Tigercat PLANETARIES SERVICE AND REPAIR MANUAL - PDF DOWNLOAD

PLANETARIES

SERVICE AND REPAIR MANUAL

ISSUE 2.0, FEBRUARY 2020 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat Planetaries TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v NON-APPROVED FIELD PRODUCT / PARTS CHANGES............................................................................... vi OUTBOARD PLANETARY– EXPLODED VIEW................................................................................................viii INBOARD PLANETARY– EXPLODED VIEW...................................................................................................... x SAFETY...............................................................................................................................................................1 DISASSEMBLY....................................................................................................................................................2 ASSEMBLY..........................................................................................................................................................3 APPENDIX A........................................................................................................................................................4

Service and Repair Manual (this manual).......................................................................................Part No. 47738AENG iii

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

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

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 Planetaries

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

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

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

Authorization by any other person is unacceptable.

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

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

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

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

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

Tigercat Industries Inc.

vi

Tigercat Planetaries

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

TIGERCAT PLANETARIES Tigercat manufactures standard and severe duty planetaries with inboard and outboard configurations. Despite the physical differences between the inboard and outboard configurations, internal parts and assembly processes are similar for all. This manual details the differences using exploded view drawings and parts lists. Where disassembly or assembly processes vary, detailed instructions are provided in the body of the text. Different housings may be shown throughout the manual.

B20 PLANETARY

B17 SEVERE DUTY PLANETARY

OUTBOARD

OUTBOARD

B17 PLANETARY

B17 PLANETARY

OUTBOARD

INBOARD

B15 PLANETARY

B15 SEVERE DUTY PLANETARY

INBOARD

C00347

vii

OUTBOARD

OUTBOARD PLANETARY– EXPLODED VIEW................................................................................................viii

Introduction

Tigercat Planetaries

4

22

23

18

2

21

25

10 50

19

11 12 13 14 15 16 17 8

3

60

9

7

C00345

Outboard Planetary– Exploded View

NOTE: This exploded view is representative of a typical Tigercat Outboard Planetary. Some parts may not appear exactly as shown. viii

24

Tigercat Planetaries ITEM

2 3 4 5 6 7 8 9 10 11 12 13

Introduction PART DESCRIPTION

ITEM

HOUSING SPINDLE CARRIER, PLANET BEARING, INNER BEARING, OUTER SEAL, FACE, MECHANICAL NUT, BEARING PLATE, LOCKING RING, SNAP SHIM SHIM SHIM

14 15 16 17 18 19 21 22 23 24 25

ix

PART DESCRIPTION

SHIM SHIM SHIM SHIM O-RING WASHER, THRUST GEAR, RING GEAR, PLANET BEARING, PLANET RING, SNAP GEAR, SUN

INBOARD PLANETARY– EXPLODED VIEW...................................................................................................... x

Introduction

Tigercat Planetaries

19 20 21 22 23 24 25

9

10

5

14

7

4

8

18

17

16

15

13 16 17

3

12

1

6

11

2

C00346

Inboard Planetary– Exploded View

NOTE: This exploded view is representative of a typical Tigercat Inboard Planetary. Some parts may not appear exactly as shown. x

Tigercat Planetaries ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13

Introduction PART DESCRIPTION

ITEM

HOUSING SPINDLE CARRIER, PLANET NUT, BEARING PLATE, LOCKING BEARING, OUTER BEARING, INNER O-RING WASHER,THRUST RING, SNAP SEAL, FACE, MECHANICAL PLUG, MAGNETIC BEARING, PLANET

14 15 16 17 18 19 20 21 22 23 24 25

xi

PART DESCRIPTION

GEAR, RING GEAR, PLANET WASHER, THRUST RING, RETAINING RING, SNAP SHIM SHIM SHIM SHIM SHIM SHIM SHIM

Introduction

Tigercat Planetaries

xii

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

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

CONTENTS – SECTION 1

ISSUE 2.0, FEBRUARY 2020

A

AIR, COMPRESSED................................................................................................................................................... 1.6

C

CALIBRATION............................................................................................................................................................. 1.7 CARRYING, PERSONAL SAFE LIFTING AND......................................................................................................... 1.8 CAUTION..................................................................................................................................................................... 1.3 CLEAN AND INSPECT................................................................................................................................................ 1.8 COMPETENT PERSON.............................................................................................................................................. 1.4 CONTAMINATION....................................................................................................................................................... 1.8

D

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

H

HAZARDOUS MATERIALS SAFETY......................................................................................................................... 1.4 FLAMMABILITY........................................................................................................................................................ 1.4 LIQUID NITROGEN................................................................................................................................................. 1.4 WORKING WITH OIL............................................................................................................................................... 1.6

I

INJURIES, GREASE INJECTION WHEN USING PNEUMATIC GREASE GUNS................................................. 1.6 INJURIES, HIGH PRESSURE INJECTION............................................................................................................... 1.5 INSTRUCTIONS AND REQUIRED RECORD KEEPING......................................................................................... 1.8

L

LIQUID NITROGEN..................................................................................................................................................... 1.4

M

MATERIAL HANDLING............................................................................................................................................... 1.8 SAFE LIFTING AND CARRYING, PERSONAL..................................................................................................... 1.8

