Tigercat SINGLE SPEED TRANSMISSION SERVICE AND REPAIR MANUAL - PDF DOWNLOAD

SINGLE SPEED TRANSMISSION

SERVICE AND REPAIR MANUAL

ISSUE 1.0, JANUARY 2017 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

Tigercat Single Speed Transmission TABLE OF CONTENTS SECTION INTRODUCTION................................................................................................................................................. v NON-APPROVED FIELD PRODUCT / PARTS CHANGES............................................................................... vi VERSION 1 SINGLE SPEED TRANSMISSION-EXPLODED VIEW.................................................................viii VERSION 2 SINGLE SPEED TRANSMISSION-EXPLODED VIEW................................................................... x SAFETY...............................................................................................................................................................1 DISASSEMBLY....................................................................................................................................................2 ASSEMBLY..........................................................................................................................................................3

Service and Repair Manual (this manual).......................................................................................Part No. 47734AENG iii

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

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

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

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

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

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

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

Tigercat Industries Inc.

v

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

Introduction

Tigercat Single Speed Transmission

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

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

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

Authorization by any other person is unacceptable.

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

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

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

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

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

Tigercat Industries Inc.

vi

Tigercat Single Speed Transmission

Introduction

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

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

TIGERCAT 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.

VERSIONS OF SINGLE SPEED TRANSMISSIONS There are two versions of single speed transmissions.

Version 1 uses a bearing cover on each end of the output shaft to hold the bearing cup in the housing. Version 1 also uses a shim between the left and right side bearing carriers and the housing, as a gasket.

Version 2 uses a bearing carrier on each end of the output shaft into which a bearing cup has been pressed. Version 2 also uses O-rings between the left and right side bearing carriers and the housing, instead of shims.

Version 1 and Version 2 parts are not interchangeable. Contact the Tigercat parts department for information about conversion kits. Refer to Tigercat parts catalogs for version specific parts.

Exploded views of each unit and chapter headings note the differences within the disassembly and assembly procedures as Version 1 and Version 2.

vii

Introduction

Tigercat Single Speed Transmission 23

25

26 27

24

22

29

52

28

39 4

19

8

7

43

6

31

40

15

10

30 16

6

19

7

11 8

4

14 13 43

12

31

50

39 9

40

32

54

19

17

5

41

43

45

43

41

3

33

1

18

43

21 X X

X

X X

X

X

X

X

X

X

X 20 44 53

C00303

NOTE: This exploded view is representative of a typical Tigercat Version 1 Single Speed transmission. Some parts may not appear exactly as shown. viii

Tigercat Single Speed Transmission

Introduction

VERSION 1 SINGLE SPEED TRANSMISSION-EXPLODED VIEW ITEM

PART DESCRIPTION

ITEM

PART DESCRIPTION

1 3 4 5 6 7 8 9

COVER BAFFLE SLEEVE, OUTPUT GEAR, INPUT COVER, BEARING, OUTPUT* SEAL, OIL SEAL, WIPER WASHER, THRUST

23 24 25 26 27 28 29 30

SEAL, OIL HUB, SHIFTING O-RING SPRING BALL FORK KEY, SHAFT SHAFT, OUTPUT

10

PIN, SPRING

31

O-RING

11 12 13 14 15 16 17 18 19 20 21 22

WASHER, THRUST SHIM* SHIM* SHIM* SHIM* CLUTCH, SPLINE CARRIER, BEARING, LEFT, SHOWN BOLT BOLT PLUG PIN, SPRING SHAFT, SHIFTING

32 33 39 40 41 43 44 45 50 52 53 54

CARRIER, BEARING, RIGHT, NOT SHOWN BOLT CONE, BEARING CUP, BEARING BEARING, BALL HOUSING PLUG, MAGNETIC GASKET GEAR, OUTPUT LOCKNUT, FLANGE PLUG, EXPANDER SHIM*

* Indicates Version 1 Part

ix

Introduction

Tigercat Single Speed Transmission

23

4

19

8

7

25

26 27

24

22

29

52

28

39

6

43

31

40 10 15

30 16

11 7

19

6

8

4

14 13 43

12

31

50

39 9

40

32

54

19

17

5

41

43

45

43

41

3

33

1

18

43

21 X X

X

X X

X

X

X X

X

X X 20 44 53

NOTE: This exploded view is representative of a typical Tigercat Version 2 Single Speed transmission. Some parts may not appear exactly as shown. x

Tigercat Single Speed Transmission

Introduction

VERSION 2 SINGLE SPEED TRANSMISSION-EXPLODED VIEW ITEM

PART DESCRIPTION

ITEM

PART DESCRIPTION

1 3 4 5 6 7 8 9

COVER BAFFLE SLEEVE, OUTPUT GEAR, INPUT CARRIER, BEARING, OUTPUT* SEAL, OIL SEAL, WIPER WASHER, THRUST

23 24 25 26 27 28 29 30

SEAL, OIL HUB, SHIFTING O-RING SPRING BALL FORK KEY, SHAFT SHAFT, OUTPUT

10

PIN, SPRING

31

O-RING

11 12 13 14 15 16 17 18 19 20 21 22

WASHER, THRUST SHIM* SHIM* SHIM* SHIM* CLUTCH, SPLINE CARRIER, BEARING, LEFT, SHOWN BOLT BOLT PLUG PIN, SPRING SHAFT, SHIFTING

