transmission TABLE OF CONTENTS

SECTION

INTRODUCTION................................................................................................................................................. v NON-APPROVED FIELD PRODUCT / PARTS CHANGES............................................................................... vi TRADEMARKS...................................................................................................................................................vii EHS TRANSMISSION (SPLASH LUBE)-EXPLODED VIEW............................................................................viii EHS TRANSMISSION (FORCED LUBE)-EXPLODED VIEW............................................................................. x EHS BAFFLE INSTALLATION............................................................................................................................ xi CLUTCH-EXPLODED VIEW..............................................................................................................................xii SAFETY..............................................................................................................................................................1 DISASSEMBLY....................................................................................................................................................2 ASSEMBLY..........................................................................................................................................................3

Service and Repair Manual.............................................................................................................Part No. 47733AENG iii

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

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

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

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

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

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

Every effort is made to send out updates on a regular basis. Report discrepancies between this manual and the components in question to the Tigercat Service Department. The release date of this document appears on the title page.

Tigercat Industries Inc.

v

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

Introduction

Tigercat EHS Transmission

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

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

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

Authorization by any other person is unacceptable.

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

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

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

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

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

Tigercat Industries Inc.

vi

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

Tigercat EHS Transmission

Introduction

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

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

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

EHS TRANSMISSIONS Tigercat manufactures two configurations of EHS Transmissions. One is a forced lube configuration and the other is an internal splash lube configuration. They are similar except for cover configurations and bearings.

vii

EHS TRANSMISSION (SPLASH LUBE)-EXPLODED VIEW............................................................................viii

Introduction

Tigercat EHS Transmission * 24 2 3

7 12

17

21

* 26

37

14

20 16 15

15

11

37

14

18

16

10 20

*

26

5

21

23

*26

9 13

34

28

* 26

27 4

18

19

35

36

13

22

6

22

1 25

22

8

22

30

33 32 31

29

C00220

EHS TRANSMISSION (SPLASH LUBE) EXPLODED VIEW

NOTE: This exploded view is representative of a typical internal splash lube Tigercat EHS transmission. Some parts may not appear exactly as shown. viii

Tigercat EHS Transmission ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Introduction

PART DESCRIPTION

ITEM

HOUSING COVER GASKET SHAFT, OUTPUT GEAR, OUTPUT GEAR, INPUT CLUTCH See CLUTCH-EXPLODED VIEW on page xii GEAR, INPUT WASHER, THRUST COUPLER, SPLINE CARRIER, BEARING, OUTPUT CARRIER, BEARING, MANIFOLD CARRIER, BEARING SLEEVE, OUTPUT SEAL, SHAFT SEAL, OIL SEAL, ROTARY, SPLIT JOINT O-RING BAFFLE

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

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

ix

PART DESCRIPTION CONE, BEARING CUP, BEARING BEARING, BALL *SHIM BOLT PLUG, EXPANDER *BOLT BOLT O-RING PLUG, MAGNETIC PLUG CONNECTOR, MODIFIED TUBE, NPT TUBE, STRAINER, SUCTION SPACER SERIAL NUMBER PLATE BOLT SPRING PIN

EHS TRANSMISSION (FORCED LUBE)-EXPLODED VIEW............................................................................. x

Introduction

Tigercat EHS Transmission

4

* 13

12

11 8

7

5

6

6 4 3

* 13

9

10

3

16

15

2

14

1

C00545

EHS TRANSMISSION (FORCED LUBE) EXPLODED VIEW

NOTE: This exploded view is representative of a forced lube Tigercat EHS transmission. Two forced lube configurations exist, as shown in the illustration. Some parts may not appear exactly as shown. x

EHS BAFFLE INSTALLATION............................................................................................................................ xi

Tigercat EHS Transmission ITEM

Introduction

PART DESCRIPTION

ITEM

PART DESCRIPTION

1 2 3

ASSEMBLED TRANSMISSION (LESS COVER) HOUSING PLUG

9 10 11

COVER NIPPLE, FITTING O-RING

4

PLUG

12

BLOCK, FORCED LUBE

5 6 7 8

HOSE ELBOW SWIVEL FITTING CONNECTOR

13 14 15 16

*BOLT GASKET SERIAL NUMBER PLATE BOLT

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

A

B

D

C

C00722

EHS Baffle Installation

NOTE: This view is representative of a Tigercat EHS transmission with an SAE-E mount cast into the housing. This modified housing requires a baffle with a different bolt pattern. Some parts may not appear exactly as shown.

ITEM

PART DESCRIPTION

ITEM

PART DESCRIPTION

A

TRANSMISSION HOUSING

C

SPACER

B

BAFFLE

D

BOLT

xi

CLUTCH-EXPLODED VIEW..............................................................................................................................

VIEW..............................................................................................................................xii xii

Introduction

Tigercat EHS Transmission

B

27

25

24

28

26

1 23

16

17

18

19

2

22

3

20

4 5

21

6

7 8 15

14

13

12

11

10

A

9

C00611

CLUTCH-EXPLODED VIEW ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A

PART DESCRIPTION Pin, Dowel, Large Pin, Dowel, Small Spring, Compression Plate, Reaction Plate, Friction Plate, Reaction, Primary Ring, Backup, Outer (A) Pin, Dowel Piston, Clutch (A) Ring, Backup, Inner (A) Quad-Ring, Inner (A) Pin, Spring Gear, Output Washer SINGLE BACKUP AND QUAD-RING CONFIGURATION. NO LONGER USED. CONTACT TIGERCAT PARTS AND SERVICE

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

PART DESCRIPTION Bolt Barrel Plug, NPT Sleeve, Gear O-ring Bearing, Needle Quad-Ring, Outer (A) Quad-Ring, Outer (B) Quad-Ring, Inner (B) Ring, Backup, Inner (B) Piston, Clutch (B) Ring, Backup, Outer (B) Coupler, Spline Clutch Retainer, Clutch DUAL BACKUP AND QUAD RING CONFIGURATION. CONTACT TIGERCAT PARTS AND SERVICE.

NOTE: This exploded view is representative of a typical Tigercat EHS transmission clutch. Some parts may not appear exactly as shown. xii

SAFETY..............................................................................................................................................................

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

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

CONTENTS –SECTION 1

ISSUE 3.1, AUGUST 2019

C

CAUTION..................................................................................................................................................................... 1.3 CLEAN AND INSPECT................................................................................................................................................ 1.9

D

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

F

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

G

GENERAL SAFETY PRECAUTIONS........................................................................................................................ 1.3 COMPETENT PERSON........................................................................................................................................... 1.4 FLAMMABILITY........................................................................................................................................................ 1.4 LIQUID NITROGEN................................................................................................................................................. 1.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)................................................................................................... 1.3 VENTILATION........................................................................................................................................................... 1.4 VITON SEALS.......................................................................................................................................................... 1.7 WORKING WITH OIL............................................................................................................................................... 1.6 GUIDE PINS............................................................................................................................................................... 1.10

H

HAZARDOUS MATERIALS SAFETY......................................................................................................................... 1.4 COMPRESSED AIR................................................................................................................................................. 1.6 VITON SEALS.......................................................................................................................................................... 1.7

I

INJECTION INJURIES, HIGH PRESSURE............................................................................................................... 1.5 INJECTION INJURIES, PNEUMATIC GREASE GUNS........................................................................................... 1.6

M

MATERIAL LIFTING AND HANDLING....................................................................................................................... 1.8 PERSONAL SAFE LIFTING AND CARRYING...................................................................................................... 1.8 SAFE SUPPORT OF COMPONENTS.................................................................................................................... 1.8

N

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

P

PERSONAL PROTECTIVE EQUIPMENT................................................................................................................. 1.3 PICTOGRAMS............................................................................................................................................................. 1.3