N

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

P

PERSON, COMPETENT............................................................................................................................................. 1.4 PICTOGRAMS............................................................................................................................................................. 1.3 PLANT AND ANIMAL HAZARDS................................................................................................................................ 1.7 PROTECTIVE EQUIPMENT (PPE), PERSONAL..................................................................................................... 1.3

R

READ THIS MANUAL FIRST...................................................................................................................................... 1.3

S

SAFETY, GENERAL.................................................................................................................................................... 1.3 SAFETY, HAZARDOUS MATERIALS........................................................................................................................ 1.4 SAFETY SYMBOLS..................................................................................................................................................... 1.3 SAFETY, VENTILATION............................................................................................................................................. 1.4 SIGNAL WORDS, UNDERSTANDING...................................................................................................................... 1.3

T

TOOLS AND MATERIALS, REQUIRED..................................................................................................................... 1.9

V

VENTILATION SAFETY.............................................................................................................................................. 1.4 VITON SEALS.............................................................................................................................................................. 1.7

W

WARNING.................................................................................................................................................................... 1.3 WORK CONDITIONS AND TOOLS........................................................................................................................... 1.7 TOOL CALIBRATION............................................................................................................................................... 1.7 WORKING WITH OIL.................................................................................................................................................. 1.5

Safety

Tigercat Planetaries

1.2

Tigercat Planetaries

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 planetaries 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 Remember, 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 which should always 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 should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message.

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

SAFETY SYMBOLS

PERSONAL PROTECTIVE EQUIPMENT (PPE)

This safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

UNDERSTANDING SIGNAL WORDS

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

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

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

WARNING

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 Planetaries

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 enviroN-ment.

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.

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

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

VENTILATION SAFETY

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

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

FLAMMABILITY

• 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.

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

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 Planetaries

Safety

HIGH PRESSURE INJECTION INJURIES

WARNING

WARNING

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

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

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

• Seek professional medical attention immediately.

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

When searching for possible fluid leaks:

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.

• Never search for leaks with your bare hands. Always 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.

• Be sure to 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. Never use any part of your body.

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

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

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

• Never handle 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.

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

WARNING

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.

Never use any hydraulic equipment suspected of being defective.

1.5

Safety

Tigercat Planetaries

GREASE INJECTION INJURIES WHEN USING PNEUMATIC GREASE GUNS

WORKING WITH OIL Direct contact with oil implies a risk of skin complaints (For example: eczema). Strict hygiene should always be observed.

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

WARNING

• Avoid contact with oil, particularly heated oil.

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

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

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

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

• Don't put oily rags in your pockets.

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

• Always keep an extra change of work cloths nearby.

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

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

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

• Avoid breathing in oil fumes.

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

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

COMPRESSED AIR Compressed air is a concentrated, high pressure, high speed stream of air that can seriously injure or kill. Air pressures of 0.3 – 0.7 bar (5 – 10 psi) can cause serious injury. Most pneumatic tools operate at 5.5 – 8.3 bar (80 – 120 psi).

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

• Do not 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.

• Never clean clothing or skin using compressed air.

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

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

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

• Use a chip guard.

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

• Air pressure of 2 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 Planetaries

Safety WORK CONDITIONS AND TOOLS

VITON SEALS

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

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 315°C (600°F).

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: • 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.

TOOL CALIBRATION

• 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

PLANT AND ANIMAL HAZARDS

• Repaired or changed

Tigercat machines are used in many countries that are home to poisonous/stinging plants and animals.

Be aware of potential dangers when clearing debris or reaching into or beneath machines or components that may contain hidden plant or animal hazards.

• 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

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

1.7

Safety

Tigercat Planetaries

MATERIAL HANDLING

CLEAN AND INSPECT WARNING

DANGER

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

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.

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

WARNING

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

Only competent personnel are permitted to operate cranes or hoists.

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.

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.

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

4. Clean and inspect each component as it is removed from the assembly. Inspect all components, housings, covers, and manifolds for burrs, nicks, scratches, porosity defects or cracks.

• Do not exceed working load limits.

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

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

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

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

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

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

PERSONAL SAFE LIFTING AND CARRYING

7. Clean and inspect all replacement components.

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

8. Verify that the correct parts are being installed.

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.

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.

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

Service reporting sheets are available from your Tigercat dealer.

1.8

Tigercat Planetaries

Safety

REQUIRED TOOLS AND MATERIALS To disassemble the planetaries 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:

A C

• Bearing Puller • Isopropyl alcohol or equivalent solvent • Clean rags • Marking pen • PPE

B

• Wooden support blocks • Torque wrench up to 136.0 N-m (100 ft/lbs) • Torque wrench up to 0-813.0 N-m (600 ft/lbs) • Rolling torque measuring tool 0-813.0 N-m (0-600 in-lb)

C00740

Retaining Ring Tool

A B7536001 Retaining Ring Tool Block (part of B7536000) B Planet Gear C Retaining Ring

• Snap ring installation tool • Lead balls 0.125, SSS-196 • Torque Multiplier up to 2712.0 N-m (2000 ft/lbs) • Kit, Torque Field Fixture, Planetary 78104B

A C00358

A 52264B Wheel End Nut Torque Tool

A

C00360

A B20-B17 Severe Duty 207897 Mechanical Seal Tool B17-B15 Standard Duty 211211 Mechanical Seal Tool