32 33 39 40 41 43 44 45 50 52 53 54

CARRIER, BEARING, RIGHT, NOT SHOWN BOLT CONE, BEARING CUP, BEARING BEARING, BALL HOUSING PLUG, MAGNETIC GASKET GEAR, OUTPUT LOCKNUT, FLANGE PLUG, EXPANDER O-RING*

* Indicates Version 2 Part

xi

Introduction

Tigercat Single Speed Transmission

xii

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

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

CONTENTS – SECTION 1

ISSUE 1.0, JANUARY 2017

A

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

CALIBRATION............................................................................................................................................................... 1.7 CARRYING, SAFE LIFTING AND................................................................................................................................. 1.8 CAUTION...................................................................................................................................................................... 1.3 CLEAN AND INSPECT.................................................................................................................................................. 1.9 D

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

GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS............................................................ 1.6 I

INJURIES, HIGH-PRESSURE INJECTION.................................................................................................................. 1.5 INSTRUCTIONS AND REQUIRED RECORD KEEPING.............................................................................................. 1.9 L

LIQUID NITROGEN....................................................................................................................................................... 1.4 LOCTITE 243 THREAD LOCKER, REMOVE FASTENERS......................................................................................... 1.9 LOCTITE 263 HIGH STRENGTH THREAD LOCKER, REMOVE FASTENERS.......................................................... 1.9 LOCTITE 518 FLANGE SEALANT, REMOVE.............................................................................................................. 1.9 N

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

PERSONAL PROTECTIVE EQUIPMENT..................................................................................................................... 1.3 PERSON, COMPETENT............................................................................................................................................... 1.4 PICTOGRAMS.............................................................................................................................................................. 1.3 R

READ THIS MANUAL FIRST........................................................................................................................................ 1.3 RECORD KEEPING...................................................................................................................................................... 1.9 REQUIRED TOOLS...................................................................................................................................................... 1.8 S

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

TOOL CALIBRATION.................................................................................................................................................... 1.7 TOOLS, REQUIRED..................................................................................................................................................... 1.8 V

VITON SEALS, SAFETY HAZARDS............................................................................................................................. 1.7 W

WARNING..................................................................................................................................................................... 1.3 WORK CONDITIONS AND TOOLS.............................................................................................................................. 1.7 WORKING WITH OIL.................................................................................................................................................... 1.6

Safety

Tigercat Standard Transmission

1.2

Tigercat Standard Transmission

Safety

READ THIS MANUAL FIRST

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

NOTICE

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

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

The information contained in this manual is current at the time of printing. Tigercat reserves the right to make changes to the Standard transmissions or manuals at any time. Changes to the manuals will not be reflected until the next revision of the document or will be issued in the form of service bulletins. Every effort is made to deliver updates on a regular basis.

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

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

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

WARNING

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

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

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

1.3

Safety

Tigercat Standard Transmission

COMPETENT PERSON

LIQUID NITROGEN

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

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

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

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

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

In lieu of such laws and regulations, dispose of materials as suggested in the MSDS/PSDS literature.

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.

WARNING

• Work in a ventilated area. Provide sufficient ventilation to prevent the build-up of toxic exhaust fumes. If indoors, use exhaust extensions to the outdoors or open the shop doors. Run the engine only when it is necessary for testing or adjustments.

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

1.4

Tigercat Standard Transmission

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 grab any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

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

• 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 Standard Transmission

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

• Avoid contact with oil, particularly heated oil.

• 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 5 – 10 psi can cause serious injury. Most pneumatic tools operate at 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 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 Standard Transmission

Safety

SAFETY HAZARDS - VITON SEALS

WORK CONDITIONS AND TOOLS 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. 600°F(315°C).

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

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

Dealer constructed tools may create a safety hazard if not constructed using the correct materials, design and workmanship. Only trained, competent personnel should design and weld fabricated equipment.

The following procedures are recommended when inspecting equipment that has been subjected to high temperatures such as fire: • Visually inspect any seals or gaskets which have suffered from heat; they will appear black and sticky.

NOTICE

• If these are found, DO NOT TOUCH .

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

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

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

TOOL CALIBRATION

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

Tools must be calibrated when:

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.

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

• Observations indicate incorrect readings

1.7

Safety

Tigercat Standard Transmission

MATERIAL HANDLING

• Loctite solvent or equivalent • Loctite 243 - SSA194

WARNING

• Loctite 263 - SSA250

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

• Loctite 518 - SSA122

DISASSEMBLY AND ASSEMBLY TOOLS

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

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

A

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

C00217

A

Output Bearing Cone Installation Tool (B7394001)

Operators must test all controls, examine chains, straps, hooks, cables and other lifting equipment prior to use.

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

REQUIRED TOOLS A

To disassembly the Standard Transmission requires the following tools, equipment and materials:

C00304

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

A

• Bearing Puller • Isopropyl alcohol or equivalent solvent • Clean rags • Marking pen • PPE • Wooden support blocks • Torque wrench • Hose Clamp - 63445B05 1.8

Shifting Shaft Grease Seal Driver (A7901000)

Tigercat Standard Transmission

Safety

CLEAN AND INSPECT

REMOVE FASTENERS SECURED WITH LOCTITE 263 HIGH STRENGTH THREAD LOCKER

WARNING

If screws treated with Loctite 263 threadlocker resist removal, heat the screw to approximately 121°C (250°F) remove the screw while still hot. Adding a breaker bar or extension to the spanner/wrench provides additional leverage. Exercise caution, fasteners may snap off unless heated sufficiently.