R

READ THIS MANUAL FIRST...................................................................................................................................... 1.3 RECORD KEEPING.................................................................................................................................................. 1.12 REQUIRED TOOLS..................................................................................................................................................... 1.9

S

SAFETY SYMBOLS..................................................................................................................................................... 1.3 SAFETY WORDS, UNDERSTANDING...................................................................................................................... 1.3 SHIPPING COMPONENTS........................................................................................................................................ 1.9

T

THREAD LOCKING /ADHESIVE COMPOUNDS AND SEALANTS...................................................................... 1.10 ADHESIVES/GASKET FORMING/SEALANT PRODUCTS................................................................................ 1.11 REMOVE FASTENERS SECURED WITH LOCTITE THREAD LOCKER COMPOUNDS............................... 1.10 REMOVE LOCTITE FLANGE SEALANT............................................................................................................. 1.10 THREAD LOCKER AND PRIMER PRODUCTS.................................................................................................. 1.11

Safety

Tigercat EHS Transmission

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

WARNING.................................................................................................................................................................... 1.3 WORK CONDITIONS AND TOOLS........................................................................................................................... 1.7 TOOL CALIBRATION............................................................................................................................................... 1.7

1.2

Tigercat EHS Transmission

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 EHS transmissions 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.

GENERAL SAFETY PRECAUTIONS Safety is a prime responsibility of all.

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

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.

These safety rules highlight both general and specific measures the operator must 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 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.

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

WARNING

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

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

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

1.3

Safety

Tigercat EHS Transmission

COMPETENT PERSON

LIQUID NITROGEN

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.

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

HAZARDOUS MATERIALS SAFETY 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, bushing, 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 Do not burn discarded items except in an approved incineration process. Burning such items creates hazardous fumes.

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

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.

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

WARNING

• 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.

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

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

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

1.4

Tigercat EHS Transmission

Safety

HIGH PRESSURE INJECTION INJURIES

WARNING

WARNING

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

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.

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.

When searching for possible fluid leaks: • Do not search for leaks with your bare hands. Wear thick protective gloves.

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.

• Wear safety goggles for eye protection.

• 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.

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.

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

• 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.

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.

When performing any service work

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

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

• Do not grab any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

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

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

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.

WARNING Do not use any hydraulic equipment suspected of being defective.

1.5

Safety

Tigercat EHS Transmission

GREASE INJECTION INJURIES WHEN USING PNEUMATIC GREASE GUNS

WORKING WITH OIL Direct contact with new or used oil may cause rashes or dermatitis. Prolonged exposure may cause blood anaemia, headaches, tremors or cancer. Follow strict hygiene procedures. Wear appropriate PPE.

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.

Other safety advice includes:

WARNING

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

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

• Avoid contact with oil, particularly heated oil.

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

WARNING

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

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

• Don't put oily rags in your pockets.

• Remove oil soiled clothing as soon as possible.

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

• Keep an extra change of work cloths nearby.

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

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.

• Avoid breathing in oil fumes.

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

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

COMPRESSED AIR

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

Compressed air is a concentrated, high pressure, high speed stream of air that can seriously injure or kill. Air pressures of 0.34 bar – 0.69 bar (5 – 10 psi) can cause serious injury. Most pneumatic tools operate at 5.5 bar – 8.3 bar (80 – 120 psi).

• 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.

Follow acceptable Health and Safety protocols for using compressed air.

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

• Do not clean clothing or skin using compressed air.

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

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

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

• Use a chip guard.

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

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

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

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

1.6

Tigercat EHS Transmission

Safety WORK CONDITIONS AND TOOLS

VITON SEALS

For proper disassembly and assembly a clean, well lit workplace is recommended. Provide sufficient room to lay out and sort various parts and assemblies.

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

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

WARNING

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

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.

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

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.

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

TOOL CALIBRATION

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

NOTICE

If these are found, do not touch.

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

• 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.

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

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.

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

Tools must be calibrated when: • New • Repaired or changed • When the scheduled calibration period has passed • Conditions other than normal operating conditions occur. For example, a device is dropped or exposed to extreme temperature.

• Observations indicate incorrect readings

1.7

Safety

Tigercat EHS Transmission

MATERIAL LIFTING AND HANDLING

PERSONAL SAFE LIFTING AND CARRYING

DANGER

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

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

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

When manually lifting components: • Wear appropriate PPE • Determine if the load is lifted, pushed, pulled or carried

WARNING

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

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

• Verify the route and destination used to move and place the load is clear of obstructions To safely lift a load,

WARNING

• Assume a stable lifting stance

Only competent personnel are permitted to operate cranes or hoists.

• 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.

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.

• Keep your back straight • Lift with legs

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

• Keep load close to waist

• Do not exceed working load limits.

• Do not twist your torso. Move your feet.

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

• Keep your head up and watch your route.

SAFE SUPPORT OF COMPONENTS

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

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

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

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

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

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

1.8

Tigercat EHS Transmission

Safety

SHIPPING COMPONENTS

REQUIRED TOOLS AND MATERIALS

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

To disassemble the EHS Transmission requires the following tools, equipment and materials: A basic set of tools is required in addition to various special tools and measuring instruments. Additional tools and fixtures used include:

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

• Bearing Puller

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

• Isopropyl alcohol or equivalent solvent

CLEAN AND INSPECT

• Marking pen

• Clean rags • PPE

WARNING

• Wooden support blocks

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

• Torque wrench • Loctite solvent or equivalent • Loctite 242-Z000002

Before servicing or repairing the EHS transmission, clean and inspect the assembly carefully. Observe and record findings while disassembling the unit:

• Loctite Primer 7649-93996

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

• Loctite 518-BW085

• Loctite 262-SSA100 Loctite 567-BW086

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.

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

A

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

C00217

A Output Bearing Cone Installation Tool (B7394001)

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

Worn components must be replaced 7. Inspect housings, covers and manifolds for burrs, nicks, scratches, misalignment or cracks.

CONTAMINATION Open ports increase the risk of contamination of the interior of the transmission. Insert a plug or a clean piece of rag in the open hole.

C00724

A Input Driver Tool (B9436000)

1.9

Safety

Tigercat EHS Transmission

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

THREAD LOCKING /ADHESIVE COMPOUNDS AND SEALANTS 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.

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

B

A

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

1. Remove the fastener. a. Apply Bonderite C-SO Paint 200 Solvent Paint Line Cleaner or equivalent and allow to penetrate. b. Apply localized heat [121°C (250°F)] if required.

Remove while hot. The addition of a breaker bar or extension to the spanner/wrench provides additional leverage. Exercise caution, fasteners may snap off unless heated sufficiently.

C00498

A Guide Pin B Grind Head From Fastener

To modify a fastener:

c.

1. Grind the head of the fastener to a diameter equal to or marginally less than the shank. Do not cut the head of the fastener off. Cutting the head off may make the fastener too short.

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

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

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

5. Mark and retain guide pins for future use.

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

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

Clean threads with a wire brush. Alternately, use a die to clear threads or a tap to clear threaded holes.

d. Wipe excess material from screw.

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.

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

3. Wipe parts with cleaning solvent for several minutes to remove residual Bonderite, then scrape with a plastic or wooden scraper.

4. Wipe parts with cleaning solvent, after scraping, to remove residual Bonderite.

1.10

Tigercat EHS Transmission THREAD LOCKER AND PRIMER PRODUCTS 1. The use of Threadlocker and Primer products requires a primer application to both parts being joined. Follow these directions and conditions.

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

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

4. Spray or brush both parts to be joined with Loctite Primer 7649 and allow to dry for a minimum of 70 seconds. Use parts within one month of priming.

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

Safety COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING Information provided from the field is used in the warranty process and is an important source of information for Tigercat customer services and product engineers.