1.9

Safety

Tigercat Planetaries

1.10

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

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

CONTENTS – SECTION 2

ISSUE 2.0, FEBRUARY 2020

B

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

D

DISASSEMBLY TASKS............................................................................................................................................... 2.3

G

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

H

HEATING BEARINGS FOR INSTALLATION............................................................................................................. 2.3

N

NOTICE........................................................................................................................................................................ 2.6

P

PLANET BEARINGS, REMOVE................................................................................................................................. 2.5 PLANET CARRIER, REMOVE................................................................................................................................... 2.6 PLANET GEAR BEARINGS B15, REMOVE.............................................................................................................. 2.5 PLANET GEAR BEARINGS B17-B20, REMOVE...................................................................................................... 2.6 PLANET GEARS, REMOVE....................................................................................................................................... 2.5

S

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

Disassembly

Tigercat Planetaries

2.2

Tigercat Planetaries SAFETY

Disassembly REMOVE RING GEAR

See, GENERAL SAFETY PRECAUTIONS on page 1.3 for references to safety warnings and messages.

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.

BEARING REMOVAL

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

A

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

B

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

3. Never heat standard product bearing cones, cups gears or steel sleeves above 120°C (250°F). If heated above this temperature, the metallurgical structure may soften, rendering them unsuitable for use.

C

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

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

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

C00276

A O-ring B Ring Gear C Housing

The ring gear may lift off the housing with little resistance or it may be jammed onto the top of the housing.

LITTLE OR NO RESISTANCE 1. Remove the ring gear and O-ring from the planetary wheel end housing. a. Remove the O-ring from the top of the ring gear. b. Insert a 0.75 in diameter metal rod into a clearance hole on the ring gear. c.

Strike the metal rod several times to loosen the ring gear.

d. Lift the ring gear straight up, off the planet gears.

Oscillate the gear ring while lifting.

2.3

Disassembly

Tigercat Planetaries

A

A

B D

B

C

D

C

E

C00353

A B C D E

SECTION A-A (N.T.S.)

Pry Bar Gear Tooth Ring Gear O-ring Housing

C00352

A B C D

MODERATE TO STRONG RESISTANCE

Pry Bar Ring Gear O-ring Support Block

4. Insert pry bars to leverage the ring gear as the gap increases. Do not damage the edge of the housing.

To remove the ring gear and O-ring from the planetary wheel end housing.

5. Incrementally pry the circumference of the ring gear from the inside until the ring gear comes free of the housing.

1. Position the planetary on its side, on a sturdy work surface.

2. Place support blocks under the spindle circumference to stop the unit from rolling.

6. Remove the O-ring from between the housing and the gear ring. There may be an O-ring on the outer surface of the ring gear. Remove it if it is still present.

3. Insert a bar with a 45° angle on the end between the inside bevel of the ring gear and the housing and strike the bar to start the ring gear moving.

2.4

Tigercat Planetaries

Disassembly REMOVE PLANET BEARINGS

REMOVE PLANET GEARS

CAUTION

NOTICE

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

Avoid damage to the inner diameter of the output gear when removing the gear sleeve and roller bearing.

Carefully inspect all gears and gear bearings for debris that may contaminate and damage other bearings or gears. Replace any damaged gears or bearings.

A

REMOVE PLANET GEAR BEARINGS B15

B

A

B

C

C

E D

D

C00278

A B C D

Snap Ring Planet Gear Planet Carrier Spindle C00350

1. Remove snap rings holding the planet gears to the planet carrier.

A B C D E

2. Remove the planet gears from the planet carrier using a bearing puller or two pry bars.

Thrust Washer Planet Gear Retaining Ring Strap or Elastic Band Planet Bearing

1. Remove the retaining ring from the groove on one side of the planet gear.

2. Remove the thrust washer from the same side of the planet gear.

3. Place a barrier on top of the same side of the planet bearing.

4. Turn the gear over.

5. Remove the retaining ring from the groove in the planet gear.

2.5

Disassembly

Tigercat Planetaries REMOVE PLANET CARRIER

6. Turn the gear onto its side.

7. Push against the thrust washer to expose a portion of the rollers so that a strap (for example, an elastic band or cardboard strip) can be wrapped around the exposed rollers to hold them in the race.

A

8. Push the bearing from the gear.

B

REMOVE PLANET GEAR BEARINGS B17 – B20

C

NOTICE Do not contact the the inner gear surface when cutting the notch.

D E A B

E

D C

C00354

A B C D E

C00325

A B C D E

Planet Gear Planet Bearing Bearing Inner Race Cut Notch Bearing Roller

Snap Ring Locking Plate Bearing Nut Planet Carrier Spindle (base)

1. Remove the snap ring securing the locking plate in the planet carrier.

A

1. Notch the bearing inner race using a die grinder with a wheel cutter.

A

2. Remove the rollers using a magnet. When enough rollers are removed from one side of the bearing, the snap ring is exposed.

B B

3. Remove the remains of the planet bearing.

4. Remove the snap ring from the inner diameter of the planet gear.

C C

C00370

A Pry Tool B Planet Carrier C Locking Plate

2.6

Tigercat Planetaries

Disassembly

2. Remove the locking plate from the planet carrier using pry tools.

A

B

A N B

M L

C

C

D

K E F

J C00351

A B C D E F G H J K L M P

G

C00355

A Bearing Nut B Planet Carrier C Metal Punch

H

Bolt (78104B) Washer (78104B) Spacer (78104B) Wheel End Nut Torque Tool (52264B) Nut (78104B) Base(78104B) Bolt (78104B) Washer (78104B) Spindle Planet Carrier Housing Clamp Plate (78104B) Torque Multiplier/Torque Wrench

If the kit or wheel end nut torque tool are unavailable: a. Secure the spindle base so that it does not turn.