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 the Standard transmission, clean and inspect the assembly carefully. Observe and record findings while disassembling the unit:

To clean the screw: 1. Apply Bonderite C-SO Paint 200 Solvent Paint Line Cleaner or equivalent.

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

2. Clean threads with a wire brush.

2. Read accompanying reports.

3. Wipe excess material from screw.

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.

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

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

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.

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

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.

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

Worn components must be replaced

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

COMPLIANCE WITH INSTRUCTIONS AND REQUIRED RECORD KEEPING

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

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.

REMOVE FASTENERS SECURED WITH LOCTITE 243 THREAD LOCKER Fasteners secured with Loctite 243 Thread Locker compound are removable using hand tools.

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

1. Remove the fastener.

2. Clean threads with a wire brush.

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

3. Wipe excess material from screw.

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

1.9

Safety

Tigercat Standard Transmission

1.10

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

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

CONTENTS – SECTION 2

ISSUE 1.0, JANUARY 2017

B

BAFFLE, REMOVE..................................................................................................................................................... 2.12 BEARING COVER, MOTOR SIDE – VERSION 1, REMOVE...................................................................................... 2.3 C

CARRIER SIDE BEARING COVER – VERSION 1, REMOVE.................................................................................... 2.6 CARRIER SIDE OUTPUT BEARING CARRIER – VERSION 2, REMOVE................................................................. 2.6 CLEANING AND INSPECTION..................................................................................................................................... 2.3 G

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

INPUT BEARING CARRIERS – VERSION 1, REMOVE........................................................................................... 2.10 INPUT BEARING CARRIERS – VERSION 2, REMOVE........................................................................................... 2.11 INPUT GEAR BEARINGS, REMOVE......................................................................................................................... 2.11 O

OUTPUT BEARING CARRIER, MOTOR SIDE – VERSION 2, REMOVE................................................................... 2.4 OUTPUT BEARING CARRIER, REMOVE.................................................................................................................... 2.6 OUTPUT SHAFT, REMOVE.......................................................................................................................................... 2.9 S

SAFETY......................................................................................................................................................................... 2.3 SHIFTING HUB, REMOVE............................................................................................................................................ 2.5 W

WIPER AND OIL SEALS, BEARING CUP FROM BEARING CARRIERS – VERSION 2, REMOVE.......................... 2.8 WIPER AND OIL SEALS FROM COVERS – VERSION 1, REMOVE.......................................................................... 2.7

Disassembly

Tigercat Standard Transmission

2.2

Tigercat Standard Transmission

Disassembly

SAFETY

REMOVE THE OUTPUT BEARING COVER, MOTOR SIDE– VERSION 1

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

A

CLEANING AND INSPECTION

B

See SECTION 1 of this manual for references to cleaning and inspecting the unit.

C

REMOVE THE GEARBOX COVER AND GASKET

D E

A

B

C

A B C D E F

Bolts Output Sleeve Output Bearing Cover Output Shaft Shifting Hub Support Blocks

1. Position housing on support blocks with the motor side facing up.

C00223

A B C D

F

C00333

D

Bolts Cover Gasket Housing

A

B

1. Remove the bolts securing the cover and remove the cover.

2. Remove and discard the cover gasket.

C00334

A Output Cover B Pry Bars

2. Remove the output bearing cover. a. Remove bolts securing the output bearing cover to the housing. b. Insert two pry bars between the output bearing cover and the housing, one opposite the other.

2.3

Disassembly c.

Tigercat Standard Transmission

Pry the output bearing cover upward, incrementally.

d. Remove the output sleeve from the output bearing cover.

B

A

3. Remove the gasket material from the output bearing cover. See, REMOVING GASKETS MADE WITH LOCTITE 518.

4. Remove the gasket material from the housing. See, REMOVING GASKETS MADE WITH LOCTITE 518.

5. Remove the bearing cup from the housing if it is free moving in the housing or if it can be extracted easily.

6. Remove the wiper seal and oil seal from the output bearing cover See, REMOVE BEARING CUP

C00326

A Output Bearing Carrier B Jack Screws

AND OIL SEALS FROM BEARING CARRIERS - VERSION 1.

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

REMOVE THE OUTPUT BEARING CARRIER, MOTOR SIDE– VERSION 2 A

4. Remove the output bearing carrier.

B

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

C

b. Remove the output sleeve from the output bearing cover

D

5. Remove the gasket material from the output bearing carrier. See, REMOVING GASKETS MADE WITH LOCTITE 518.

E

6. Remove the gasket material from the housing. See, REMOVING GASKETS MADE WITH LOCTITE 518.

7. Remove the wiper seal and oil seal from the output bearing carrier. See, REMOVE BEARING CUP

AND OIL SEALS FROM BEARING CARRIERS - VERSION 2.

C00282

A B C D E F

F

Bolts Output Sleeve Output Bearing Carrier Output Shaft Shifting Hub Support Blocks

1. Position housing on support blocks with the motor side facing up.

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

2.4

Tigercat Standard Transmission

Disassembly

REMOVE THE SHIFTING HUB CAUTION

A

Wear eye protection. Loaded compression springs in the shifting hub may be released with force when the hub is removed from the housing.

B C

A D E A F

B C D

G E C00284

A B C D E F G

C00283

A B C D E

Shift Fork Shaft Shifting Hub Shaft Key Shift Fork Nut

Shift Fork Shaft Support Block Pry Bar Shifting Hub Ball Bearings Compression Springs Shift Fork

4. Place a support block in the housing and pry the shifting hub up and out of the housing.

1. Remove the nut securing the shift fork to the shift fork shaft.

5. Remove springs and ball bearings from the shifting hub.

2. Remove the shaft key. It may remain with the shaft, or it may fall into the housing. If necessary, pry it from the top of the key way using a lady slipper tool.

