Tigercat TRACK DRIVE GEARBOX SERVICE AND REPAIR MANUAL - PDF DOWNLOAD

PUMP DRIVE GEARBOXES 6 INCH AND 8 INCH

SERVICE AND REPAIR MANUAL

ISSUE 1.0, DECEMBER 2018 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat Pump Drive Gearboxes TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v NON-APPROVED FIELD PRODUCT / PARTS CHANGES............................................................................... vi 6 inch Pump Drive Gearbox - Exploded View....................................................................................................viii 8 inch Pump Drive Gearbox - Exploded View...................................................................................................... x 8 inch Pump Drive Gearbox, Inverted - Exploded View......................................................................................xii SAFETY...............................................................................................................................................................1 DISASSEMBLY....................................................................................................................................................2 ASSEMBLY..........................................................................................................................................................3

This Manual Part No. 47736AENG iii

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

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

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 Pump Drive Gearboxes

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 Pump Drive Gearboxes

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.

TIGERCAT PUMP DRIVE GEARBOXES Tigercat manufactures numerous configurations of Pump Drive Gearboxes. Despite any physical differences between the configurations, internal parts and assembly processes are similar for each gearbox type. This manual details the differences using exploded view drawings and parts lists. Where disassembly or assembly processes vary, detailed instructions are provided in the body of the text. Different pump drive gearboxes may be shown throughout the manual.

Pump Drive Gearboxes vary by pump size, 6 inch or 8 inch, and by the type and position of pump adaptor plates, based on customer orders.

vii

6 inch Pump Drive Gearbox - Exploded View....................................................................................................viii

Introduction

Tigercat Pump Drive Gearboxes

5

14

10

24

25

16

2

23

22

4

6

18 8 9

17

7

4

3

4

3

4

21

13 19 3 15

1

4

4 26 12 13

4 15

20

4

11

13

3

21

15 C00499

6 inch Pump Drive Gearbox - Exploded View

NOTE: This exploded view is representative of a typical Tigercat 6 inch Pump Drive Gearbox. Some parts may not appear exactly as shown. viii

Tigercat Pump Drive Gearboxes ITEM

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

Introduction

PART DESCRIPTION

ITEM

HOUSING COVER, INPUT GEAR BEARING SHAFT SEAL ELBOW BREATHER CONNECTOR WASHER PLUG, MAGNETIC SENSOR PLUG

14 15 16 17 18 19 20 21 22 23 24 25 26

ix

PART DESCRIPTION

BOLT BOLT PIN, SPRING TUBE, DIPSTICK DIPSTICK PLUG, EXPNSION PLATE, ADAPTER PLATE, ADAPTER PLATE HUB BOLT WASHER PLUG

8 inch Pump Drive Gearbox - Exploded View...................................................................................................... x

Introduction

Tigercat Pump Drive Gearboxes

34

15

31

32 2

9 19 22

3

5

5 26

28

14

5

13

4 5

26 23 1

29

8

6

11

18

30 25

17

10

20

27

24

21

33

16

7

30

12

C00500

8 inch Pump Drive Gearbox - Exploded View

NOTE: This exploded view is representative of a typical Tigercat 8 inch Pump Drive Gearbox. Some parts may not appear exactly as shown. x

Tigercat Pump Drive Gearboxes ITEM

Introduction

PART DESCRIPTION

ITEM

1 HOUSING 18 2 COVER, INPUT 19 3 GEAR, INPUT 20 4 GEAR, OUTPUT 21 5 BEARING 22 6 PLATE, ADAPTER 23 7 PLATE, ADAPTER 24 8 PLATE, ADAPTER 25 9 SHAFT 26 10 COVER, ADAPTER, PUMP 27 11 ADAPTER, SPLINE 28 12 ADAPTER, SPLINE 29 13 TUBE,DIPSTICK 30 14 DIPSTICK 31 15 BOLT 32 16 BOLT 33 17 BOLT 34 * Adapter plate O-rings are shipped in a separate bag with the pump drive gearbox.

xi

PART DESCRIPTION

RING, RETAINING O-RING O-RING O-RING SEAL PLUG, EXPANSION PLUG, MAGNETIC PLUG PLUG PLUG PLUG O-RING * O-RING * WASHER PIN, SPRING SENSOR, TEMPERATURE PLATE, GUARD

8 inch Pump Drive Gearbox, Inverted - Exploded View......................................................................................xii

Introduction

Tigercat Pump Drive Gearboxes

15

21

17

16 28

13

18

19

12

11

22

10

14

20

26 1 25

26 25 24 23

9 8 29

6 5

4

24

2

23

8

3

7 27

25

26

25

C00549

8 inch Pump Drive Gearbox, Inverted - Exploded View

NOTE: This exploded view is representative of an inverted Tigercat 8 inch Pump Drive Gearbox showing the forced lube pump and tubing. Some parts may not appear exactly as shown.

xii

Tigercat Pump Drive Gearboxes ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Introduction

PART DESCRIPTION

ITEM

PUMP DRIVE GEARBOX PLATE, ADAPTER, PUMP PUMP SPLINE, ADAPTER O-RING RING, RETAINING CONNECTOR BOLT TUBE TUBE TUBE TUBE TUBE FITTING, ELBOW BOLT

16 17 18 19 20 21 22 23 24 25 26 27 28 29

xiii

PART DESCRIPTION

VALVE, CHECK CONNECTOR FITTING, ELBOW SENSOR, PRESSURE/TEMPERATURE FITTING, UNION MANIFOLD, LUBE PLUG, NPT PLUG, NPT PLUG, EXPANSION PLUG, ORB PLUG, NPT PLUG, NPT FITTING, ADAPTER, T CONNECTOR

Introduction

Tigercat Pump Drive Gearboxes

xiv

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

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

CONTENTS – SECTION 1 C

ISSUE 1.0, DECEMBER 2018

CALIBRATION............................................................................................................................................................... 1.6 CAUTION...................................................................................................................................................................... 1.3 CLEAN AND INSPECT.................................................................................................................................................. 1.8 COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING......................................................... 1.10 D