A

3. Remove the bearing nut securing the planet carrier to the spindle using the Planetary Torque Field Fixture, Kit. Assemble the kit as directed by the instructions included with the kit.

4. Remove the bearing nut.

B C00435

A Good Strike Angle B Metal Punch

b. Rest a metal punch in a scalloped portion of the nut and strike firmly in a counterclockwise direction. Strike the punch at an angle away from the threads as indicated.

2.7

Disassembly

Tigercat Planetaries A

F

B

A B

C

D

E

C

E D

C00356

A B C D E

C00357

Shims Planet Carrier Thrust Washer Spindle Housing

A B C D E F

5. Lift the planet carrier from the housing.

Lifting Ring Inner Bearing Cup Housing Spindle Nut Bearing Cone

8. Insert M16-2 lifting rings with nuts or equivalent in opposite positions in the housing.

6. Remove the shims from the top of the spindle.

7. Remove the thrust washer from the top of the bearing cone.

9. Raise the housing clear of the spindle by two inches.

The bearing cone will come free from the top of the spindle. If the bearing cone does not come free, place a piece of wood on the top of the spindle and strike down on the spindle. Do not damage the end of the spindle.

2.8

Tigercat Planetaries

Disassembly H

A

A

B

B C C

D E

G

F C00434

A B C D E F G H

C00359

A Outer Bearing B Mechanical Face Seal (one of two symmetrical parts) C Spindle

10. Remove the outer bearing using a bearing separator.

11. Manually lift the mechanical face seal from the spindle.

Housing Mechanical Face Seal (one of two symmetrical parts) Outer Bearing Cup Support Block Nut Lift Ring Inner Bearing Cup Metal Punch

12. Raise the housing and move to a sturdy level work surface and rest it on its side. Use support blocks to stop the housing from rolling.

13. Remove the lifting rings.

14. Remove the mechanical face seal from the housing.

15. Turn the housing to rest on the flange.

16. Drive the bearing cups from the inside of the housing using a punch.

See BEARING REMOVAL on page 2.3.

2.9

Disassembly

Tigercat Planetaries

2.10

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

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

CONTENTS – SECTION 3

ISSUE 2.0, FEBRUARY 2020

A

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

B

BEARING CONE, INSTALL INNER............................................................................................................................ 3.9 BEARING INSTALLATION INSTRUCTIONS............................................................................................................ 3.3

C

CLEANING AND INSPECTION.................................................................................................................................. 3.3 COOLING BEARINGS FOR INSTALLATION............................................................................................................ 3.3

F

FITTINGS AND PLUGS.............................................................................................................................................. 3.4 FILL/OIL LEVEL PLUGS.......................................................................................................................................... 3.4 MAGNETIC PLUGS................................................................................................................................................. 3.4

H

HEATER, BEARING INDUCTION.............................................................................................................................. 3.3 HEATING BEARINGS FOR INSTALLATION............................................................................................................. 3.3

M

MECHANICAL FACE SEAL, INNER (DRIVE END), INSTALL................................................................................. 3.8

O

OUTER BEARING CONE, INSTALL.................................................................................................................. 3.6, 3.7 OUTER BEARING CUP, INSTALL.............................................................................................................................. 3.7

P

PLANETARY GEARS, INSTALL............................................................................................................................... 3.13 PLANETARY HOUSING, INSTALL............................................................................................................................. 3.8 PLANET CARRIER, INSTALL..................................................................................................................................... 3.9 LOCKING PLATE, INSTALL.................................................................................................................................. 3.11 ROLLING TORQUE CALCULATE FOR NEW BEARINGS................................................................................................................. 3.10 CALCULATE FOR REUSED BEARINGS.......................................................................................................... 3.10 PLANET GEAR BEARINGS, B15, INSTALL............................................................................................................ 3.12 PLANET GEAR BEARINGS B17– B20, INSTALL.................................................................................................... 3.13

S

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

Assembly

Tigercat Planetaries

3.2

Tigercat Planetaries

Assembly

SAFETY

BEARING INDUCTION HEATER

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

WARNING

CLEANING AND INSPECTION

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

See, CLEAN AND INSPECT on page 1.8.

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

Induction 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 assembly.

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

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 and magnetic field hazards.

2. Leave bearings in packages until ready for assembly.

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

COOLING BEARINGS AND SLEEVES FOR INSTALLATION

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

WARNING

5. Large bearings, take longer to heat and cool down.

Provide enough time to fully heat and cool bearings.

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.

HEATING BEARINGS FOR INSTALLATION

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

WARNING

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

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

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

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.

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

Cooling shrinks bearings and sleeves for assembly with machine features to provide the tightest fit possible between surfaces.

4. Heat and cool bearing components gradually.

Cool parts using liquid nitrogen where available, or cool parts in a freezer unit or a period of time to allow them to reach minimum temperature.

5. Use feeler gauges to ensure 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.

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

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

3.3

Assembly

Tigercat Planetaries INSTALL INNER MECHANICAL FACE SEAL (WHEEL END)

PRIOR TO ASSEMBLY Prior to planetary assembly: 1. Have all required parts readily available.