6. Remove the o-ring.

3. Cover the shifting hub with several heavy rags (not shown) to contain the loaded springs when released as the hub is pried from the housing.

2.5

Disassembly

Tigercat Standard Transmission

REMOVE THE CARRIER SIDE BEARING COVER – VERSION 1

2. Remove the cover. a. Remove bolts securing the bearing cover to the housing.

A

b. Insert two pry bars between the bearing cover and the housing, one opposite the other.

B C

c.

D

Pry the bearing cover upward, incrementally.

d. Remove the output sleeve from the bearing cover.

3. Remove any shims from between the bearing cover and the housing.

4. Remove the bearing cup from the housing if it is free moving in the housing or if it can be extracted easily.

Otherwise see, REMOVE WIPER AND OIL SEALS FROM COVERS– VERSION 1.

REMOVE THE CARRIER SIDE OUTPUT BEARING CARRIER – VERSION 2 A B E C00335

A B C D E

C

Bolts Output Sleeve Bearing Cover Shims Support Blocks

D E

1. Position housing on support blocks with the carrier side of the housing facing up.

A

B

C00285

A B C D E

Output Sleeve Bolts Output Bearing Carrier Shims Output Shaft

1. Position housing on support blocks with the shifting hub facing down.

C00336

A Bearing Cover B Pry Bars

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

2.6

Tigercat Standard Transmission B

Disassembly REMOVE WIPER AND OIL SEALS FROM COVERS – VERSION 1

A

A B B

C A C00326

A Output Bearing Carrier B Jack Screws

B

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

E

D

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

F C00338

b. Remove the output sleeve.

A B C D E F

5. Remove any shims from between the output bearing carrier and the housing.

6. Remove the wiper seal and oil seal. See, REMOVE

BEARING CUP, WIPER AND OIL SEALS FROM BEARING CARRIERS– VERSION 2.

Output Sleeve Metal Strap Bearing Cover Oil Seal Wiper Seal Clamps

1. Place the bearing cover with the outer surface face down, on the work bench.

2. Clamp the bearing cover to the work bench using C-clamps. Use support blocks and plates to raise it high enough above the work surface to allow the seals to be removed.

3. Remove the oil and wiper seals. a. Cut a piece of metal strap approximately 16mm (0.625 inch) wide and 222mm (8.75 inches) long or equivalent. b. Fit the strap into the U-channel of the oil seal. c.

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

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

2.7

Disassembly

Tigercat Standard Transmission

REMOVE WIPER AND OIL SEALS, BEARING CUP FROM BEARING CARRIERS – VERSION 2

A

A B

B

C

A C D E

D

F

E

B

C00286

C00270

A B C D E F

C

A

A B C D E

B

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

Output Sleeve Metal Strap Oil Seal Wiper Seal Bearing Carrier

5. Remove the oil and wiper seals. a. Cut a piece of metal strap approximately 16mm (0.625 inch) wide and 222mm (8.75 inches) long or equivalent.

1. Place the bearing carrier with the outer surface face down, on the work bench.

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

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

c.

3. Insert the output sleeve into the bearing carrier with the top flange facing up. The oil seal and wiper seal act to centre the output sleeve.

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

4. Pry the bearing cup from the bearing carrier using pry bars. Once there is sufficient clearance, use lady slipper pry bars to continue removing the bearing cup.

e. Discard the seals.

2.8

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

Tigercat Standard Transmission

Disassembly

REMOVE THE OUTPUT SHAFT

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

A E

4. Strike the output shaft downward using a dead-blow hammer. If a dead-blow hammer is not available, protect the end of the spline using hardwood, or by installing several oversized washers secured with a bolt to the end of the shaft. Torque the bolt to 34 Nm (25 lbf-ft) before striking.

D

5. Remove the bearing cone from the carrier side of the housing. The bearing cup was removed with the bearing cover/output bearing carrier.

B

C

6. Strike the shaft until the output shaft and motor side bearing cone fall onto the wooden barrier/rag.

A

C00337

A B C D E

A

Bearing Cone Output Shaft Barrier to Protect Splines Shifting Fork Wedges

B C

1. Remove the shifting fork.

2. Place a wooden blank or heavy rag beneath the output shaft to protect the spline end.

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

D A

A C00307

B

A B C D

C

O-ring Output Shaft Spring Pin Bearing Cone

7. Remove the bearing cone from the output shaft using a bearing puller.

8. Remove the spring pin from the output shaft.

C00289

9. Remove the o-rings from the output shaft.

A Bolt B Washers C Output Shaft (Spline End)

2.9

Disassembly

Tigercat Standard Transmission CAUTION

REMOVE THE INPUT BEARING CARRIERS – VERSION 1

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

A B C

A

D E F D

E B

C C00291

A B C D

Output Gear Housing Clutch Thrust Washer

10. Remove the output gear from the housing.

11. Remove the thrust washer from the housing.

C00348

12. Remove the clutch from the housing.

A B C D E F G H

H

G

Bolts Left Bearing Carrier Right Bearing Carrier Shim Ball Bearing Input Gear Housing Support Block

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

2. Remove each input gear from the housing.

3. Remove the shim from between each bearing carrier and the housing. Discard the shims if damaged.

2.10

Tigercat Standard Transmission REMOVE THE INPUT BEARING CARRIERS – VERSION 2

Disassembly REMOVE THE INPUT GEAR BEARINGS E

A

A

B C

B

D

D

E F

C

A

E C00314

A B C D E

H

G

C00305

A B C D E F G H

Ball Bearing Bearing Separator Support Block Input Gear Blank

1. Remove the ball bearings from each end of the input gears using a bearing separator resting on support blocks. a. Cover the gear end with a piece of wood or brass or carefully drive the gear from the bearing using a punch in a star pattern. Do not damage the gear end.