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

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

5. Apply several drops of Threadlocker 262 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.

ADHESIVES/GASKET FORMING/SEALANT PRODUCTS

CAUTION Loctite adhesive, 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. When applying adhesives: 1. Prepare surfaces per manufacturer's instructions.

2. Apply adhesives and secure components according to the manufacturer's suggested cure time.

When using gasket forming and sealant products: 1. Remove oil/ grease from the parts to be assembled.

2. Apply a bead of 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. Fixture time is 25 minutes at 25°C (77°F).

5. Wipe excess gasket forming product from the site.

1.11

Safety

Tigercat EHS Transmission

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.

Once a bolt has been torqued, it may stretch. IfAND the COMPLIANCE WITH INSTRUCTIONS bolt is reused, RECORD there is a risk it will fail. It is by far REQUIRED KEEPING less expensive to replace a bolt than to have it fail.

Information fromprovide the fielda is used of in the Engineeringprovided calculations margin safety, warranty process and is an important source of taking into consideration material or process flaws, information for Tigercat customer services product torque tool inaccuracies or the absence of and torque tools. engineers.

To indicate which bolts may be reused and under what conditions, theseinformation. conditions: Insufficient or Provide thefollow requested incomplete information may negatively impact or delay UNLESS OTHERWISE SPECIFIED warranty decisions and service actions.

Unless otherwise specified, torque bolts in compliance Service sheets Specification are available using on-line with the reporting General Torque a at standard http//:www.Tigercat.com, or from the nearest Tigercat bolt torque sequence. See, GENERAL TORQUE dealer.

SPECIFICATIONS on page 1.13. 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.

If the bolt is rated ** Do not REUSE-REPLACE, replace the washer.

C

B

A

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

• Setting torque wrenches (Type 2).

LOAD

C00711

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

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

Select the torque wrench 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, TOOL CALIBRATION on page 1.7.

1.12

Tigercat EHS Transmission

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 5 BOLTS

GRADE 8 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS

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

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

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

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

METRIC

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

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

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

1.13

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

Safety

Tigercat EHS Transmission

1.14

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

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

CONTENTS – SECTION 2 B

ISSUE 3.1, AUGUST 2019

BAFFLE, REMOVE...................................................................................................................................................... 2.9

C

CLEAN AND INSPECT................................................................................................................................................ 2.3 CLUTCH, DISASSEMBLE.......................................................................................................................................... 2.9

D

DISASSEMBLE THE CLUTCH................................................................................................................................... 2.9 FOR TRANSMISSIONS BUILT USING DUAL BACKUP AND SINGLE QUAD RINGS ON EACH SIDE........ 2.12 FOR TRANSMISSIONS BUILT USING SINGLE BACKUP AND QUAD RINGS ON EACH SIDE................... 2.12 DISASSEMBLY TASKS............................................................................................................................................... 2.3

G

GEARBOX COVER AND GASKET, REMOVE.......................................................................................................... 2.3

I

INPUT BEARING CARRIERS, REMOVE.................................................................................................................. 2.8 INPUT GEAR BEARINGS, REMOVE........................................................................................................................ 2.8

M

MANIFOLD BEARING CARRIER, REMOVE............................................................................................................ 2.3

O

OUTPUT BEARING CARRIERS, REMOVE.............................................................................................................. 2.4 REMOVE BEARING CUP........................................................................................................................................ 2.5 REMOVE OIL AND WIPER SEAL........................................................................................................................... 2.5 OUTPUT SHAFT, REMOVE........................................................................................................................................ 2.6

R

ROLLER BEARING/GEAR SLEEVE, DISASSEMBLE........................................................................................... 2.12

S

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

Disassembly

Tigercat EHS Transmission

2.2

Tigercat EHS Transmission

Disassembly

SAFETY

REMOVE THE MOTOR SIDE MANIFOLD BEARING CARRIER

See CLEAN AND INSPECT on page 1.9 of this manual for references to safety warnings and messages.

A

CLEAN AND INSPECT See CLEAN AND INSPECT on page 1.9 of this manual for references to cleaning and inspecting the unit.

B

C

REMOVE OIL FROM THE TRANSMISSION While most transmissions are drained prior to shipping some residual oil may remain in the transmission.

Remove the magnetic plug from the bottom of the housing if there is oil, and drain it into a container for recycling or proper disposal.

D

Use clean rags to remove the balance of the oil as it is accessed.

C00629

REMOVE THE COVER AND GASKET

A B C D

The transmission may have transfer case components such as motors, yokes and brackets installed that must be removed before servicing.

*

Manifold Bearing Carrier *Bolts Housing Support Blocks

1. Position the housing on support blocks, with the manifold bearing carrier facing up.

A A

B

B

B

C

C00224

A Manifold Bearing Carrier B Jack Screws * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

C00223

2. Remove *bolts securing the manifold bearing carrier to the housing.

A *Bolts B Cover C Gasket * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

3. Apply two jack screws of sufficient length to the 3/8-16 UNC in threaded holes in the manifold bearing carrier and incrementally thread them clockwise to raise the carrier from the housing.

1. Remove the *bolts securing the cover then remove the cover.

4. Extract the jack bolts from the manifold bearing carrier.

2. Remove and discard the transmission cover gasket.

Do not mar machined surfaces.

2.3

Disassembly

Tigercat EHS Transmission *

REMOVE OUTPUT SIDE BEARING CARRIERS

A

*

B

A B

C

C D D E

E

C00225

C00225

A *Bolts B Output Sleeve C Output Bearing Carrier D Rotary Seal E Housing * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

A *Bolts B Output Sleeve C Output Bearing Carrier D Shims E Housing * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

5. Remove the manifold bearing carrier.

1. Turn the housing on the support blocks so the input bearing carriers are facing up.

6. Remove the gasket material from the manifold bearing carrier. See, THREAD LOCKING / ADHESIVE COMPOUNDS AND SEALANTS on page 1.10.

2. Remove *bolts securing the output bearing carrier to the housing.

3. Apply two jack screws of sufficient length to the 3/8-16 UNC in threaded holes in the output bearing carrier and incrementally thread them clockwise to raise the carrier from the housing.

7. Remove the gasket material from the housing.

8. Remove the output sleeve.

9. Remove the rotary seals from the manifold bearing carrier.

4. Extract the jack bolts from the output bearing carrier.

5. Remove the output bearing carrier.

6. Remove the output sleeve.

7. Remove any shims present.

8. Remove the rotary seals from the output bearing carrier.

2.4

Tigercat EHS Transmission

Disassembly

REMOVE BEARING CUP FROM OUTPUT BEARING CARRIERS

REMOVE OIL AND WIPER SEAL FROM OUTPUT BEARING CARRIERS

A A

B C

B

E

F

A

D

C B

C00270

A B C D E F

C

A

D

E

B C00286

Output Sleeve Oil Seal Wiper Seal Bearing Carrier Bearing Cup Pry Bars

A B C D E

1. Place the output bearing carrier, with the outer surface facedown, on the work bench.

Output Sleeve Metal Strap Oil Seal Wiper Seal Bearing Carrier

1. Remove the rotary seals. a. Cut a piece of metal shipping strap approximately 19 mm (0.75 in) wide, 222 mm (8.75 in) long and at least 0.76 mm (0.030 in) thick or equivalent.

2. Clamp the carrier to the work bench using C-clamps.

Do not overtighten the C-clamps.

3. Insert the output sleeve into the carrier with the top flange facing up. The seals act to centre the output sleeve.

b. Fit the strap into the U-channel of the oil seal. c.

4. Pry the bearing cup from the carrier using a pry bar.

Once there is sufficient clearance, use lady slipper pry bars to continue removing the bearing cup.

Align the output sleeve, with the flange facing up, on top of the strap.

d. Strike the top of the output sleeve using a rubber mallet to drive the seals from the carrier. e. Discard the seals.