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

GASKET FORMING/SEALANT PRODUCTS............................................................................................................... 1.9 H

HAZARDS..................................................................................................................................................................... 1.4 COMPRESSED AIR................................................................................................................................................... 1.5 FLAMMABILITY......................................................................................................................................................... 1.4 LIQUID NITROGEN................................................................................................................................................... 1.4 VENTILATION............................................................................................................................................................ 1.4 VITON SEALS............................................................................................................................................................ 1.5 WORK CONDITIONS AND TOOLS........................................................................................................................... 1.6 WORKING WITH OIL................................................................................................................................................. 1.5 M

MATERIAL LIFTING AND HANDLING.......................................................................................................................... 1.6 N

NOTICE......................................................................................................................................................................... 1.3 P

PERSONAL PROTECTIVE EQUIPMENT..................................................................................................................... 1.3 PERSONAL SAFE LIFTING AND CARRYING............................................................................................................. 1.7 PICTOGRAMS.............................................................................................................................................................. 1.3 R

REMOVE FASTENERS SECURED WITH LOCTITE THREAD LOCKER COMPOUNDS........................................... 1.9 REMOVE LOCTITE FLANGE SEALANT...................................................................................................................... 1.9 REQUIRED TOOLS...................................................................................................................................................... 1.7 S

SAFETY......................................................................................................................................................................... 1.3 SAFETY SYMBOLS................................................................................................................................................... 1.3 UNDERSTANDING SIGNAL WORDS....................................................................................................................... 1.3 T

THREAD LOCKER AND PRIMER PRODUCTS........................................................................................................... 1.9 THREAD LOCKING COMPOUNDS AND SEALANTS.................................................................................................. 1.9 TOOLS, DISASSEMBLY AND ASSEMBLY................................................................................................................... 1.8 TOOLS, REQUIRED..................................................................................................................................................... 1.6 W

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

Safety

Tigercat Pump Drive Gearboxes

1.2

Tigercat Pump Drive Gearboxes

Safety

READ THIS MANUAL FIRST

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

CAUTION

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

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

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

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

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.

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

SAFETY

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.

SAFETY SYMBOLS

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.

This safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

PERSONAL PROTECTIVE EQUIPMENT (PPE)

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.

1.3

Safety

Tigercat Pump Drive Gearboxes

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

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

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

LIQUID NITROGEN

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

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 WARNING

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

Hazardous solvents, oils, fuels and materials are present or are used to service pump drives.

Read and understand MSDS/PSDS literature.

VENTILATION

WARNING

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

DO NOT burn discarded items except in an approved incineration process. Burning such items creates hazardous fumes.

• 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.

• 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.

• 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.

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

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

1.4

Tigercat Pump Drive Gearboxes

Safety

WORKING WITH OIL

VITON SEALS

WARNING

WARNING

Direct contact with oil may cause moderate skin, eye or lung irritations. See the MSDS or PSDS for proper handling and storage of machine oils.

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

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

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).

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

• Avoid breathing in oil fumes.

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

• Wash hands and arms frequently.

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

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

Oil soiled clothing should be changed as soon as possible.

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

COMPRESSED AIR

If these are found, DO NOT touch.

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

• 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.

Follow acceptable Health and Safety protocols for using compressed air.

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

• Never clean clothing or skin using compressed air.

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

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

• Use a chip guard.

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

1.5

Safety

Tigercat Pump Drive Gearboxes

WORK CONDITIONS AND TOOLS

DANGER

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.

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

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

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

WARNING

MATERIAL LIFTING AND HANDLING

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

WARNING Only competent personnel are permitted to operate cranes or hoists.

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.

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.

CALIBRATION

• DO NOT exceed working load limits.

NOTICE

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

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

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

• DO NOT shock, bounce or jerk a load when lowering or lifting.

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.

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

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.

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

1.6

Tigercat Pump Drive Gearboxes

Safety

PERSONAL SAFE LIFTING AND CARRYING

REQUIRED TOOLS

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.

To disassemble a pump drive 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:

When manually lifting components:

• Bearing Puller

• Wear appropriate PPE

• Isopropyl alcohol or Tigercat approved equivalent solvent

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

• Clean rags

• Consider if a lifting device can be used

• Marking pen

• Determine if the load weight is within your safe lifting capacity

• PPE • Support Stands

• Verify the route and destination used to move and place the load is clear of obstructions

• Wooden support blocks

To safely lift a load,

• Torque Multiplier

• Assume a stable lifting stance

• Torque wrench up to 600 ft/lbs

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

• Snap ring installation tool • Tapered punches suitable for seating expansion plugs, [9.0mm (0.359 inch)]

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

• Loctite solvent or Tigercat approved equivalent

• Keep your back straight

• Loctite 242 - SSA001

• Lift with legs

• Loctite 567 - SSA054

• Keep load close to waist

• Loctite 648 - SSA244

• DO NOT twist your torso. Move your feet.

• Loctite 5699 - SSL063

• Keep your head up and watch your route.

• Loctite Primer 7649 - 93996

SAFE SUPPORT OF COMPONENTS Pump drives are heavy and represent a crush hazard if not adequately supported and braced. Use robust stands or wooden blocks to support and brace major components so they DO NOT fall or roll. When removing one major component from another ensure that both components are adequately supported.

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.

1.7

Safety

Tigercat Pump Drive Gearboxes

DISASSEMBLY AND ASSEMBLY TOOLS

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

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

C00531

A Input Seal Tool (A7626000) 8 inch pump

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

2. Read accompanying reports.

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

C00550

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

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

A Input Seal Tool (40096A) 6 inch pump

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

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

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

C00557

A Runout Dial Gauge (B8621000)

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

Worn components must be replaced.

1.8

Tigercat Pump Drive Gearboxes

Safety

THREAD LOCKING COMPOUNDS AND SEALANTS

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

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.

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 primer and allow to dry for a minimum of 70 seconds. Parts should be used within one month of priming. Parts that are primed for future use must be kept free of contamination.

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

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

1. Remove the fastener.

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

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

Remove while hot. c.

7. Wipe excess Loctite from the site.

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

Clean threads with a wire brush.

d. Wipe excess material from screw.