Bolts Left Bearing Carrier Right Bearing Carrier O-rings Ball Bearing Input Gear Housing Support Block

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

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

2. Remove each input gear from the housing.

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

2.11

Disassembly

Tigercat Standard Transmission

REMOVE THE BAFFLE A B

C

D C00328

A B C B

Magnetic Plug Housing Bolt Baffle

1. Orient the housing on support blocks with the carrier side facing up.

2. Remove bolts securing the baffle to the housing.

See, REMOVING FASTENERS SECURED WITH LOCTITE 263 HIGH STRENGTH THREAD LOCKER. 3. Remove the baffle.

4. Remove and clean the magnetic plug. Debris on the plug may provide useful diagnostic clues.

2.12

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

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

CONTENTS – SECTION 3

ISSUE 1.0, JANUARY 2017

A

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

BAFFLE INSTALLATION............................................................................................................................................... 3.7 BEARING CARRIER INSTALLATION – VERSION 1................................................................................................... 3.8 BEARING CARRIER INSTALLATION – VERSION 2................................................................................................... 3.9 BEARING INSTALLATION INSTRUCTIONS................................................................................................................ 3.3 C

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

HEATER, BEARING INDUCTION................................................................................................................................. 3.3 HEATING BEARINGS FOR INSTALLATION................................................................................................................. 3.3 HOUSING ASSEMBLY.................................................................................................................................................. 3.7 HOUSING COVER INSTALLATION........................................................................................................................... 3.16 I

INPUT GEAR BEARINGS, INSTALL............................................................................................................................. 3.5 INPUT GEAR ENDPLAY MEASUREMENT................................................................................................................ 3.10 INPUT GEAR INSTALLATION...................................................................................................................................... 3.8 INSPECTION AND CLEANING..................................................................................................................................... 3.3 M

MEASUREMENT, INPUT GEAR ENDPLAY............................................................................................................... 3.10 MEASUREMENT, MOTOR BORE RUNOUT................................................................................................................ 3.9 O

OUTPUT BEARING CARRIER – VERSION 2............................................................................................................. 3.6 OUTPUT BEARING COVER – VERSION 1................................................................................................................. 3.6 OUTPUT GEAR BEARING CONE, INSTALL................................................................................................................ 3.5 OUTPUT GEAR INSTALLATION - PART A................................................................................................................. 3.10 OUTPUT GEAR INSTALLATION - PART B................................................................................................................. 3.12 OUTPUT SHAFT PRELOAD....................................................................................................................................... 3.14 R

REASSEMBLY, PRIOR TO............................................................................................................................................ 3.4 S

SAFETY......................................................................................................................................................................... 3.3 SHIFTING FORK INSTALLATION............................................................................................................................... 3.15 SHIFTING HUB INSTALLATION................................................................................................................................. 3.11

Assembly

Tigercat Standard Transmission

3.2

Tigercat Standard Transmission

Assembly

SAFETY

BEARING INDUCTION HEATER

See SECTION 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 4m (15 ft) of an induction heater.

See SECTION 1 of this manual for references to cleaning and inspecting the unit.

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 hazards 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. 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, be sure they have enough time to fully heat and cool.

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

HEATING BEARINGS FOR INSTALLATION

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

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

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

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

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

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

3. Take extreme care that standard product bearings, gears, or steel sleeves are never heated 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.

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

4. Heat and cool bearing components gradually.

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.

3.3

Assembly

Tigercat Standard Transmission

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).

PRIOR TO ASSEMBLY Prior to standard transmission reassembly: 1. Have all required parts readily available.

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

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

• Ensure they are the right parts.

• Verify orientation.

• Replace damaged or worn components as required.

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

3.4

Tigercat Standard Transmission

Assembly

INSTALL INPUT GEAR BEARINGS

INSTALL OUTPUT GEAR BEARING CONE

1. Heat the bearings as described in SECTION 3 of this manual.

1. Heat the bearing cone as described in SECTION 3 of this manual.

A

A

B B

D A

C

A

C00308

A Ball Bearing B Input Gear

C00309

A B C D

2. Install bearings onto each end of the input gears with the bearing shields facing the gear.

3. Allow the bearings to cool to the touch.

O-ring Bearing Cone Output Shaft Spring Pin

2. Install the bearing cone onto the output shaft. Note the orientation of the bearing taper.

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

3. Allow the bearing to cool to the touch.

4. Verify that each bearing is fully seated on the output shaft bearing shoulder. If the bearing is not fully seated, carefully tap it into place using tool B7394001 or a punch that contacts the inner race of the bearing only. Tap the bearing in a star shaped pattern.

See SECTION 1 of this manual for references to disassembly and assembly tools.

3.5

Assembly

Tigercat Standard Transmission

OUTPUT BEARING COVER – VERSION 1

d. Insert the output sleeve with both seals into the output bearing cover, then push it into place until the oil seal rests against the seat in the bearing cover.