NOTICE

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

The two halves of the mechanical face seal are matched by the manufacturer and are not interchangeable with other seal components.

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

Successful installation of the face seal depends upon seal condition and placement. Two ring and seal components, placed metal face to metal face, comprise the mechanical face seal.

• Ensure they are the right parts.

• Verify orientation.

• Replace damaged or worn components as required.

Inspect the face seals, housing, and spindle prior to installation:

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

• Clean all oil or protective coating from the housing and spindle

5. If fitting a new spindle, fully install the wheel bearing nut onto the spindle to verify that the part is free of burrs.

• Inspect for nicks, scratches or damage of the sealing surfaces. If found, remove using sandpaper or similar device.

FITTINGS AND PLUGS

• Inspect for damage or deformation of O-rings

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

• Inspect for nicks, scratches or damage on the spindle that will impact seal seating • Verify that the face seal tool is clean and oil free.

Fittings/plugs that must be removed and replaced during the assembly process should be installed finger tight only, until final assembly.

A

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

B

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

D

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

2. Insert the plug, finger tight, then torque to 27 N-m (20 lfb-ft).

C SECTION A-A NTS

A

D C00361

A B C D E

3.4

A

E

Spindle Face Seal Tool Face Seal (one half, shown not fully seated) Outer Bearing Cone Spindle Flange

Tigercat Planetaries

Assembly

FOR B20, B17 AND B15 SEVERE DUTY PLANETARY UNITS, USE FLOATING FACE SEAL TOOL 207897.

FOR B15 AND B17 STANDARD DUTY PLANETARY UNITS, USE FLOATING FACE SEAL TOOL 211211.

1. Place a face seal into the face seal tool with the metal edge of the face seal facing up in the plastic frame of the tool. The O-ring faces out.

O-RING TWISTED

a. Use the correct face seal tool: Severe planetary – use tool #207897.

Standard planetary – use tool #211211. b. Use clean rags dampened with isopropyl alcohol to lightly lubricate the face seals after they are secured in the face seal tool. Do not spray alcohol directly onto the O-ring.

O-RING PRESSED IN

2. Install the face seal on the spindle immediately after the isopropyl alcohol is applied by pressing down evenly on the tool. Alcohol evaporates quickly. The longer the wait before installation, the less lubricant effect the alcohol has.

0.5 mm (0.020 in)

A

B

C

INSTALL MECHANICAL FACE SEAL WITHOUT FACE SEAL TOOL 3. Push the outer circumference of the face seal down using a thin tab of wood or plastic in the same way one might use a shoe horn. Simultaneously, gently press down on the sliding surface with a finger to seat the face seal.

C00362

A Spindle Seat B O-ring C Metal Seal Frame

Do not adjust the face seal once it is installed. If required, remove the seal and begin the installation process again.

1. Inspect the face seal to verify correct installation.

Verify that: a. The metal frame of the seal is parallel to the spindle seat within a margin of 0.5 mm (0.020 in).

A

b. The O-ring is not twisted in the metal frame. c.

B C

The metal frame/O-ring is not pressed in at an angle.

2. Use one of two methods to verify correct O-ring seating.

C00637

A Tab B Sliding Surface C O-ring

3.5

Assembly

Tigercat Planetaries INSTALL OUTER BEARING CONE

Method 1 a. The O-ring sits slightly above the spindle seat. Insert the tip of the fore-finger in the gap between the metal frame and O-ring. You should be able to feel the O-ring and metal frame evenly as you feel along the circumference of the metal frame. If the distance in the gap between any of the seal components or spindle seat feel uneven, the seal is not installed correctly.

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

1. Heat the outer bearing cone for one and one half hours minimum at 120°C (250°F). See, BEARING INSTALLATION INSTRUCTIONS on page 3.3.

Method 2 a. Measure the distance from the top of the metal frame to the top of the spindle seat in three places equally placed. The dimensions must be within 0.5 mm (0.020 in) of one another.

A

NOTICE Use isopropyl alcohol only. Do not substitute any other chemical cleaning agent. The seal must be lightly lubricated before it is applied to the spindle.

B

1. Allow the alcohol to dry completely before starting further assembly.

C

2. Apply gear oil to the bearing cup and sliding surface of the mechanical seal.

C00368

A Outer Bearing Cone B Spindle C Face Seal

2. Install the outer bearing cone onto the spindle. Note the orientation of the bearing taper.

3. Allow the bearing to cool to the touch.

4. Verify that the outer bearing cone is fully seated on the spindle bearing shoulder using a 0.0254 – 0.0508 mm (0.001 – 0.002 in) feeler gauge.

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.

5. Apply a light coat of oil to the bearing and splines.

Do not lubricate the sliding surface of the face seal.

3.6

Tigercat Planetaries

Assembly

INSTALL INNER BEARING CUP

INSTALL OUTER BEARING CUP 1. Orient the housing with the ring gear flange facing down.

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

A

1. Orient the housing with ring gear flange facing up.

B

A

C B

C00365

A Outer Bearing Cup B Standard Axle Housing C Plug Magnetic

C00364

A Inner Bearing Cup B Standard Axle Housing

2. Cool the bearing cup in liquid nitrogen until the reaction of the nitrogen ceases (if available) or overnight in a freezer. See, COOLING BEARINGS AND SLEEVES FOR INSTALLATION on page 3.3.