GASKET FORMING/SEALANT PRODUCTS

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

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

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

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

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

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. Apply the mating part.

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

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

5. Wipe excess gasket forming product from the site.

1.9

Safety

Tigercat Pump Drive Gearboxes

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.

1.10

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

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

CONTENTS – SECTION 2

ISSUE 1.0, DECEMBER 2018

D

DISASSEMBLE THE PUMP DRIVE GEARBOX DIPSTICK TUBE, REMOVE....................................................................................................................................... 2.5 INPUT COVER, REMOVE......................................................................................................................................... 2.8 INPUT SHAFT, REMOVE........................................................................................................................................... 2.6 INPUT SPUR GEAR, REMOVE................................................................................................................................. 2.9 PUMP ADAPTER PLATES, REMOVE..................................................................................................................... 2.10 REMOVE THE DRIVE PLATE/HUB........................................................................................................................... 2.4 SENSOR LOCATIONS............................................................................................................................................... 2.6 SPUR GEAR BEARINGS, REMOVE....................................................................................................................... 2.11 SPUR GEARS, REMOVE........................................................................................................................................ 2.10 M

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

PREPARE TO DISASSEMBLE THE PUMP DRIVE GEARBOX REMOVE OIL............................................................................................................................................................. 2.4 S

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

Disassembly

Tigercat Pump Drive Gearboxes

2.2

Tigercat Pump Drive Gearboxes

Disassembly

SAFETY

narrow top of the housing, facing the observer.

See SECTION 1 of this manual for references to safety warnings and messages.

Both pumps drives may be installed in a standard orientation with the single output port to the top of the housing, or they may be inverted with the single output port to the bottom.

MACHINE ORIENTATION

C00502

C00488

6 inch Pump Drive Gearbox-Inverted Installation Output Port Locations

6 inch Pump Drive Gearbox-Standard Installation Output Port Locations

Inverted pump drive gearboxes may or may not have dipsticks or dipstick tubes which may be located elsewhere in the final machine assembly.

I

C00501

8 inch Pump Drive Gearbox-Standard Installation Output Port Locations

C00513

Port Identification-Input Port Location

Positional references for the standard installation of a pump drive gearbox are based on viewing the pump drive gearbox with the single output port (A) at the

2.3

Disassembly

Tigercat Pump Drive Gearboxes

PREPARE TO DISASSEMBLE THE PUMP DRIVE GEARBOX

DISASSEMBLE THE PUMP DRIVE GEARBOX REMOVE THE FLEX DRIVE COUPLING

WARNING Pump Drive Gearbox components are heavy. Use appropriate lifting devices. Support and brace major components so they DO NOT fall or roll.

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

C

D

A

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

There are two sizes of pump drive gearboxes used in Tigercat machines: 6 inch and 8 inch. Both types are shown in this manual. Both the 6 inch and 8 inch pump drive gearboxes may be installed in an inverted orientation.

B C00489

A B C D

The 8 inch pump drive may be built with, or without a forced lubrication oil system.

The drive plate/ hub may or may not be present.

Housing Pump Drive Input Shaft Flex Drive Coupling Input Cover

1. Remove the flex drive coupling (if present) from the pump drive input shaft and set it aside for cleaning and inspection.

See PERSONAL SAFE LIFTING AND CARRYING in Section 1.

REMOVE RESIDUAL OIL

See SAFE SUPPORT OF COMPONENTS in Section 1.

WARNING

See, MATERIAL LIFTING AND HANDLING on page 1.6.

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

In lieu of such laws and regulations, dispose of materials as suggested in the MSDS/PSDS literature. See WORKING WITH OIL in Section 1.

Service the pump drive gearbox on a clean, robust work surface. The work area: • Must be level • Must be clean

Most oil will be drained from the pump drive gearbox prior to removal from the machine. An 8 inch gearbox may contain up to 7.7 l (2 gal US). A 6 inch gearbox may contain up to 4.0 l (1 gal US).

NOTICE Use the correct tools to loosen and tighten fittings, sensors and tubes.

2.4

Tigercat Pump Drive Gearboxes

Disassembly REMOVE DIPSTICK TUBE The dipstick tube is factory installed and is only removed when cracked or broken.

A

STRAIGHT DIPSTICK TUBE B

If sufficient material extends above the housing.

1. Remove and retain the dipstick.

2. Remove the tube with standard hand tools.

3. Clean the mounting hole with solvent and a wire brush.

If insufficient dipstick tube extends outside of the housing, remove a pump adapter and spur gear nearest the dipstick tube, then repeat steps 2 from inside the housing.

EXTENDED DIPSTICK TUBE

C

A B

C00503

Drain Plug Locations

C

A Inverted Orientation B Standard Orientation C Magnetic Drain Plug

D

1. Support the pump drive gearbox in an upright position. The magnetic drain plugs are positioned on the bottom surface of the housing, based on whether it is a standard installation or an inverted installation.

In some instances the drain plugs are located in a drain fitting unit consisting of several fittings.

2. Position a container of suitable size beneath the housing, then remove the magnetic drain plug from the bottom of the pump drive gearbox. Inspect the drain plug for debris and metal filings, record findings, then clean the drain plug thoroughly.

C00533

A B C D

3. Disconnect any tubes or hoses connected to the drain fitting unit (if present).

Dipstick Dipstick Tube Extension Housing Dipstick Tube

1. Loosen the jam nut securing the dipstick tube extension to the dipstick tube then remove the extension.

4. Disconnect the drain fitting unit from the housing using a wrench. DO NOT use the drain fitting unit to extract the parts.

2. Remove the dipstick tube extension by following removal instruction for the straight dipstick tube.

See, STRAIGHT DIPSTICK TUBE, above.

2.5

Disassembly

Tigercat Pump Drive Gearboxes

REMOVE SENSORS

REMOVE BREATHER COMPONENTS

Temperature or pressure sensors are utilized on different orientations of 6-inch and 8 inch pump gearboxes.

Temperature sensors are installed in different locations depending on the unit orientation. Pressure sensors are affixed to the lubrication manifold of the 8-inch pump drive gearbox.