Two identical output bearing covers are used in the Version 1 standard transmission.

e. Remove the output sleeve.

A

OUTPUT BEARING CARRIER – VERSION 2

B

WARNING

C

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

Two identical output bearing carriers are used in the Version 2 standard transmission.

D

1. Cool the bearing cups to -65°F using liquid nitrogen (if available) or as cold as possible, over-night in a freezer.

A

D

A

B C

B

C00341

A B C D

Output Sleeve Wiper Seal Oil Seal Output Bearing Cover

CAUTION

C

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

D

E

1. Place the output bearing covers, each with the outer surface facing up on the work surface.

2. Install the wiper seal and oil seal.

C00310

a. Apply a small amount of gear oil to the wiper seal and the oil seal. Flex the inner surface of the oil seal to make it pliable. This will aid with installing the seals.

A B C D E

b. Orient the wiper seal with the open channel facing the bottom of the flange of the output sleeve, then apply it to the sleeve. c.

Bearing Cup Output Bearing Carrier Oil Seal Wiper Seal Output Sleeve

2. Place the output bearing carriers, each with the outer surface face down, on the work surface.

3. Insert the cooled bearing cups into each output bearing carrier. Verify that the bearing cups are fully seated.

Orient the oil seal with the open channel facing away from the bottom of the flange of the output sleeve, then apply the seal.

3.6

Tigercat Standard Transmission

Assembly HOUSING ASSEMBLY

CAUTION

BAFFLE INSTALLATION

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

A B

A B

C C

D

D

C00306

A B C D

E

1. Orient the housing on support blocks with the left and right side bearing carriers facing up.

C00301

A B C D E

Output Bearing Carrier Oil Seal Output Sleeve Wiper Seal Bearing Cup

2. Insert the baffle with the mounting tabs facing down.

3. Apply Loctite 263 to four bolts then, secure the baffle to the housing.

4. Torque each bolt to 50 Nm (37 lbf-ft).

4. Place the output bearing carriers, each with the outer surface facing up on the work surface.

5. Install the magnetic plug.

5. Install the wiper seal and oil seal. a. Apply a small amount of gear oil to the wiper seal and the oil seal. Flex the inner surface of the oil seal to make it pliable. This will aid with installing the seals onto the transmission output sleeve. b. Orient the wiper seal with the open channel facing the bottom of the flange of the output sleeve, then apply it to the sleeve. c.

Magnetic Plug Housing Bolt Baffle

Orient the oil seal with the open channel facing away from the bottom of the flange of the output sleeve, then apply the seal.

d. Insert the output sleeve with both seals into the output bearing carrier, then push it into place until the oil seal rests against the seat in the bearing carrier. e. Remove the output sleeve.

3.7

Assembly

Tigercat Standard Transmission

INPUT GEAR INSTALLATION

BEARING CARRIER INSTALLATION –VERSION 1

CAUTION

Version 1 standard transmissions utilize a shim as a gasket between the housing and the carrier.

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 D

B

C

A B C00311

A B C D

Left Bearing Carrier Shim Spring Pin Oil Hole in Housing and Bearing Carrier

1. Apply a small amount of gear oil to both sides of each shim.

2. Align each shim with the bearing carrier mounting holes and place the shim on the housing.

C00339

3. Align the oil hole in the left bearing carrier with the corresponding oil hole in the housing then, insert it into the housing.

C

A Input Gear B Housing C Support Blocks

4. Align the oil hole in the right bearing carrier (not shown) with the corresponding oil hole in the housing then, insert it into the housing.

1. Orient the housing on support blocks with the left and right side bearing carriers facing up.

5. Apply Loctite 243 to four bolts securing each of the two carriers.

2. Insert the one input gear into the carrier opening, with the gear at the top.

6. Tighten each bolt, finger tight, then torque to 108 Nm (80 lbf-ft) in a diagonally opposed pattern.

3. Align the lower bearing in the lower bearing seat in the housing.

7. Manually turn each gear three revolutions to set the bearings. If the gear will not turn, contact the Tigercat service department.

4. Insert the other input gear into the carrier opening, with the gear at the top.

5. Align the lower bearing into the lower bearing seat in the housing.

3.8

Tigercat Standard Transmission

Assembly

BEARING CARRIER INSTALLATION –VERSION 2

MOTOR BORE RUNOUT MEASUREMENT

NOTICE

Version 2 standard transmissions utilize a an o-ring between the housing and the carrier.

Verify the motor bore runout measurement on both the left and right input gears.

A D

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

B

C C A

C00311

A B C D

Left Bearing Carrier O-ring Spring Pin Oil Hole in Housing and Bearing Carrier

B C00256

A Measuring Rod B Dial Indicator C Input Gear

1. Lightly oil the o-rings and apply one to each bearing carrier.

2. Align the oil hole in the left bearing carrier with the oil hole in the left side of the housing and slide it into position.

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

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

3. Align the oil hole in the right side bearing carrier with the oil hole in the right side of the housing and slide it into position.(not shown).

4. Apply Loctite 243 to four bolts securing each of the two carriers.

4. Turn the input shaft to measure the runout of the input shaft. If the runout exceeds 0.004 inches, contact the Tigercat service department.

5. Tighten each bolt, finger tight, then torque to 108 Nm (80 lbf-ft) in a diagonally opposed pattern.

5. Repeat steps 1 through 4 for the other input gear.

6. Manually turn each gear three revolutions to set the bearings. If the gear will not turn, contact the Tigercat service department.