2. Cool the bearing cup in liquid nitrogen until the reaction of the nitrogen ceases (if available) or overnight in a freezer. See, COOLING BEARINGS AND SLEEVES FOR INSTALLATION on page 3.3.

3. Place the outer bearing cup into the housing.

3. Place the bearing cup into the housing.

4. Allow the bearing to warm to room temperature.

4. Allow the bearing to warm to room temperature.

5. Verify the outer bearing cup is fully seated in the axle housing by using a 0.0254 – 0.051 mm (0.001 – 0.002 in) feeler gauge. If the outer bearing cup is not fully seated, carefully tap it into place using a punch that contacts the upper edge only. Tap the outer bearing cup in a star shaped pattern.

5. Verify that the bearing cup is fully seated in the housing using a 0.0254 – 0.0508 mm (0.001 – 0.002 in) feeler gauge. If the bearing cup is not fully seated, carefully tap it into place using a punch that contacts the upper edge only. Tap the bearing cup in a star shaped pattern.

6. Install required magnetic plug. a.

Apply a small amount of gear oil to the fill/oil level plug seat.

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

3.7

Assembly

Tigercat Planetaries

INSTALL INNER MECHANICAL FACE SEAL (DRIVE END)

INSTALL PLANETARY HOUSING A

FOR B20 AND B17 SEVERE DUTY PLANETARY UNITS, USE FACE SEAL TOOL 207897.

FOR B15 AND B17 STANDARD DUTY PLANETARY UNITS, USE FACE SEAL TOOL 211211.

B

NOTICE Use isopropyl alcohol only. Do not substitute any other chemical cleaning agent. The seal must dry before it is applied to the spindle.

D A

C

C00367

B

A B C D

Lifting Ring Nut Housing Support Block

1. Lay the housing on its side.

C

2. Insert M16-2.0 in lifting rings with nuts or equivalent in opposite positions in the ring gear end of the housing.

3. Lift the housing so that it is centred over the spindle, then slowly lower it onto the spindle.

C00366

A Floating Seal Tool B Face Seal C Housing

7. Install the inner face seal by following step 1 through step 5 of INSTALL INNER MECHANICAL FACE SEAL (WHEEL END) on page 3.4.

8. Allow the alcohol to dry completely before starting further assembly.

3.8

Tigercat Planetaries

Assembly

INSTALL INNER BEARING CONE

INSTALL PLANET CARRIER A B

A

C B D E

F C G

C00367

C00369

A Inner Bearing Cone B Inner Bearing Cup C Housing

A B C D E F G

1. Install the bearing cone onto the spindle. Note the orientation of the bearing taper.

2. Verify that all bearings are at room temperature.

Snap Ring Locking Plate Bearing Nut Planet Carrier Thrust Washer Spindle Housing

1. Lubricate the thrust washer with white assembly grease, then place it on the spindle.

3. Apply a light coat of oil to the bearing and splines.

4. Turn the housing three revolutions in each direction.

2. Verify that all bearings are at room temperature.

5. Lift the housing and inspect the face sea. If the seal has shifted or is twisted, remove the seal, then replace it. See, INSTALL INNER MECHANICAL FACE SEAL (DRIVE END) on page 3.8.

3. Lower the planet carrier onto the spindle end.

4. Apply a small amount of white assembly grease to the bottom of the bearing nut then install the wheel bearing nut onto the spindle.

5. Torque the bearing nut to 1830 N-m (1350 lbf-ft) to seat the bearing.

6. Remove the nut using the wheel end nut torque tool.

3.9

Assembly

Tigercat Planetaries

ROLLING TORQUE

RT Total = RT Initial + RT Target 14. Increase nut torque then measure RT Total.

D

A

15. Verify that the torque value is within the RT Target values on the Planetary Torque Value Chart.

16. Remove the bearing nut, then remove the lead balls.

17. Measure and record the thickness of each compressed ball. Add the measured value of each ball together, then divide by 4 to determine the average gap dimension.

B C

18. Determine the number and thickness of shims required +0.0, -0.05 mm (+0.00, -0.002 in) to equal the calculated value of the gap. Measure shims individually to verify the values.

A B

C00741

A B C D

C

Bearing Nut Retaining Ring Shims Locking Plate

D

7. Apply a light coat of assembly grease to the end of the spindle.

8. Place four 3.18 mm diameter (0.125 in diameter) lead balls equally spaced on the end of the spindle on the flat shoulder between the threads and spline teeth.

C00436

A B C D

9. Install the bearing nut then torque to 27 N-m (20 lbf-ft). Rotate the housing three revolutions in each direction.

10. Measure and record the value of the initial rolling torque (RT Initial) three times.

Retaining Ring Locking Plate Bearing Nut Shims

19. Apply the selected shims, onto the spindle, with the thinner shims on top.

CALCULATE FOR NEW BEARINGS 11. Increase the bearing nut torque to the value specified in the Planetary Torque Value Chart in APPENDIX A - CALCULATING PLANETARY BEARING PRELOAD on page 4.3.

CALCULATE FOR REUSED BEARINGS 12. Increase the bearing nut torque to the value specified in the Setup Nut Torque Chart for Reused Bearings in, CALCULATE FOR REUSED BEARINGS on page 3.10.