2. Use a brass punch to tap the seals from the carrier if a metal strap or suitable substitute is not available.

2.5

Disassembly

Tigercat EHS Transmission

REMOVE THE OUTPUT SHAFT A

CAUTION

B

The caution symbols indicate potential pin points between the gears and housing.

C

J

C00289

H

G

A Bolt B Washers C Output Shaft (Spline End)

NOTICE

F

Oversize washers on the spline end of the output shaft must be sized to pass through the inside diameter of the bearing race.

A

B

4. Strike the output shaft downward using a dead-blow hammer. If a dead-blow hammer is not available, protect the end of the spline using hardwood, or by securing several oversized washers to the end of the shaft using a 5/8 in – 18 x 1.0 in long bolt. Torque the bolt to 34 N-m (25 lbf-ft) before striking.

C D C00226

A B C D E F G H J

E

5. Remove the output shaft.

Support Blocks Output Shaft Piece of Wood to Protect Splines Thrust Washer Bearing Cone Washers Bolt Wedge or Block to Support Output Gear Output Gear

A B

1. Turn the housing on support blocks so the input bearing carriers are facing down.

C

2. Place a piece of wood or heavy rag beneath the output shaft to protect the spline end.

3. Support the output gear with wooden wedges to prevent damage to the baffle resulting from the downward force used to remove the shaft.

C00227

A Bearing Cone B Thrust Washer C Output Shaft

6. Remove the bolt and washers.

7. Press the output shaft from the thrust washer and bearing cone.

2.6

Tigercat EHS Transmission

Disassembly

REMOVE THE CLUTCH AND OUTPUT GEAR CAUTION A

The clutch and gear are not secure. Position the housing so the parts remain in the housing when it is turned over.

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

C00230

A V-ring (may or may not be present)

11. Remove the V-ring from the housing and discard, if present. Transmissions built after transmission serial number 10027757 do not have the V-ring installed.

A

B C00229

A Output Gear B Clutch

8. Position the housing on support blocks, with the input bearing carriers facing up.

9. Remove the output gear from the housing.

10. Remove the clutch. Wipe any lubricant from the clutch.

NOTICE Do not replace the V-ring during reassembly.

If the V-ring is damaged during installation or operation material may clog the suction line reducing clutch pressure.

2.7

Disassembly

Tigercat EHS Transmission

REMOVE THE INPUT SIDE BEARING CARRIERS

REMOVE THE INPUT GEAR BEARINGS *

A

E

A

B B

C D

E

C

D

A

C00313

A B C D E

Ball Bearing Bearing Separator Support Block Right Input Gear Blank

1. Remove the bearings from each end of the right and left input gears (right gear shown). a. Use a bearing separator resting on support blocks.

C00231

b. Cover the gear end with a blank or carefully drive the gear from the bearing using a punch in a star pattern. Do not damage the gear end.

A *Bolts B Bearing Carriers C O-rings D Left Input Gear E Right Input Gear * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

c.

CAUTION Gear teeth are sharp. Handle with care to avoid personal injury and/or damage to gear teeth.

1. Remove bolts securing the bearing carriers to the housing, then remove the carriers.

2. Remove each input gear from the housing.

3. Remove and discard the O-ring from each bearing carrier.

2.8

Tap the gear from the bearing, once the bearing begins to move.

Tigercat EHS Transmission

Disassembly

REMOVE THE BAFFLE

DISASSEMBLE THE CLUTCH A 2

4

D

A B

5

E

C

6 1

C00253

A B C D E

D

C

3

B

Housing Support Blocks Bolt Shim Baffle

C00242

A Bolts B Washers C Clutch D Support Blocks Numbers represent pattern for loosening and torquing bolts

1. Remove bolts securing the baffle to the housing.

See,THREAD LOCKING /ADHESIVE COMPOUNDS AND SEALANTS on page 1.10.

1. Place the clutch on support blocks with the output gear facing up.

2. Remove two shims supporting the baffle from inside the housing.

CAUTION

3. Remove the baffle.

The reaction and friction plates may be under tension from the compression springs. Release the tension on the plates and retainer gradually.

2. Loosen the *bolts holding the barrel to the output gear and clutch retainer incrementally, in a star pattern as shown.

3. Tap each bolt head to ensure the plates or springs do not bind after the completion of each pattern.

4. Continue to loosen each bolt until the bolts are almost removed and turn easily. Do not remove the bolts until the clutch is turned with the clutch retainer facing up.

2.9

Disassembly

Tigercat EHS Transmission

A A B

B

C

H

G

G

F

D

F E

*E

D

C

C00243

A B C D E F G H

Clutch Retainer Output Gear O-ring Washer *Bolt Cardboard or Protective Material Barrel Support Blocks

5. Place a piece of wood or heavy rag beneath the barrel.

6. Remove the remaining *bolts securing the clutch retainer and barrel to the output gear. Lower the barrel onto the work surface once the bolts and washers are removed.

7. Remove the clutch retainer.

8. Remove two small O-rings from the barrel.

C00244

A B C D E F G

Compression Springs Reaction Plate Friction Plates Primary Reaction Plate Large Dowels Pins Output Gear Small Dowels Pins

9. Remove the compression springs from the small dowel pins.

10. Remove and wipe the reaction plates and the primary reaction plate using isopropyl alcohol and lint-free rags.

11. Remove and wipe the friction plates with a lint-free rag only. Do not use cleaners or solvents.

NOTICE Do not clean friction plates using solvents or cleaners. Absorptive materials used in manufacturing will retain chemicals and change the designed performance of the plates.

2.10

Tigercat EHS Transmission

Disassembly

F

A

A E

B B C

C00245

A Dowel Pins B Output Gear

D

C00247

12. Remove six dowel pins from the output gear.

A B C D E F

A

B

Oil Hole (stop this hole using a plug or rag) Output Gear Support Blocks Clutch Piston Air Nozzle Oil Hole

14. Remove the clutch piston from the output gear. a. Place a piece of wood or heavy rag beneath the clutch piston.

C

b. Turn the output gear on the support blocks, so the clutch piston faces the work surface. c.

C00246

A Spline Coupler B Gear Sleeve C Output Gear

Insert a compressed air nozzle in one of the oil holes in the output gear.

d. Stop the oil hole directly opposite the selected hole with a heavy rag or plug. Do not use a finger to block the hole. See, HIGH PRESSURE INJECTION INJURIES on page 1.5. (This step is shown without a stop for clarity.)

13. Remove the spline coupler from the gear sleeve.

e. Apply air to push the clutch piston from the cavity in the flange of the output gear.

WARNING Prevent compressed air injuries. Use a rag or other barrier to stop the hole.

2.11

Disassembly

Tigercat EHS Transmission

FOR TRANSMISSIONS BUILT USING SINGLE BACKUP AND QUAD RINGS ON EACH SIDE E

DISASSEMBLE THE ROLLER BEARING/ GEAR SLEEVE NOTICE

A

Disassemble the roller bearing/gear sleeve only if damaged or contaminated.

D B

C

1. Place the output gear on support blocks with the spline end of the gear sleeve facing up.

A

D

C00248

A B C D E

Inner Quad-Ring Outer Quad-Ring Clutch Piston Outer Backup Ring Inner Backup Ring

FOR TRANSMISSIONS BUILT USING DUAL BACKUP AND SINGLE QUAD RINGS ON EACH SIDE

C A B C D

A E B

Output Gear Support Blocks Gear Sleeve Roller Bearing

2. Drive the gear sleeve from the bearing using a brass punch or an appropriate diameter cylinder.

NOTICE

D C

Do not damage the inner diameter of the output gear and gear sleeve during removal.