FOR 6 INCH PUMP DRIVE GEARBOXES

A B C

A B A C

E

B

D

C00506

A B C D

C00532

A B C D

1. Remove the breather.

C

D

Breather Component Locations

6 Inch Pump Drive Gearbox 8 Inch Pump Drive Gearbox Temperature Sensor Pressure/Temperature Sensor

2. Remove the connector from the elbow.

Drain Plug Locations

3. Remove the elbow from the housing if present.

6 Inch Pump Drive Gearbox 8 Inch Pump Drive Gearbox Temperature Sensor Pressure/Temperature Sensor

REMOVE INPUT SHAFT FOR 6 INCH PUMP DRIVE GEARBOX

1. Note the type and location of the sensor being removed.

1. Pull the input shaft from the input side of the pump drive gearbox.

2. Remove and inspect each sensor for damage.

FOR 8 INCH PUMP DRIVE GEARBOX

3. Retain undamaged sensors for re-installation.

2. To remove the input shaft from the 8 inch pump drive gearbox, the pump cover plate, cover plate/pump must be removed and a retaining clip removed from the end of the input shaft. See, REMOVE PUMP COVER PLATE AND TUBING on page 2.7.

2.6

Tigercat Pump Drive Gearboxes

Disassembly

REMOVE PUMP COVER PLATE AND TUBING P

WARNING

A

N

DO NOT reuse crushed or bent tubes.

M

3. Disconnect tube fittings from the pump.

L

4. Remove two bolts securing the lubrication manifold to the housing.

K B

5. Remove the manifold/tubes. Clean and inspect tubes and manifold.

C D

J

A

E

B C D

K

E F

J

H

G

F

C00504

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

8 inch Pump Drive Gearbox (example only)

Tube Assembly (example) Pump Cover Plate (without forced lubrication) O-ring Pump Cover Plate (with forced lubrication) Housing Input Cover Lubrication Manifold Bolt Bolt Sensor (Pressure/Temperature) Spline Adapter Retaining Ring Pump Bolt

C00505

A B C D E F G H J K

1. Orient the pump drive gearbox on the work surface with the input cover facing down.

H

G

Housing Retaining Ring O-ring No-Pump Cover Plate Bolt Washer Bolt Adapter Plate ( if interfering with removal of pump cover) O-ring Input Shaft

6. Remove any adapter plates that interfere with the pump cover plate. See, REMOVE PUMP ADAPTER PLATES on page 2.10

FOR FORCED LUBE ORIENTATION 2. Disconnect hydraulic tube fittings from the housing.

7. Remove 2 bolts securing the pump to the pump cover plate, then remove the pump.

a. Note the location of all fittings and tubes, then disconnect them. DO NOT use the tubes as levers to remove fittings. Use correct tools to loosen and install fittings and plugs.

8. Remove the O-ring from between the pump and the pump cover plate.

9. Remove the spline adapter from inside the input end of the input shaft, then remove the retaining ring from inside the spline adapter.

b. Place absorbent rags beneath the tube/fittings.

Tubes may have residual gear oil within.

2.7

Disassembly

Tigercat Pump Drive Gearboxes REMOVE INPUT COVER

10. Remove 2 bolts securing the pump cover plate to the gearbox housing.

1. Place the pump drive gearbox on support blocks, on a work surface with the input cover facing up. Use lifting straps or chains and lifting rings.

11. Remove the O-ring from between the pump cover plate and the housing.

12. Clean and inspect components. Replace any that are damaged.

FOR 6 INCH PUMP DRIVE GEARBOX

13. Contact the Tigercat parts department for replacement pumps and tubing specific to the forced lube machine configuration being serviced.

A

B

A C

D

B

D F

E C C00509

A B C D

Housing Retaining Ring O-ring Input Shaft

C00507

A B C D E F

14. Remove the retaining ring from the end of the input shaft.

15. Remove the input shaft from the spur gear.

Bolt Washer Oil Seal Input Cover Input Shaft Housing

2. Remove bolts with washers securing the input cover to the housing, then remove the input cover.

16. Remove the O-ring from the input shaft.

3. Tap the input oil seal from the input cover using a punch.

2.8

Tigercat Pump Drive Gearboxes

Disassembly REMOVE INPUT SPUR GEAR

FOR 8 INCH PUMP DRIVE GEARBOXES Some configurations of 8 inch pump drive gearboxes utilize a coupler guard plate which is held in place using longer bolts (4x) with additional washers (8x) that act as spacers. If the guard plate is not present, the bolts are all of equal length.

A

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.

B

C A D

E F

B C00551

C00508

A B C D E F

A Spur Gear/Bearings B Housing

Bolt Washer Input Cover Oil Seal Input Shaft Housing

1. Place thumbs inside the input spur gear, then curl remaining fingers under the edge of the bearing.

2. Lift the gear straight out of the housing.

NOTICE Bolts securing the coupler guard plate (4x) are 50mm (2 inches) long (if the guard plate is present) with two additional washers each. The remaining bolts are 40mm (1.57 inches) long.

Verify that the correct length bolts are used to secure the guard plate.

1. Remove bolts with washers securing the input cover and coupler guard plate (if present) to the housing, then remove the input cover. If the coupler guard plate is there, remove two washers from beneath each mounting hole of the coupler guard plate.

2. Tap the input oil seal from the input cover using a punch.

2.9

Disassembly

Tigercat Pump Drive Gearboxes

REMOVE PUMP ADAPTER PLATES Pump adapter plates, adapter splines, fasteners and O-rings are specific to individual pump configurations.

See Tigercat Publications Online or contact the Tigercat Parts Department for machine specific parts information.

The following illustrations and procedures are representative of one of many configurations.

When removing adapter plates and fasteners note the location and types of fasteners used to secure the adapter plates to the housing.

A

H

3. Remove fasteners securing each pump adapter plate to the output side of the housing. Note and record the type and position of each pump adapter plate and the style of fastener used in each location.

4. Remove any Loctite 5699 from the pump drive gearbox housing and from each pump adapter plate.

See GASKET FORMING/SEALANT PRODUCTS on page 1.9.