3.9

Assembly

Tigercat Standard Transmission OUTPUT GEAR INSTALLATION - PART A

INPUT GEAR ENDPLAY MEASUREMENT

NOTICE

F

Verify the endplay measurement on both the left and right input gears.

C

A

E

1. Ensure the input gear assembly is fully seated.

A

B C

E B

D E

A B C D E F C00257

A B C D E F

D

C00318

F

C

Output Gear Housing Thrust Washer Spring Pin Output Shaft Clutch Spline

1. Orient the housing with the cover side of the housing facing up and the motor bores facing forward.

Dial Indicator Measuring Rod Top Surface of Input Gear Housing Input Gear Pry Bar

1 A 3

B

2

2. Mount a dial indicator on the surface of the housing.

3. Position the measuring rod from the indicator so that it is perpendicular and touching the top surface of the input gear (parallel to the gear axis).

G

4. Turn the input shaft three times, then set the indicator to zero.

D

5. Pry the input gear upward as far as it will go, then record the value. The acceptable range of endplay is between 0.09mm (0.039 inches) and 2.41mm (0.095 inches). If the value of endplay is outside of this range contact the Tigercat service department.

E F C00317

A B C D E F G

3.10

Output Gear Housing Baffle Thrust Washer Clutch Spline Spring Pin Output Shaft

C

Tigercat Standard Transmission CAUTION

Assembly SHIFTING HUB INSTALLATION

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

2. Rest the output gear in the baffle with the spline facing the motor bores. See 1 of the previous illustration.

C

3. Install the output shaft into the clutch spline.

D

a. Apply assembly grease to the output shaft diameter containing the spring pin. b. Insert the output shaft through the centre bore of the housing. c.

Orient the clutch spline with the outer splines facing the output gear. See 2 of the previous illustration.

F

d. Lower the clutch spline into the baffle, then slide the output shaft into the clutch spline.

C00315

A B C D E F

4. Insert the output shaft into the thrust washer. See 3 of the previous illustration. a. Verify the oil channels face the output gear. b. Align the spring pin in the shaft with the spring pin slot in the thrust washer. c.

Lower the thrust washer into the baffle, then slide the thrust washer onto the output shaft, against the output shaft clutch spline.

5. Insert the output shaft into the output gear, then rest the output shaft/output gear against the carrier side of the housing.

E

Shifting Shaft O-ring Spring Gear Clamp Ball Shifting Hub

1. Apply white assembly grease to each ball hole on the shifting hub.

2. Apply a small amount of gear oil to the o-ring and install it on the shifting hub.

3. Insert the shifting shaft into the shifting hub. The threaded end of the shaft is away from the o-ring groove on the hub.

4. Verify that the shaft moves freely in the shifting hub.

5. Align the grooves on the shaft with the holes in the shifting hub.

6. Insert a ball and a compression spring into each hole.

7. Apply a gear clamp over the shifting hub then tighten the clamp to compress the springs.

3.11

Assembly

Tigercat Standard Transmission

A

B

OUTPUT GEAR INSTALLATION - PART B

C

OUTPUT BEARING COVER/CARRIER GASKET

B F E C

D

C00316

A

Output shaft, thrust washer, clutch spline, output gear not shown for clarity.

A B C D E F

Oil Seal Gear Clamp Shifting Hub Subassembly Shifting Hub Bore Housing Assembly Tool A7901000

B C C00320

8. Apply white assembly grease to the shifting hub bore in the housing.

9. Insert the shifting hub subassembly, working from outside the housing, into the bore until the gear clamp rests against the outer wall of the housing.

A Output Bearing Carrier Flange/Output Cover Flange B Lubrication Hole Area C Loctite 518

Apply a bead of Loctite 518 to the perimeter of the flange of the output cover/output bearing carrier and around each bolt hole. Avoid sealant in the lubrication hole.

10. Tap the hub into the housing using tool A7901000, until the springs have cleared the gear clamp and are contained within the housing bore.

11. Apply Loctite 518 to the outer diameter of the oil seal and install it on the shifting shaft protruding from the outside of the housing. Press the oil seal firmly in place.

3.12

Tigercat Standard Transmission

Assembly OUTPUT BEARING CARRIER INSTALLATION – VERSION 2

OUTPUT BEARING COVER INSTALLATION – VERSION 1

A

A

B

B

E

F

E

D

C00349

A B C D E F

C00321

C

Bearing Cup Housing Output Shaft Output Bearing Cover Bolts Oil Holes

1. Insert the output-bearing cup in the output shaft bore on the motor side of the housing.

A B C D E

D

C

Housing Output Shaft Output Bearing Carrier Bolts Oil Holes

1. Align the lubrication hole in the output bearing carrier with the oil hole in the transmission housing.

2. Install the output bearing carrier into the housing.

3. Secure using six bolts.

4. Apply Loctite 243 to each bolt and thread into housing.

5. Torque each bolt to 108 Nm (80 lbf-ft) using a star pattern.

2. Tap the circumference of the output bearing cup incrementally with a brass punch until it is installed into the housing or until the mounting bolts can be threaded into the bolt holes.