C00613

A B C D E

B

C00249

Inner Quad-Ring Clutch Piston Outer Quad-Ring Outer Backup Ring Inner Backup Ring

15. Remove and discard the quad-rings and backup rings from the grooves in the clutch piston.

2.12

Tigercat EHS Transmission

Disassembly

A

B

C

E

D

C00325

A B C D E

Output Gear Roller Roller Bearing Bearing Race Cut Notch

3. Carefully notch the bearing race using a die grinder with a wheel cutter. The notch must be large enough to allow removal of a single roller from the bearing.

4. Remove the rollers, one at a time, using a magnet.

When the rollers are removed from one side of the bearing, the other side will fall out.

A

B C00252

A Snap Ring B Output Gear

5. Remove the snap ring from the inner diameter of the output gear.

2.13

Disassembly

Tigercat EHS Transmission

2.14

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

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

CONTENTS – SECTION 3

ISSUE 3.1, AUGUST 2019

A

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

B

BAFFLE, INSTALL..................................................................................................................................................... 3.12 BEARING CARRIER MANIFOLD............................................................................................................................... 3.6 BEARING INSTALLATION HEATING................................................................................................................................................................... 3.3 INDUCTION HEATER.............................................................................................................................................. 3.3 INPUT GEAR............................................................................................................................................................ 3.4 BEARINGS AND SLEEVES, COOLING.................................................................................................................... 3.3 BLEED SCREWS, FITTINGS AND PLUGS, INSTALL............................................................................................. 3.4

C

CARRIER MANIFOLD, BEARING.............................................................................................................................. 3.6 CLEANING AND INSPECTION.................................................................................................................................. 3.3 CLUTCH....................................................................................................................................................................... 3.7 INSTALL BARREL.................................................................................................................................................... 3.8 INSTALL CLUTCH PISTON..................................................................................................................................... 3.8 ROLLER BEARING/GEAR SLEEVE....................................................................................................................... 3.7

G

GEARBOX GASKET AND COVER.......................................................................................................................... 3.19 GEAR CONTACT PATTERN TEST.......................................................................................................................... 3.19

H

HEATER, BEARING INDUCTION.............................................................................................................................. 3.3 HOUSING................................................................................................................................................................... 3.12 INSTALL BAFFLE................................................................................................................................................... 3.12 INSTALL INPUT GEAR.......................................................................................................................................... 3.12 MOTOR BORE RUNOUT MEASUREMENT........................................................................................................ 3.14

I

INPUT GEAR INSTALLATION.................................................................................................................................. 3.12

M

MANIFOLD BEARING CARRIER............................................................................................................................... 3.6 MOTOR BORE RUNOUT MEASUREMENT........................................................................................................... 3.14

O

OUTPUT BEARING CARRIER................................................................................................................................... 3.5 OUTPUT BEARING MANIFOLD.............................................................................................................................. 3.16 OUTPUT SHAFT BEARING PRELOAD............................................................................................................... 3.17 OUTPUT GEAR......................................................................................................................................................... 3.14

Q

QUAD RINGS, INNER AND OUTER.......................................................................................................................... 3.9

R

ROLLER BEARING/GEAR SLEEVE.......................................................................................................................... 3.7

S

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

Assembly

Tigercat EHS Transmission

3.2

Tigercat EHS Transmission

Assembly

SAFETY

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

See SECTION 1– SAFETY on page 1.1 for references to safety warnings and messages.

CLEAN AND INSPECT

BEARING INDUCTION HEATER

See CLEAN AND INSPECT on page 1.9 for references to cleaning and inspecting the unit.

WARNING

BEARING INSTALLATION INSTRUCTIONS

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.

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

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

2. Leave bearings in packages until ready for installation.

3. Bearing cups and cones must be correctly matched.

Do not interchange bearing components.

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.

4. Verify bearing usage with the exploded view at the front of this manual and by measuring the bearing and mating parts.

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

COOLING BEARINGS AND SLEEVES FOR INSTALLATION

6. The larger the bearing, the longer it takes to heat and to cool down. Be sure to allow enough time to fully heat and cool bearings.

WARNING

HEATING BEARINGS FOR INSTALLATION

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

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

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

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

Cooling may take place in a freezer unit where the part is left for a period of time and allowed to reach a minimum temperature. When available, use liquid nitrogen to cool the parts. Immerse parts in liquid nitrogen until reaction of the nitrogen stops, signifying the part is cooled.

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

3. Take extreme care that standard product bearings, gears, or steel sleeves are not heated above 120°C (250°F). If bearings, gears, or steel sleeves are heated above this temperature, the metallurgical structure may soften, rendering them unusable.

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.

4. Heat and cool bearing components gradually.

3.3

Assembly

Tigercat EHS Transmission INSTALL INPUT GEAR BEARINGS

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

1. Heat the bearings as described in HEATING BEARINGS FOR INSTALLATION on page 3.3 of this manual.

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

A

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

PRIOR TO ASSEMBLY

B

Prior to EHS transmission assembly:

C

1. Have all required parts readily available.

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

A

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

• Ensure they are the right parts.

C00258

• Verify orientation.

A Ball Bearing B Right Input Gear C Left Input Gear

• Replace damaged or worn components as required.

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

2. Install bearings onto each end of the input gears.

INSTALL FITTINGS AND PLUGS

4. Verify each bearing is fully seated on the gear bearing shoulder, using feeler gauges. If the bearing is not fully seated, carefully tap it into place using a punch that contacts the inner race of the bearing only. Tap the bearing in a star shaped pattern.

3. Allow the bearings to cool to the touch.

Bleed screw seats, bleed screws, fittings threaded plugs and expander plugs may be made of materials more malleable than steel and may be subject to deformation and compression if overtightened. Finger tighten these parts so they can be removed as required during assembly, until final tightening is needed.

When completing final installation of plugs, fittings and bleed screws: 1. Apply lubricant or sealant to the part as instructed.

2. Tighten the part finger tight. It must be snug in the threaded hole.

3. Unless otherwise specified, finger tighten the part, then tighten an additional half turn.

4. When installing expander plugs use the correct size punch.

5. Apply steps 1 – 3 for other fittings and plugs unless otherwise indicated.

3.4

Tigercat EHS Transmission

Assembly

OUTPUT BEARING CARRIER WARNING

A

Chilled components may damage exposed tissues. Use appropriate PPE when handling chilled parts.

B

C

1. Place the output bearing carrier with the outer face on the work surface.

2. Press the output bearing cup into the output bearing carrier using output bearing cone installation tool B7394001 or equivalent. Verify the cup is fully seated using a feeler gauge.

D

E A

C00301

A B C D E

B

4. Install the wiper and oil seals using Input Driver Tool B9436000 or if the tool is unavailable, use the output sleeve and a ram extension to seat the wiper and oil seals.

C

D

5. Inspect each seal for damage or deformation.

6. Apply a small amount of gear oil to the wiper seal and oil seal. Flex the inner surface of the oil seal to make it pliable. This aids with the installation of the output sleeve.

C00263

A B C D

Output Bearing Carrier Oil Seal Output Sleeve Wiper Seal Bearing Cup

Bearing Cup Output Bearing Carrier Oil Seal Wiper Seal

7. Push the wiper seal onto the input driver tool or the output sleeve, with the open channel facing the bottom of the flange.

3. Place the output bearing carrier with the outer surface face up on the work surface.

8. Push the oil seal onto the input driver tool or the output sleeve, with the open channel facing away from the flange.

CAUTION

9. Insert the input driver tool or the output sleeve with both seals into the output bearing carrier, then press it into place until the oil seal rests against the seat in the bearing carrier.

Flex the seals minimally so they do not deform and take a permanent set. If deformed, do not use.