13. Measure the total rolling torque (RT Total) to verify that the target rolling torque (RT Target) value is below or just within the target range specified in the applicable chart.

3.10

Tigercat Planetaries

Assembly INSTALL LOCKING PLATE A

E

A

B

N B

M L

C D

K E

D

J C00351

A B C D E F G H J K L M N

A B C D E

G H

C

C00742

F

Retaining Ring Spline End Locking Plate Planet Carrier Bearing Nut

24. Install the locking plate. a. Increase the torque on the wheel bearing nut incrementally, using tool 52264B, to align the lobes on the nut with the locking plate.

Components of Planetary Torque Field Kit 78104B Bolt (78104B) Washer (78104B) Spacer (78104B) Wheel End Nut Torque Tool (52264B) Nut (78104B) Base(78104B) Bolt (78104B) Washer (78104B) Spindle Planet Carrier Housing Clamp Plate (78104B) Torque Multiplier/Torque Wrench

b. Fit the locking plate onto the nut, then drop the locking plate into the aligned locking gap. Do not hammer the locking plate into position. c.

20. Install the bearing nut securing the planet carrier to the spindle using the Planetary Torque Field Fixture, Kit. Assemble the kit as directed by the instructions included with the kit.

21. Tighten the nut to 1830 N-m (1350 lbf-ft) using the wheel end nut torque tool, and Planetary Torque Field Fixture Kit. 22. Remove the Planetary Torque Field Fixture, Kit. 23. Measure the rolling torque to verify that the rolling torque target value is achieved. If the rolling torque is not within acceptable limits, repeat step 5 – 12 until the appropriate value is achieved.

3.11

Install the snap ring into the groove in the planet carrier to secure the locking plate.

Assembly

Tigercat Planetaries

INSTALL PLANET GEAR BEARINGS B15

A A

E

B

B

C B C

D D

A

C00740

A B C D E

C00373

A B C D

Positioning of Parts in Planet Gear

Retaining Ring Thrust Washer Planet Bearing Planet Gear

1. Orient the planet gear with engravings facing down.

2. Place Retaining Ring Plunger Tool (B7536003) on top of the planet gear.

3. Insert a retaining ring into the top of the tool so that ring is level.

Retaining Ring Tool

B7536001 Retaining Ring Block Tool (part of B7536000) B7536002 Retaining Ring Tool (part of B7536000) B7536003 Retaining Ring Plunger Tool (part of B7536000) Planet Gear Retaining Ring

4. Insert the Retaining Ring Tool (B7536002) on top of the retaining ring, then push downward until the retaining ring snaps into the top groove on the inside of the planet gear.

5. Turn the planet gear over so that the engravings face up.

6. Insert a thrust washer into the planet gear.

7. Align the bearing with shipping tube, engravings facing up,on the planet gear then, insert (drop) the bearing in place against the thrust washer.

8. Insert a retaining ring into the top of the planet gear.

Follow steps 2 – 4.

9. Verify that the bearing spins freely. The bearing in the gear will have 0.051 – 0.914 mm (0.002 – 0.036 in) endplay.

3.12

Tigercat Planetaries

Assembly

INSTALL PLANET GEAR BEARINGS B17 – B20

INSTALL PLANET GEARS

1. Orient the planet gear with engravings facing up.

WARNING

2. Align the planet bearing/shipping sleeve with engravings facing up on the planet gear. Do not remove the shipping sleeve.

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

3. Press the bearing into the gear until the external snap ring on the bearing snaps into the central groove in the gear.

CAUTION

A

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

B

1. Heat the assembled planet gears for a minimum of one and one half hours at 120°C (250°F).

See HEATING BEARINGS FOR INSTALLATION on page 3.3.

C 9.5 mm (0.375 in)

A

B

C C00351

A ABS Coupler B Planet Bearing With Shipping Sleeve C Planet Gear D

C00278

A B C D

Retaining Ring Planet Gear Planet Carrier Housing

2. Align each bearing/gear with the bearing shoulder (engravings) facing up, then install each onto a planet carrier post.

3.13

Assembly

Tigercat Planetaries

3. Verify each bearing is fully seated on the carrier post while the bearing is still hot. If not fully seated, carefully tap it into place using a punch contacting the inner bearing race only. Tap the bearing in a star shaped pattern while the bearing is still hot.

3. Turn the ring gear over, then install the ring gear on the housing. Beware of pinch points.

4. Install snap rings on the top of each planet carrier post.

5. Install the O-ring in the ring gear groove.

5. Lubricate each needle bearing with gear oil.

4. Apply grease to the second O-ring and the O-ring groove on the ring gear.

6. Cover the open end of the planetary with a clean drop sheet to prevent contamination.

6. Rotate the housing to verify that the gears turn freely, without obstruction, in both directions.

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

A

B

C

A

D

C00375

A B C D

Top O-ring Ring Gear Groove (both sides) Ring Gear Housing

1. Apply grease to the O-ring and the O-ring groove on the ring gear.

2. Install the O-ring in the ring gear groove.

3.14

APPENDIX A........................................................................................................................................................4

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

CONTENTS – SECTION 4 C

ISSUE 2.0, FEBRUARY 2020

CALCULATING PLANETARY BEARING PRELOAD, APPENDIX A........................................................................ 4.3 CALCULATION EXAMPLE......................................................................................................................................... 4.4