5. DO NOT mar the machined contact surfaces of the adapters plates or housing.

REMOVE SPUR GEARS

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.

B G

NOTICE

C

DO NOT damage machined surfaces. Use non marring tools to remove sealant or grease.

A A F

E

D

C00510

A B C D E F G H

A

Adapter Plate Mounting (per specified configuration) Bolt Flat Head Pump Adapter Plate O-ring Housing Bolt Socket Head Bolt Button Head Stud Nut

1. Turn the pump drive gearbox on the work surface, with the pump adapter plates facing up. Use lifting straps or chains and lifting rings.

2. Remove any spline adapters with O-rings from the inside of spur gears (if present). Identify each spline adapter with a marker to assist in matching adapters with gear splines during assembly.

B C00511

A Spur Gear/Bearings B Housing

1. Remove the spur gears from output ports. Lift the spur gear/bearings straight up and out of the housing.

2. Remove remaining oil with clean rags when the inside of the housing is accessible. Absorb excess gear oil, then dispose of rags in a fireproof container.

2.10

Tigercat Pump Drive Gearboxes

Disassembly

3. Inspect oil passages for each output port. Note any obstructions or damage.

4. Pass a magnetic pickup through the interior of the gearbox to pick up any loose metal debris. Note the quantity and type of filings if found, as a diagnostic tool.

REMOVE SPUR GEAR BEARINGS 1. Place bearing/spur gear on level surface.

2. Remove top bearing using a gear puller.

3. Turn the bearing/spur gear over.

4. Remove the bearing using a gear puller.

5. Clean and inspect spur gears and bearings .

2.11

Disassembly

Tigercat Pump Drive Gearboxes

2.12

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

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

CONTENTS – SECTION 3

ISSUE 1.0, DECEMBER 2018

A

ADAPTER PLATES, INSTALL....................................................................................................................................... 3.8 B

BEARING/GEAR ASSEMBLY BEARING INDUCTION HEATER............................................................................................................................... 3.6 HEATING BEARINGS FOR INSTALLATION............................................................................................................. 3.6 INSTALL BEARINGS ONTO SPUR GEARS.............................................................................................................. 3.7 INSTALL OUTPUT GEARS........................................................................................................................................ 3.7 PUMP PILOT BORE, MEASURE............................................................................................................................... 3.9 C

CLEANING AND INSPECTION..................................................................................................................................... 3.3 D

DIPSTICK, THREADED PLUGS, EXPANSION PLUGS, INSTALL DIPSTICK EXTENSION TUBE................................................................................................................................ 3.15 DIPSTICK TUBE........................................................................................................................................................ 3.5 EXPANSION PLUG.................................................................................................................................................... 3.6 MAGNETIC PLUG..................................................................................................................................................... 3.6 THREADED ORB PLUGS......................................................................................................................................... 3.6 H

HOUSING INSPECTION............................................................................................................................................... 3.4 I

INPUT COVER, INSPECTION...................................................................................................................................... 3.4 INPUT COVER, INSTALL............................................................................................................................................ 3.11 INPUT COVER OIL SEAL, INSTALL........................................................................................................................... 3.10 INPUT GEAR, INSTALL.............................................................................................................................................. 3.10 INPUT SHAFT INSTALL 6 INCH............................................................................................................................................ 3.12, 3.16 INSTALL 8 INCH...................................................................................................................................................... 3.12 M

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

PRIOR TO ASSEMBLY................................................................................................................................................. 3.3 R

REASSEMBLY COMPLETED..................................................................................................................................... 3.16 S

SAFETY......................................................................................................................................................................... 3.3 T

TUBES AND CONNECTORS...................................................................................................................................... 3.14

Assembly

Tigercat Pump Drive Gearboxes

3.2

Tigercat Pump Drive Gearboxes

Assembly

SAFETY

PRIOR TO ASSEMBLY

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

Prior to pump drive gearbox assembly: 1. Have all required parts readily available.

MACHINE ORIENTATION

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

See MACHINE ORIENTATION on page 2.3. for pictorial references to bogie pump drive gearbox views.

These are based on viewing the pump drive gearbox with the differential yoke facing the observer.

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

• Ensure they are the right parts.

WARNING

• Verify orientation.

Pump drive gearbox components are heavy.

Use appropriate lifting devices. Support and brace major components so they do not fall or roll. When removing one major component from another ensure that both components are adequately supported and level.

• Replace damaged or worn components as required.

• Verify that machined surfaces are damage free.

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

NOTICE

This procedure is for use with a pump drive gearbox.

See 47731AENG Pump Drive Gearboxes, SERVICE AND REPAIR MANUAL, DISASSEMBLY to disassemble a pump drive gearbox.

It is imperative that the inside of the pump drive gearbox be clear of dirt, debris and tools when reassembled. Foreign materials inside the housing will cause premature failure of pump drive gearbox components.

See PERSONAL SAFE LIFTING AND CARRYING on page 1.7.

See SAFE SUPPORT OF COMPONENTS on page 1.7.

Service the pump drive gearbox on a clean, robust work surface or on a floor or section of ground. The work area: • Must be level • Must be clean • Have a barrier (tarpaulin or sheets of plywood) on the ground if not in a workshop.

• Must have components blocked to eliminate movement

CLEANING AND INSPECTION See CLEAN AND INSPECT on page 1.8. for references to cleaning and inspecting the unit.

3.3

Assembly

Tigercat Pump Drive Gearboxes

HOUSING INSPECTION

INPUT COVER INSPECTION 1. Inspect input oil passages to verify that each is clear of burrs or blockage.

2. Clean all surfaces of oil, grease and dirt using isopropyl alcohol.

A

3. Use compressed air if available to remove debris from the passages. See, COMPRESSED AIR on page 1.5.

ADAPTER PLATE INSPECTION

C

B

A number of adapter plates are used on the 6 inch and 8 inch pump drive gearboxes. Each adapter plate has four oil ports that must be clear of burrs or blockage.