3. Align the lubrication hole in the output bearing cover with the oil hole in the transmission housing.

4. Install the output bearing cover into the housing.

5. Secure using six bolts.

6. Apply Loctite 243 to each bolt and thread into housing.

7. Torque each bolt to 108 Nm (80 lbf-ft) using a star pattern.

3.13

Assembly

Tigercat Standard Transmission

OUTPUT SHAFT PRELOAD

A B

A

C

B

D E

C

F

D

E

G

C00322

A B C D E F

Bolts Output Bearing Carrier Bearing Cone Output Shaft Support Blocks Shim Pack

1. Position the gear box housing on support blocks with the left and right side bearing carriers facing up.

2. Heat the bearing cone as described in SECTION 3 of this manual.

F

C00028

A B C D E F G

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

8. Select a starting shim pack containing the following shims:

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

Shim Size

Qty

Total Shim Thickness

0.51mm (0.020 inch)

2

1.02mm (0.040 inch)

4. Allow the bearing to cool to room temperature.

0.18mm (0.007 inch)

2

0.36mm (0.014 inch)

0.13mm (0.005 inch)

4

0.51mm (0.020 inch)

0.08mm (0.003 inch)

1

0.08 (0.003 inch)

Total =

1.96mm (0.077 inch)

5. Verify that the bearing is fully seated on the output shaft shoulder using tool B7394001. If tool B7394001 is unavailable carefully tap the bearing into place using a punch that contacts the inner race of the bearing only. Tap the bearing in a star shaped pattern.

9. Verify the thickness of each shim.

6. Install the output bearing carrier, insert each bolt, then torque to 108 Nm (80 lbf-ft). Do not apply Loctite.

11. Insert each bolt, then torque to 108 Nm (80 lbf-ft).

Do not apply Loctite.

7. Rotate the output shaft several turns, then strike the end of the shaft with a rubber mallet to seat the bearings.

10. Remove the output bearing carrier and install the shims from the starting shim pack.

12. Place a dial indicator on the housing so that the measuring tool rests perpendicular to the housing on the end of the output shaft.

13. Set the dial indicator to zero.

3.14

Tigercat Standard Transmission Preload Calculations +

–

1.1mm (0.043 inch)

Measured End Play

0.05mm (0.002 inch)

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

1.14mm (0.045 inch)

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

1.96mm (0.077 inch)

Measured Value of Starting Shim Pack

1.14mm (0.045 inch)

Measured End Play and Specified Preload.

0.81mm (0.032 inch)

Calculated Value of Shims

Assembly 21. Place a dial indicator on the housing so that the measuring tool rests perpendicular to the housing on the end of the output shaft.

22. Set the dial indicator to zero.

23. Pry the output shaft up and down using a pry bar under the output shaft. Turn the gear several times and measure for any end play variance. The value must be 0.00mm (0.00 inches).

24. If there is a measured variance repeat steps 8 through 20, adjusting shim sizes until there is no end play. When zero end play is achieved:

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

14. Pry the output shaft up and down using a pry bar under the output shaft. Turn the gear several times and record the variance. Repeat and record the measurement two more times. The value of the preload measurement must be 0.025mm – 0.076 (0.001 – 0.003 inches).

a. Remove the bolts securing the output bearing carrier. b. Apply Loctite 243 to each bolt. c.

Install and torque each bolt to 108 Nm (80 lbf-ft).

SHIFTING FORK INSTALLATION

15. Determine the required shims by adding the measured end play (up and down variance) to the specified preload value. Subtract that value from the starting shim pack value to calculate the value of the shims required. See the example in the Preload Calculations chart.

A

B

16. Remove the output bearing carrier.

Shim Size

Qty

0.5mm (0.020 inch

1

Total Shim Thickness 0.5mm (0.020 inch)

0.18mm (0.007 inch)

1

0.18mm (0.007 inch)

0.13mm (0.005 inch)

1

0.13mm (0.005 inch)

Total =

0.81mm (0.032 inch)

C

D

17. Select the necessary shims to match the calculated value total. See the example in the previous chart.

18. Remove the output bearing carrier.

E

19. Verify the measurement of the combined shims then align them with the mounting holes and install them onto the housing.

C00319

20. Install the output bearing carrier:

A B C D E

a. Orient the oil hole in the carrier with the oil hole in the transmission housing. b. Insert the spring pin. c.

Install and torque each bolt to 108 Nm (80 lbf-ft).

Shifting Shaft Clutch Spline Output Gear Shifting Fork Output Shaft

1. Slide the shifting shaft away from the motor end of the housing until the shoulder on the threaded end of the shifting shaft is almost flush with the shoulder of the shifting hub. The grooves in the shaft will catch on the spring loaded balls in the shifting hub, stopping it.

3.15

Assembly

Tigercat Standard Transmission

2. Slide the shifting fork into the groove on the spline clutch and tap the shifting fork to seat it fully on the spline clutch.

HOUSING COVER INSTALLATION A

B

3. Fit the mounting hole over the threaded end of the shifting shaft.

C

F

A

B

C

D

E C00273

A B C D E F

C00327

A Shaft Key B Nut C Shifting Fork

4. Fit a nut (the first few threads) to secure the fork loosely to the shifting shaft. Do not tighten the nut.

5. Apply a light coat of gear oil to the shaft key.

6. Align the keyway in the shifting fork to the keyway in the shifting shaft and insert the shaft key.

Output Sleeve Magnetic Plug Housing Gasket Bolts Cover

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

2. Install the gasket.

3. Install the cover and secure using bolts torqued to 45 Nm (33 lbf-ft).

4. Install the magnetic plug.

7. Remove the nut and apply Loctite 243 to the shaft and nut.

8. Thread the nut onto the end of the shifting shaft, then torque to 68 Nm (50lbf-ft).

9. Strike the end of the shifting shaft using a rubber mallet, from outside of the housing, to fully seat the clutch spline in the output gear.

3.16