Appendix A

Tigercat Planetaries

4.2

Tigercat Planetaries

Appendix A

APPENDIX A - CALCULATING PLANETARY BEARING PRELOAD Planetary Torque Value Chart Planetary Size/Type

Nut TorqueSeal (NTs)

Average Seal Rolling Torque (RTs)

Initial Nut Torque-Bearing (NTb) (Incrementally increase as needed)

Average Rolling Torque (RT)

Bearing Rolling Torque( RTb) RTb = RT - RTs

Bearing Preload Rolling Torque Target (RTbt)

B20

27 N-m (20 lbf-ft).

237 N-m (175 lbf-ft)

23.5 ± 9.5 N-m (207.5 ± 82.5 in-lb)

B17 Severe

27 N-m (20 lbf-ft).

271 N-m (200 lbf-ft)

23.5 ± 9.5 N-m (207.5 ± 82.5 in-lb)

B17

27 N-m (20 lbf-ft).

203 N-m (150 lbf-ft)

8.0 N-m ± 2.0N-m (70 ± 15.0 in-lb)

B15 Severe

27 N-m (20 lbf-ft).

203 N-m (150 lbf-ft)

23.5 ± 9.5 N-m (207.5 ± 82.5 in-lb)

B15

27 N-m (20 lbf-ft).

203 N-m (150 lbf-ft)

7.5 ± 1.5 N-m (65.0 ± 15.0 in-lb)

3. Rotate the housing three times in each direction then torque the nut to 27 N-m (20 lbf-ft).

A

4. Take three measurements of the seal rolling torque and record the average value (RTs).

5. Torque the nut using the initial bearing nut torque (NTb) value indicated in the Planetary Torque Values Chart for the size and type of planetary bearing serviced. Take three measurements of the rolling torque and record the average value (RT).

B

6. Calculate the bearing rolling torque (RTb) by subtracting RTs from RT.

A C

RTb= RT - RTs 7. The calculated final bearing rolling torque (RTb) must measure near the middle of the range indicated in bearing rolling torque target (RTbt) values.

B

8. If the target value is not met, repeat step 5 through step 8, incrementally increasing NTb until a value near the mid-range of the RTbt is achieved.

9. See the example on the following page. The shaded columns indicate fields requiring measurements and calculations.

C00419

A Planet Carrier B Spindle End C Lead Ball

10. Remove the nut.

NEW BEARINGS

11. Remove four lead balls from the top of the spindle.

1. Place four lead balls (SSS-196), evenly spaced on the surface of the spindle.

12. Measure the flattened thickness of each lead ball and record the value.

2. Install the wheel bearing nut and apply seal nut torque (NTs) to compress the seals using the Wheel End Nut Torque Tool (52264B).

4.3

Appendix A

Tigercat Planetaries

13. Calculate the number and size of shims required to equal the measured averaged thickness of the lead balls. The thickness of the shims must be within + 0.00 mm (+0.000 in) to 0.05 mm (-0.002 in) of the averaged measured thickness of the compressed lead balls.

RE-USED BEARINGS 14. If the bearings are being re-used, use the values found in the Setup Nut Torque Chart for Re-Used Bearings. The rolling torque (RT) is not applicable.

Differential

Setup Nut Torque

B20

305 N-m (225 lbf-ft)

B17 Severe

305 N-m (225 lbf-ft)

B17 Standard

270 N-m (200 lbf-ft)

B15 Severe

270 N-m (200 lbf-ft)

B15 Standard

270 N-m (200 lbf-ft)

Setup Nut Torque Chart for Re-used Bearings

CALCULATION EXAMPLE Planetary Torque Value Chart Example Planetary Size/Type

B20

Nut TorqueSeal (NTs)

27 N-m (20 lbf-ft).

Average Seal Rolling Torque (RTs)

Initial Nut Torque-Bearing (NTb) (Incrementally increase as needed)

Average Rolling Torque (RT)

Bearing Rolling Torque( RTb) RTb = RT RTs

Bearing Preload Rolling Torque Target (RTbt)

[225+225+230] ÷ 3 = 227

305 N-m (225 lbf-ft)

[349+345+350] ÷3 = 348

≈ 121 not in range

23.5 ± 9.5 N-m (207.5 ± 82.5 in-lb)

352 N-m (260 lbf-ft)

[370, 365, 370] ÷3= 372

≈ 145 just in range

23.5 ± 9.5 N-m (207.5 ± 82.5 in-lb)

406 N-m (300 lbf-ft)

[450, 450, 455] ÷3= 442

≈ 215 near mid value

23.5 ± 9.5 N-m (207.5 ± 82.5 in-lb)

21. Increase NTb in small increments, repeating step 4 and step 5, until RT falls near the mid-range of RTbt.

15. Torque the nut to NTs 27 N-m (20 lbf-ft).

16. Take three measurements of the seal rolling torque and record the average value (RTs).

[225 + 225 + 230] ÷ 3 = RTs 227.

The RTs value is a one-time measurement and does not change unless the seals change.

17. Torque the nut to NTb 305 N-m (225 lbf-ft).

18. Take three measurements of the rolling torque and record the average value (RT).

[350 + 350 + 345] ÷ 3 = RT 348.

19. Calculate RTb. RT 348 - RTs 227 ≈ RTb 121.

20. The calculated RT value of 121 in-lb does not fall within the RTbt range.

4.4