1. Inspect the input oil passages to verify that each is clear of burrs or blockage.

2. Clean all surfaces of oil, grease and dirt using isopropyl alcohol.

C00512

Port Identification-Output Side View

3. Use compressed air if available to remove debris from the passages. See, COMPRESSED AIR on page 1.5.

I

C00513

Port Identification-Input Side View

1. Inspect the input and output ports to verify that each oil passage is clear of burrs or blockage.

2. Clean all surfaces of oil, grease and dirt using isopropyl alcohol.

3. Use compressed air if available to remove debris from the passages. See, COMPRESSED AIR on page 1.5.

3.4

Tigercat Pump Drive Gearboxes

Assembly DIPSTICK TUBE

INSTALL DIPSTICK, THREADED PLUGS, EXPANSION PLUGS

There are two dipstick configurations. One uses a dipstick tube with a flared top. The other uses a dipstick tube with a connector on the end. Both tubes are installed the same way.

NOTICE Use the correct tools to tighten fittings.

H

B

1. Verify that the mounting hole in the housing is clean and free of debris, grease and oil. See, REMOVE DIPSTICK TUBE on page 2.5..

A

A

B

B

G

C

C

F

G

D

B

E

B

C00527

A B C D E F G H

F

E

D

For 6-Inch Pump Drive Gearbox - Dipstick, Threaded Plugs, Expansion Plug Housing Plug Expansion Plug Magnetic Plug Plug Plug ORB Dipstick Tube Dipstick

C00534

A B C D E F G

Dipstick Tube Installation

Dipstick Tube Alignment Mark Bead of Loctite 648 Vent Hole Housing Tube Shoulder Dipstick

The dipstick tube and expansion plugs are factory installed and rarely require replacement unless damaged. The magnetic plug is removed and reinstalled during oil changes.

2. Place an alignment mark above the shoulder of the tube in line with the vent hole below the shoulder on the dipstick tube.

There are two types of dipstick: straight and angled. If the dipstick tube requires replacement, install it early in the reassembly process to allow for Loctite drying time.

3. Apply a bead of Loctite 648 around the circumference of the tube, just below the shoulder on the dipstick tube.

To install the dipstick extension tube see, INSTALL DIPSTICK EXTENSION TUBE on page 3.15.

4. Insert the dipstick tube into the mounting hole with the vent hole/alignment mark on the tube facing towards the input gear.

5. Push down on the dipstick tube as far as it will go.

6. Seat the tube using a tapered punch suitable for seating expansion plugs, [9.0mm (0.359 inch)] so that the tube shoulder rests against the outside of the housing.

3.5

Assembly

Tigercat Pump Drive Gearboxes

THREADED ORB PLUGS

HEATING BEARINGS FOR INSTALLATION

1. Verify that the threaded hole is clean and free of debris, grease and oil.

WARNING

2. Apply a light coat of gear oil to the O-ring portion of the plug.

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

3. Install the plug finger tight, then wrench tighten.

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

MAGNETIC PLUG 1. Verify that the threaded hole is clean and free of debris, grease and oil.

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

2. Apply a light coat of Loctite 567 pipe-joint compound to the plug.

3. Heat standard product bearings, gears, or steel sleeves to 120°C (250°F). DO NOT heat 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.

3. Install the plug finger tight, then torque to 38Nm (28 lbf-ft).

EXPANSION PLUG 1. Verify that the mounting hole in the housing is clean and free of debris, grease and oil.

4. Heat and cool bearing components gradually.

2. Apply a bead of Loctite 648 around the circumference of the expansion plug.

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.

3. Place the plug in the mounting hole.

4. Seat the plug so that the top of the plug is flush with the outer surface of the housing using a tapered punch suitable for seating expansion plugs.

BEARING INDUCTION HEATER

BEARING/GEAR ASSEMBLY

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.

Observe manufacturer's safety warnings and cautions.

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.

2. Leave bearings in packages until ready for assembly.

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.

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

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

5. The larger the bearing, the more time it takes to heat and the longer it takes to cool down. When heating bearings, permit sufficient time to fully heat and cool.

3.6

Tigercat Pump Drive Gearboxes

Assembly

INSTALL BEARINGS ONTO SPUR GEARS

INSTALL OUTPUT GEARS CAUTION

WARNING

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.

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

A

1. Clean the inside of the housing using isopropyl alcohol. Verify the removal of oil, grease, dirt and debris.

B

A

A

C

C00519

A Bearing B Spur Gear C Bearing Shield

Install Bearings

B C00520

A Gear/bearings B Housing

1. Heat bearings to 120°C (250°F).In lieu of induction heating, bearings may be brought to temperature gradually in an oven. DO NOT over heat the bearings.

Output Gear Installation

2. Install assembled gear/bearings into the bearing seats inside the housing. The retaining ring groove on the gear must face up.

2. Install the bearings onto each side of the spur gear. a. The bearing shields must face the gear. b. The bearing races must be fully seated on the bearing shoulder of the gear.

3. Verify that the bearing is fully seated using a feeler gauge after the bearing has cooled to the touch.

3.7

Assembly

Tigercat Pump Drive Gearboxes

INSTALL ADAPTER PLATES K A B J

C

H

D

E

F

G C00521

A B C D E

Adapter Plate Mounting

O-ring (specific to each adapter plate, shown for reference) Adapter Plate Washer Bolt Stud

F G H J K

Housing Gasket Compound (Loctite 5699) Nut Embossed Arrow Bolt

The arrangement of adapter plates is determined by the information recorded during disassembly or as provided by the Tigercat parts department.

Identify the required components required to assemble the pump drive gearbox and clean thoroughly using isopropyl alcohol. See,CLEAN AND INSPECT on page 1.8..

1. Apply a continuous bead of Loctite 5699 gasket compound around the circumference of the adapter plate and the mounting holes. DO NOT get gasket compound in the mounting holes or oil ports.

See,GASKET FORMING/SEALANT PRODUCTS on page 1.9.

Determine the placement of adapter plates by: • Port position: A, B or C. • Adapter plate size: SAE A, B, C or D. • Bolt pattern: horizontal or vertical.

2. Select the appropriate fasteners for each adapter plate:

• Embossed arrow and oil port orientation.

Adapter plates must be oriented with lubrication holes to the top of the bore as indicated by the embossed arrow, for both regular and inverted pump drive installation.