10. Remove the input driver tool or the output sleeve.

3.5

Assembly

Tigercat EHS Transmission

BEARING CARRIER MANIFOLD CAUTION A

Flex the oil seals minimally so they do not deform and take a permanent set. If deformed, do not use.

B

1. Place the manifold bearing carrier face down on the work surface.

C

2. Press the manifold bearing cup into the output bearing carrier using output bearing cone installation tool B7394001 or equivalent. Verify the cup is fully seated using a feeler gauge.

D

E A F

B

C00261

A B C D E F

C

9. Install the wiper and oil seals using Input Driver Tool B9436000 or if the tool is unavailable, use the output sleeve as a tool and a press ram extension to seat the wiper and oil seals.

D

10. Inspect each seal for damage or deformation.

E

11. Apply a small amount of gear oil to the wiper seal and oil seal. Flex the inner surface of the oil seal to make it pliable. This aids with the installation of the output sleeve.

C00263

A B C D E

Manifold Bearing Carrier Oil Seal Output Sleeve Wiper Seal Bearing Cup Rotary Seals

Rotary Seals Bearing Cup Bearing Carrier Manifold Oil Seal Wiper Seal

12. Push the wiper seal onto the input driver tool or the output sleeve, with the open channel facing the bottom of the flange.

3. Place the manifold bearing carrier face up on the work surface.

13. Push the oil seal onto the input driver tool or the output sleeve, with the open channel facing away from the flange.

4. Inspect each rotary seal for damage or deformation.

5. Orient the seals so the injection marks on each seal face one another.

14. Insert the input driver tool or the output sleeve with both seals into the output bearing carrier, then press it into place until the oil seal rests against the seat in the bearing carrier.

6. Lubricate each seal with assembly grease.

7. Open the seals and apply them to the manifold with the hook ends of one seal 180° from the hook ends of the other. Do not deform the seals.

15. Remove the input driver tool or the output sleeve.

8. Lock the hook ends of each seal.

3.6

Tigercat EHS Transmission

Assembly

CLUTCH A

ROLLER BEARING/GEAR SLEEVE

NOTICE

B

Do not remove the bearing shipping sleeve from the bearing until the assembly procedure is complete.

A

C

A

D

1. Heat the needle roller bearing. See, HEATING BEARINGS FOR INSTALLATION on page 3.3

B A

A

C

B

A-A

C

D

C00268

A B C D

C00267

A Needle Roller Bearing B Shipping Sleeve C Gear Sleeve

Gear Sleeve/Needle Bearing Shipping Sleeve Output Gear Support Blocks

5. Orient the output gear on support blocks, with the barrel side of the gear facing up. There must be sufficient space for the gear sleeve/bearing to protrude from the bottom.

2. Install the bearing onto the gear sleeve so the radius end of the bearing inner race is in contact with the shoulder of the gear sleeve.

6. Align the sleeve/bearing (with the shipping sleeve still on the bearing) with the output gear.

3. Verify the bearing is fully seated on the gear sleeve shoulder. If the bearing is not fully seated, carefully tap it into place using a punch that contacts the inner race of the bearing only. Tap the bearing in a star shaped pattern.

a. Hold the shipping sleeve securely, then press the top of the sleeve/bearing until the roller bearing is seated and the lock ring is engaged. b. Tap the top of the gear sleeve lightly, using a dead blow hammer, if the bearing does not seat completely.

4. Allow the gear sleeve to warm to the touch.

7. Discard the shipping sleeve.

3.7

Assembly

Tigercat EHS Transmission

INSTALL BARREL F

5. Align the inlet ports on the barrel with the outlet ports on the output gear then lower the barrel onto the output gear.

A

INSTALL CLUTCH PISTON Several possible clutch piston assemblies may be encountered. Depth and width of the ring/seal grooves vary between assemblies (a, b, c). Assemblies with single backup rings and seals are to be replaced with the dual backup ring configuration. Backup rings, seals and pistons from previous configurations are not compatible with the latest clutch piston. If rings or seals are ordered, a replacement kit with the new piston, quad rings and dual ring configuration will be sent. If only dual configuration rings or seals only are required, contact Tigercat Parts and Service or an authorized Tigercat dealer to specify.

B C

E

C00260

A B C D E F

NOTICE

D

Do not pin or damage the rings when inserting the piston. If damaged, replace. Do not tap the piston into place.

Barrel O-ring Gear Sleeve/Needle Bearing Output Gear Spring Pin O-ring seat

c

b

a

1. Insert spring pins in each side of the output gear.

2. Check oil ports for debris and clean as required.

A F A

A

C00299

E

A

D

B

A NPT Plug B Barrel

For new barrels follow step 3: 3. Install NPT plugs in the barrel. a. Clean NPT plugs.

C00634

A B C D E F a b c

b. Apply Loctite 262 and insert plugs into holes on the barrel. c.

Blow out excess Loctite with compressed air.

d. Peen plugs in place using a small centre punch.

4. Lubricate O-rings with white assembly grease, then install them in the seats on the barrel.

3.8

B

C

B

Outer Backup Ring Inner Backup Ring Inner Seal Piston Outer Seal O-ring Representative of groove dimension variance

Tigercat EHS Transmission

Assembly

1. Place the output gear on support blocks near the edge of the work surface.

9. Install the outer backup ring into the outer groove on the piston so the outer quad ring is positioned in between the outer backup rings.

2. Install dowel pins into the holes in the piston groove of the output gear.

G

B

A B

F

C

A

B

C

C

E

D

C00300

B

A B C D A

C F

Piston (with rings installed) Alignment Holes Dowel Pin Output Gear

10. Align the holes in the piston with the dowel pins in the output gear, then insert the piston into the gear.

Do not use a hammer to insert the piston.

G

C00612

A B C D E F G

D

Inner Backup Ring Piston Outer Backup Ring Output Gear Dowel Pin Outer Quad-Ring Inner Quad-Ring

A

E

3. Lubricate two inner and two outer backup rings, and the inner and outer quad-rings with gear oil. Do not use grease.

B

C

4. Install an inner backup ring into the inner groove on the piston.

5. Install the inner quad ring into the inner groove on the piston.

D

6. Install an inner backup ring into the inner groove on the piston so the inner quad ring is positioned in between the inner backup rings.

7. Install an outer backup ring into the outer groove on the piston.

C00265

A B C D E

8. Install the outer quad ring into the outer groove on the piston.

3.9

Clutch Spline Coupler Large Dowel Output Gear/Piston Gear Sleeve Small Dowel

Assembly

Tigercat EHS Transmission

11. Insert two large dowels and four small dowels in the output gear.

12. Install the clutch spline coupler onto the gear sleeve.

NOTICE

18. Verify the plates move freely, without binding on the clutch spline coupler and they move freely on the dowels.

19. Set a compression spring on each of the four small dowels.

Do not clean friction plates using solvents or cleaners. Absorptive materials used to manufacture the plates will retain chemicals and change the designed performance of the plates.

A B

A

G

C

B D

E

*F

F C C00269

E

A Clutch Retainer B Alignment Hole C Output Gear (support blocks not shown) D Spring Pin E Washers F *Bolts G Compression Springs * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

D

C00266

A B C D E F

Reaction Plates Friction Plates Primary Reaction Plate Output Gear/Piston Clutch Spline Coupler Compression Springs

13. Wipe both sides of each friction plate with a clean lint free cloth prior to installation.

20. Position the clutch retainer onto the output gear assembly so the spring pin hole in the gear is aligned with the corresponding hole in the retainer.

21. Press down on the retainer to ensure the springs function smoothly without binding.

14. Clean both sides of the primary reaction plate and the reaction plates using isopropyl alcohol and dry using clean lint-free rags.

15. Apply gear oil between each plate prior to assembly.

16. Install the primary reaction plate onto the dowels.

17. Alternate the assembly of friction and reaction plates. The last plate on the stack is a reaction plate.

Ensure the tabs on the reaction plates align on the large dowels.