3.8

Tigercat Pump Drive Gearboxes

Assembly MEASURE PUMP PILOT BORE

3. Orient the adapter plate with the appropriate tapped holes and oil ports in the housing, then install the adapter plate.

1. Centre a dial indicator on the radial axis of the output gear. Use runout dial gauge (B8621000) or equivalent.

a. Fit the adapter plate onto the housing. b. Apply Loctite 7649 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9.. c.

2. Extend the measuring rod to contact the pilot bore surface.

3. Rotate the gear a minimum of one full revolution and observe and record the maximum and minimum values on the dial indicator. Runout should be 0.05mm (0.002 inch) maximum.

Apply Loctite 242 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9..

4. Insert and thread the prepared fasteners finger tight into each tapped hole, then torque each to the following values:

A

a. Socket head fastener - 216Nm (159 lbf-ft).

B

b. Button head fastener with washers 142Nm (105 lbf-ft) c.

Stud into housing - 350Nm (225lbf-ft).

F

d. Nut on stud - 233Nm (172 lbf-ft).

C

FOR 8 INCH PUMP DRIVE GEARBOX

D

e. Socket head fastener - 233Nm (172 lbf-ft).

5. O-rings specific to each installed adapter plate are placed in a bag. They are installed on the pumps at the time of assembly in the machine.

E C00522

A B C D E F

3.9

Pilot Bore Measuring Rod End of Gear Housing Adapter Plate Dial Indicator

Adapter Plate Runout

Assembly

Tigercat Pump Drive Gearboxes

INSTALL INPUT GEAR

INSTALL INPUT COVER OIL SEAL

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 C

C A

C00525

Input Cover Oil Seal Installation

Oil Seal Press Tool for 6-inch pump drive 40096A A Oil Seal Press Tool for 8-inch pump drive A7627000 B Oil Seal C Input Cover (8 inch shown)

1. Place the input cover on the work surface with the convex side facing down.

B C00526

A Gear B Housing C Oil Seal Seat

Output Gear Installation

2. Press the oil seal into the input cover using the oil seal press tool so that the top edge of the oil seal is flush with the top of the input cover. Note the orientation of the oil seal.

1. Turn the housing over so that the input side faces up. Use lifting straps or chains and lifting rings.

FOR 6-INCH PUMP DRIVE GEARBOX INPUT COVERS Use oil seal press tool 40096A.

2. Install the gear into the input port with the oil seal seat facing up.

3. Immobilize the input gear, then turn each output gear independently to verify that there is radial play for each.

FOR 8-INCH PUMP DRIVE GEARBOX SAE3 INPUT COVERS Use oil seal press tool A7627000.

3.10

Tigercat Pump Drive Gearboxes

Assembly

INSTALL INPUT COVER

A

1. Turn the input cover with the convex side facing up.

B

C

A B

D

C E

F E D C00508

A B C D E C00524

A B C D E F

Bolt Washer Input Cover Oil Seal Housing

Input Cover Installation 8 inch

FOR 6 INCH PUMP DRIVE GEARBOXES

Input Cover Installation 6 inch

Input Cover 5699 Gasket Compound Pattern Housing Bolt Washer Embossed Arrow

6. Insert the prepared hex head fasteners and thread them finger tight into each tapped hole, then torque each to - 216Nm (159 lbf-ft).

FOR 8 INCH PUMP DRIVE GEARBOXES WITHOUT COUPLER GUARD PLATE

2. Apply a continuous bead of Loctite 5699 gasket compound to the contact circumference of the input cover and around each bolt hole and spring pin hole.

DO NOT get gasket compound in the bolt holes.

7. Insert the prepared hex head fasteners and thread them finger tight into each tapped hole, then torque each to - 233Nm (172 lbf-ft).

3. Lubricate the top of the gear with gear oil.

4. Orient the input cover so that the lubrication holes are to the top of the bore as indicated by the embossed arrow, for both regular and inverted pump drive installation.

5. Carefully install the input cover. DO NOT damage the oil seal when lowering the input cover in place. a. Apply Loctite 7649 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9. b. Apply Loctite 242 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9.

3.11

Assembly

Tigercat Pump Drive Gearboxes

INSTALL 6 INCH PUMP DRIVE GEARBOX INPUT SHAFT The 6 inch input shaft is the last part assembled in the 6 inch pump drive. See, INSTALL 6 INCH PUMP DRIVE GEARBOX INPUT SHAFT on page 3.16..

INSTALL 8 INCH PUMP DRIVE GEARBOX INPUT SHAFT

4. Apply two washers each to four counter-bores on the input cover with the same hole patter as the coupler guard plate.

5. Align the coupler guard plate carefully on top of the washers.

6. Install the coupler guard plate. There must be two washers under the guard plate at each bolt hole. a. Apply Loctite 7649 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9.

A B

b. Apply Loctite 242 to fasteners and tapped holes. THREAD LOCKING COMPOUNDS AND SEALANTS on page 1.12.

C D

7. Insert the prepared hex head fasteners with washers and thread them finger tight into each tapped hole, then torque each to - 233Nm (172 lbf-ft).

E

F

Input Side

D G

C00580

Output Side

Pump/Pump Adapter Plate Installation (shown upright)

A B C D E F G

Input Cover Washers O-ring Input Shaft Bolt Coupler Guard Plate Retaining Ring

1. Apply a light coat of gear oil on the O-ring and install it on the input shaft.

2. Install the input shaft through the centre gear from the input side of the housing.

3. Install a retaining ring on the end of the input shaft from the output side of the housing.

3.12

Tigercat Pump Drive Gearboxes

Assembly

INSTALL PUMP COVER PLATE

FORCED LUBRICATION CONFIGURATION

8-inch pump drive gearboxes are built with either a nopump cover plate for a splash lubrication configuration, or pump cover plate used as a mount for the pump.

Pump cover plates are located on the central port on the output side of the housing.