3.10

Tigercat EHS Transmission

Assembly A B

E

A

A C

D

D B C00297

A B C D E

Clutch Retainer Output Gear Components Bolt Work Surface Support Blocks

C00331

A B C D

22. Move the clutch to the edge of the work surface to expose bolt holes from the bottom of the output gear.

23. Apply Primer 7649 and Loctite 262 to the *bolts used to secure the retainer to the clutch assembly. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.11.

C

A

Retainer Clearance Gap 0.025 mm (0.001 in) Dowel Feeler Gauge

27. When the retainer is secured, verify there is a clearance gap of 0.025 mm (0.001 in) between the retainer and the dowel using a feeler gauge.

24. Install two *bolts opposite one another, from beneath, to hold the retainer. Torque each *bolt to 108 N-m (80 lbf-ft).

NOTICE The clutch spline coupler is aligned with the reaction and friction plates. If it moves from the seated position, and the plates become misaligned, the clutch must be dismantled to correct the alignment problem. Secure the clutch spline coupler before turning the clutch over.

25. Turn the clutch over to expose the bolt holes.

26. Install the remaining *bolts and tighten each incrementally until the retainer rests against the output gear. Torque each bolt to 108 N-m (80 lbf-ft), in a star pattern.

3.11

Assembly

Tigercat EHS Transmission

HOUSING

INSTALL INPUT GEAR

INSTALL BAFFLE

CAUTION A

Gear teeth are sharp. Handle with care to avoid personal injury and/or damage to gear teeth.

D

NOTICE Insert each input gear in the correct opening in the housing.

*A C00253

A B C D

C

B B

Housing Bolt Shim Baffle

F C D

1. Place the housing on support blocks with the output side of the housing facing up.

E

2. Insert the baffle with the widest mounting tabs facing the manifold side of the housing.

3. Insert a shim between the manifold side of the housing and each of the widest mounting tabs.

4. Apply Primer 7649 and Loctite 242 to four bolts and secure the baffle to the housing. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.11.

5. Torque each bolt to 50 N-m (37 lbf-ft).

C00259

A *Bolt B Bearing Carrier C O-ring D Right Input Gear E Housing F Oil Hole * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

NOTICE Verify there is endplay on both the left and right input gears after they are installed.

1. Insert the right input gear with the largest diameter gear into the carrier opening, with the gear at the top.

2. Align the lower bearing to seat in the lower opening.

3.12

Tigercat EHS Transmission

Assembly INPUT GEAR ENDPLAY

*A A

B C D E

B

C F

C

C00630

A Housing B Input Gear C Pry Bar

C00255

A *Bolt B Bearing Carrier C Oil Hole D O-ring E Left Input Gear F Housing * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

3. Insert the left input gear, into the carrier opening, with the gear at the bottom. Align the lower bearing to seat in the lower opening.

Move the input gears axially to verify there is end play on each gear and the bearings are not preloaded.

MOTOR BORE RUNOUT MEASUREMENT 1. Turn the housing on support blocks so the input side of the housing faces up.

A

4. Apply a small amount of gear oil to each O-ring and install an O-ring on each bearing carrier.

C

5. Align the oil hole in the each carrier with the oil holes in the housing and slide the carriers into position.

6. Apply Primer 7649 and Loctite 242 to each of four *bolts securing the two carriers and the threaded holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.11.

B

7. Tighten each *bolt, finger tight, then torque to 108 N-m (80 lbf-ft) in a diagonally opposed pattern.

C00256

8. Manually turn each gear three revolutions to set the bearings. If the gear will not turn, contact the Tigercat Service Department.

A Measuring Rod B Dial Indicator C Input Gear

2. Mount a dial indicator on the spline end of an input gear.

3. Position the measuring rod from the indicator perpendicular to and touching the inner wall of the motor bore.

3.13

Assembly

Tigercat EHS Transmission

4. Turn the input shaft to measure the runout of the input shaft. If the runout exceeds 0.076 mm (0.003 in), contact the Tigercat Service Department.

A

OUTPUT GEAR

B

C

A

D

C00294

E

A Output Gear B Output Shaft C Shoulder of Shaft Raised 0.025 – 0.762 mm (0.001 – 0.030 in)

6. Verify the output shaft is fully seated and the shaft shoulder sits 0.025 – 0.762 mm (0.001 – 0.003 in) higher than the output gear.

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

B C C00292

A B C D E

Output Shaft Clutch Spline Coupler Clutch Output Gear Transmission Housing

7. Heat the bearing cone as described in HEATING BEARINGS FOR INSTALLATION on page 3.3 of this manual.

A

1. Position the transmission housing with the input bearing carriers facing upwards.

B

2. Apply a small amount of gear oil to the O-rings and install one in the groove on each end of the output shaft.

3. Install the clutch unit into the housing.

4. Install the output gear on top of the clutch.

C00647

5. Align the spline teeth of the input gear and clutch spline coupler using the output shaft.

C

A Output Shaft B Bearing Cone C Thrust Washer

NOTICE Bearings must be cool to the touch before being tapped into place.

8. Seat the thrust washer and heated bearing cone onto the output shaft.

3.14

Tigercat EHS Transmission

Assembly

9. Allow to cool for 5 minutes or until the temperature is cool to the touch, below 25°C (86°F), then tap into place using tool B7394001. Use an IR thermometer to verify temperatures, if available. Note the orientation of the bearing cone. The thrust washer must not spin.

OUTPUT BEARING MANIFOLD *A B

A starting shim pack consists of various thicknesses and quantities of shims.

Shim Size

Qty

Total Thickness

0.51 mm (0.020 in)

2

1.02 mm (0.040 in)

0.18 mm (0.007 in)

2

0.36 mm (0.014 in)

0.13 mm (0.005 in)

4

0.51 mm (0.020 in)

0.08 mm (0.003 in)

1

0.08 (0.003 in)

Total =

1.97 mm (0.077 in)

C D

F

E

10. Install a 1.97 mm (0.077 in) shim pack onto the housing.

11. Install the output bearing carrier so the lubrication hole in the housing and carrier align.

C00295

12. Insert and tighten four temporary bolts to 108 N-m (80 lbf-ft). Do not apply thread locking compounds to the bolts.

A *Bolts B Manifold Bearing Carrier C O-ring D Bearing Cone E Output Shaft F Lubrication Hole * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

A B C

I

D E

H

F

1. Turn the housing on support blocks so the open motor bore side of the housing faces up.

2. Heat the shaft bearing cone as described in HEATING BEARINGS FOR INSTALLATION on page 3.3 of this manual.

3. Install the bearing cone onto the output shaft. Note the orientation of the bearing cone.

4. Allow the bearing cone to cool to the touch then seat the bearing cone with tool B7394001.

5. Apply a small amount of gear oil to the O-ring and install the O-ring on the output shaft.

NOTICE C00302

A B C D E

Do not force the manifold into position. Forcing the manifold may damage the seals.

G

Alignment Dowels Output Bearing Carrier O-ring Bearing Cone Shim Pack

F G H I

Thrust Washer Output Shaft Spring Pin Oil Holes

6. Install a spring pin in the up facing surface of the gearbox housing, to aid in aligning the output bearing carrier. See illustration C00302.

3.15

Assembly

Tigercat EHS Transmission OUTPUT SHAFT BEARING PRELOAD

*

A B C

B

G D E

C A

C00296

B

A Manifold Bearing Carrier Flange B Lubrication Hole Area C Loctite 518

F C00271

A *Bolts B Output Bearing Carrier C Starting Shim Pack D Output Shaft E Housing F Support Block G Temporary Alignment Dowels * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

7. Apply a bead of Loctite 518 to the inside perimeter of the flange of the manifold bearing carrier and around each bolt hole. Avoid sealant in the lubrication hole.