A

B

SPLASH LUBRICATION CONFIGURATION

A M

B

L K J H D

C

E

E

C00529

D

C

C00528

A B C D E

Housing Input Shaft Port O-ring Bolt Pump Cover Plate

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

Cover Installation

1. Apply a light coat of gear oil on the pump cover plate O-ring and install it on the cover plate.

2. Install the no-pump cover plate. a. Fit the no-pump cover plate onto the housing.

F

Pump/Pump Adapter Plate Installation

Housing Input Shaft Port O-ring Spline Adapter O-ring Fitting (ORB) Bolt Fitting (ORB) Gear Pump Retaining Ring Bolt Pump Cover Plate

1. Apply a light coat of gear oil on the pump cover plate O-ring and install it in the pump cover plate.

b. Apply Loctite 7649 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9. c.

G

2. Install the pump adapter plate. a. Fit the pump adapter plate onto the housing.

Apply Loctite 242 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9..

3. Insert and thread the prepared fasteners finger tight into each tapped hole, then torque each to 68Nm (50 lbf-ft).

3.13

b. Apply Loctite 7649 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9. c.

Apply Loctite 242 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9..

Assembly

Tigercat Pump Drive Gearboxes

3. Insert and thread the prepared fasteners finger tight into each tapped hole, then torque each to 68Nm (50 lbf-ft).

TUBES AND CONNECTORS

4. Install the retaining ring in the spline adapter.

Install previously removed hydraulic tubes and fittings onto the pump drive gearbox. DO NOT re-use bent, creased or crushed tubing or fittings.

5. Place the spline adapter into the end of the input shaft.

DO NOT turn fittings using the tubing. Use correct tools to loosen and tighten fittings.

6. Apply a light coat of gear oil on the O-ring and install it onto the pump.

Review the Operator's Manual for the machine being serviced to determine the appropriate components and fitting sites.

7. Install the gear pump onto the pump adapter plate. a. Apply Loctite 7649 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9.

FORCED LUBRICATION A

C

b. Apply Loctite 242 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9.. c.

B

D

J

E

Align the gear pump with the pump adapter plate.

d. Fit the splines of the gear pump shaft into the spline adapter in the end of the input shaft. e. Install each fastener finger tight, then torque to 67Nm (50 lbf-ft).

H

8. Apply a light coat of gear oil to the gasket of the ORB fittings for the gear pump. Install each fitting finger tight, then torque to 47Nm (35 lbf-ft).

G

F C00553

A B C D E F G H J

Tube Tube Tube Tube Elbow Fitting Straight Connector Lubrication Feed Tube Straight Connector Lube Manifold

1. Clean the lube manifold mounting holes in the housing. See, REMOVE FASTENERS SECURED WITH LOCTITE THREAD LOCKER COMPOUNDS on page 1.9..

2. Clean the fitting sites in the housing of oil and particulates. Use isopropyl alcohol and a clean, lintfree cloth.

3.14

Tigercat Pump Drive Gearboxes

Assembly A

INSTALL DIPSTICK EXTENSION TUBE

A B

F

C B E

C D D C00554

A B C D E F

Straight Connector Lube Manifold Check Valve Temperature/Pressure Sensor Elbow Fitting Tee Adapter

3. Install the assembled lube manifold block. a. Verify that all fittings and devices are correctly installed and tightened. Thread the temperature/ pressure sensor into the elbow fitting on the end of the manifold unit. b. Fit the lube manifold block to the housing. c.

Loosely thread the fittings on the attached tubes into the housing. DO NOT tighten.

C00533

A B C D

1. Align the dipstick extension tube with the fitting on the end of the dipstick tube in the housing. The end of the extension tube faces out from the output gears.

2. Thread the connector on the extension tube to the fitting on the tube in the housing, finger-tight, then using wrenches, tighten an additional half-turn

d. Apply Loctite 7649 to fasteners and tapped holes securing the lube manifold to the housing.

See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9. e. Apply Loctite 242 to fasteners and tapped holes. See, THREAD LOCKER AND PRIMER PRODUCTS on page 1.9.. f.

Dipstick Dipstick Tube Extension Housing Dipstick Tube

Torque each bolt to 34Nm (25 lbf-ft).

3.15

Assembly

Tigercat Pump Drive Gearboxes

INSTALL PRESSURE/TEMPERATURE SENSORS

INSTALL ADAPTERS FOR 6 INCH PUMP DRIVE GEARBOX 1. Determine which adapters are used in which spur gear/bearing, then install the required adapter inside the spline of the appropriate spur gear/bearing.

FOR 8 INCH PUMP DRIVE GEARBOX D A B

D

A

B

B

B C

C

C00532

A B C D

A B C D

Sensor Locations

6 Inch Pump Drive Gearbox Temperature Sensor Pressure/Temperature Sensor (page 3.14) reference 8 Inch Pump Drive Gearbox

Temperature and/or pressure sensors are utilized on different configurations of 6-inch and 8 inch oil pump gearboxes.

C

C00523

B

D

Spline Adapter Installation

Spline Adapters Retaining Rings Spur Gear Bearing Shield

1. Determine if adapters are used in the gear/bearing, then install retaining clips in the groove(s) inside the spline of the spur gear/bearing.

1. Clean the sensor per manufacturer's recommendations.

2. Install assembled gear/bearings into the housing with the retaining clip nearest the output side of the housing.

2. Apply a light coat of gear oil to the O-ring on the sensor.

INSTALL 6 INCH PUMP DRIVE GEARBOX INPUT SHAFT

3. Clean the mounting hole with solvent and a wire brush. See, REMOVE FASTENERS SECURED WITH LOCTITE THREAD LOCKER COMPOUNDS on page 1.9.

1. Clean the input shaft of oil, grease and dirt using isopropyl alcohol and dry thoroughly using compressed air or a soft, lint-free cloth.

4. Thread the sensor into the housing finger-tight, then turn an additional 1/4 turn using a wrench. DO NOT overtighten the sensor.

2. Align the splines on either end of the input shaft with the splines in the centre gear 3. Insert the input shaft into the centre gear as far as it will go.

4. Manually rotate the shaft to verify that it moves freely.

REASSEMBLY COMPLETED Keep dirt and debris from entering the unit. If the pump drive gearbox is not intended for immediate installation into the machine, cover open ports with a clean barrier covering.

3.16