8. Align the lubrication hole in the manifold bearing carrier with the oil hole in the transmission housing.

9. Install the manifold bearing carrier into the housing and secure using six *bolts. Apply Primer 7649 and Loctite 242 to each *bolt and threaded hole and torque to 108 N-m (80 lbf-ft). See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.11.

1. Position the gear box housing on support blocks with the input bearing carriers facing up.

2. Remove *bolts securing the output bearing carrier to the housing and remove the carrier and shims. Do not damage the shims.

3. Reinstall the output bearing carrier to the housing (less shim pack) and torque all *bolts to 108 N-m (80 lbf-ft) to seat bearing cups. Do not apply threadlocker compound.

4. Remove the output bearing carrier.

C

A B

C00432

A Housing B Plug (Right) C Plug (Left)

5. Install two temporary alignment dowels in the output bearing carrier bolt holes.

6. Select a starting shim pack containing the shims described in the shim pack chart or reuse shims if undamaged.

7. Verify the thickness of each shim.

10. Apply Loctite 567 to the left and right level plugs and thread into the housing. See, INSTALL FITTINGS AND PLUGS on page 3.4.

3.16

Tigercat EHS Transmission

Assembly

Shim Size

Qty

Total Shim Thickness

0.51 mm (0.020 in)

2

1.02 mm (0.040 in)

0.18 mm (0.007 in)

2

0.36 mm (0.014 in)

0.13 mm (0.005 in)

4

0.51 mm (0.020 in)

0.08 mm (0.003 in)

1

0.08 (0.003 in)

Total =

1.97 mm (0.077 in)

Shim Pack Chart

NOTICE

11. Place a dial indicator on the housing so the measuring tool rests perpendicular to the housing on the end of the output shaft, then set the dial indicator to zero.

12. Pry the output shaft up and down using a pry bar under the output shaft. Turn the gear several times and record the variance. Zero the dial indicator before each measurement. The dial indicator must return to zero. Tap the end of the shaft with a rubber mallet if required. Repeat and record the measurement two more times.

13. Determine the required shims by adding the measured end play to the specified preload value.

Subtract that value from the starting shim pack value to calculate the final value of the shims required. For example:

Bearings must be cooled to the touch before proceeding.

8. Place the shim pack onto the alignment dowels.

9. Install the output bearing carrier and tighten each bolt 108 N-m (80 lbf-ft). Do not apply Loctite.

Preload Calculations

10. Turn the output shaft several rotations and tap the end of the shaft with a rubber mallet to seat the bearings.

1.1 mm (0.043 in)

Measured End Play

+

0.05 mm (0.002 in)

Specified Preload 0.03 mm – 0.08 mm ( 0.001 in – 0.003 in)

–

1.14 mm (0.045 in)

Measured End Play and Specified Preload. Subtract This Value From the Starting Shim Pack*

1.97 mm (0.077 in)

Measured Value of Starting Shim Pack

1.14 mm (0.045 in)

Measured End Play and Specified Preload.

0.81 mm (0.032 in)

Calculated Value of Shims

A B C – D

Select shims from the shim pack that when added together equal the calculated distance, 0.81 mm (0.032 in).

14. Final bearing preload value must measure between be 0.0252 mm – 0.076 mm (0.001 in – 0.003 in).

E

15. Remove the output bearing carrier and the shim pack.

16. Select the necessary shims to match the calculated value. For example:

F

Dial Indicator Measuring Rod Output Shaft Output Bearing Carrier (With Starting Shim Pack – hidden) Housing Support Block Pry Bar

Qty

0.5 mm (0.020 in

1

0.5 mm (0.020 in)

0.18 mm (0.007 in)

1

0.18 mm (0.007 in)

1

0.13 mm (0.005 in)

Total =

0.81 mm (0.032 in)

0.13 mm (0.005 in)

G C00272

A B C D E F G

Shim Size

Total Shim Thickness

17. Install the calculated shim pack.

3.17

Assembly

Tigercat EHS Transmission GEAR CONTACT PATTERN TEST

18. Install the output bearing carrier: a. Orient the oil hole in the carrier with the oil hole in the transmission housing.

1. Apply contact pattern paint on four to six teeth on the output gear.

b. Insert the spring pin.

2. Install the gearbox cover. Do not apply thread locking products to the bolts.

c.

Apply Primer 7649 and Loctite 242 to each bolt and threaded hole, then install and torque each bolt to 108 N-m (80 lbf-ft).

3. Spin the output gear a minimum of twenty times in both directions.

19. Repeat steps 11 – 12 to measure for endplay variance. The measured variance must be 0.000 mm (0.000 in).

4. Remove the gearbox cover and inspect the paint patterns on gears. Paint distribution must be present along the centre of the tooth.

20. If the measured variance does not meet the required value, repeat steps 2 – 19.

5. Verify contact patterns are consistent with accurate contact setup. If irregular paint patterns are observed, contact the Tigercat Service Department.

See, CONTACT PATTERN REFERENCES on page 3.20.

A

B

GEARBOX GASKET AND COVER A

B

E

C C

*D C00273

A Output Sleeve B Transmission Housing C Gearbox Gasket D *Bolts E Gearbox Cover * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

21. Apply white assembly grease to each output sleeve and install carefully into the bearing carriers. Do not force the sleeves to avoid damage to the oil seals.

C00548

A Gearbox Gasket B Guide Pin C Housing

1. Check carefully for loose components, bolts, springs or tools.

1. Install guide pins. See, GUIDE PINS on page 1.10.

2. Install the gearbox gasket on the guide pins.

3. Clean housing oil passages of oil and debris.

3.18

Tigercat EHS Transmission

Assembly A

C

B

8. Apply Loctite 7649 then Loctite 242 to 19 of 21 *bolts and holes used to secure the cover to the housing, and secure using *bolts torqued to 45 N-m (33 lbf-ft).

Leave two holes and bolts on the front left of the housing unpopulated.

9. Apply gear oil to the O-ring and install it into the lube block manifold.

10. Align the lube block manifold to the cover and secure using *bolts torqued to 45 N-m (33 lbf-ft). Do not apply Loctite to these bolts.

C00547

A Plug B Nipple fitting C Gearbox Cover

4. Apply Loctite 7649, then Loctite 242 to nipple fittings and holes in the gearbox cover.

A

5. Apply Loctite 7649, then Loctite 242 to NPT plugs and holes in the gearbox cover. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.11.

6. Install the nipple fittings and plugs into the gearbox cover. See, INSTALL FITTINGS AND PLUGS on page 3.4.

7. Align the cover on the guide pins. The cover aligns in one orientation only.

*E D

A B

C00803

A Magnetic Plug

11. Place the transmission on support blocks of sufficient height to clear the input shaft.

12. Install the magnetic plug, finger tight, in the threaded hole in the bottom of the transmission, then torque to 68 N-m (50 lbf-ft).

C

C00546

A Lube Block Manifold B O-ring C Gearbox Cover D Two Unpopulated Bolt Holes E *Bolts * INSPECT. See, FASTENER TORQUE AND REUSE on page 1.12.

3.19

Assembly

Tigercat EHS Transmission

CONTACT PATTERN REFERENCES Run a contact pattern check after replacing input shaft, input gears and output gear using the images below as a reference.

Good Contact Pattern Contact is centered All teeth make contact Approximately 50% of the tooth width is covered by paint

C00822

Bad Contact Pattern Lead Error

Contact location is off center Teeth are contacting at the sides of the tooth face

C00823

Profile Error

Contact pattern is localized at tip or root of gear face

C00824

Pitch Error

Tooth is not making contact (no paint on tooth)

C00825

Runout Error

Pattern varies around the diameter of the gear

COO826

3.20