PM-000111-A Trencher: Service and Repair Manual - November 2014
2
All BIGFOOT AND HIGHDRIVE TRENCHERS
This manual is intended to be used by persons with reasonably mechanical skills and understanding of mechanical components.
This manual will assist in the disassembly and assembly of the above model Trenchers. Item numbers, indicated in pa-rentheses throughout
this manual, refer to the exploded parts breakdown drawing. Individual customer specications may vary from exploded drawing and standard
part numbers shown. Contact Digga Australia for enquiries.
For any spare or replacement parts, contact Digga Service and Spares or a local Digga representative. For identication purposes always try
to have available the trencher type and serial number. This information may be necessary for verication of any component part numbers.
Component part numbers and/or manufacturing gear set numbers may be stamped on individual parts. This information may also be helpful in
identifying replacement components.
MODELS COVERED IN THIS MANUAL
MINI BIGFOOT
BIGFOOTBIGFOOT XDHYDRIVEHYDRIVE XD
3
PLANETARY GEAR OIL
The Trencher Planetary Unit is a sealed Unit. If there is any sign of oil leaks please contact your nearest DIGGA dealer before carrying out
any repairs, as there can be other causes for seal leaks.
OPERATING IN ASIA PACIFIC AND EUROPE
The Planetary Drive Unit in the Trencher when operating in Asia Pacic and Europe uses the Gear Oil VALVOLINE EPG ISO 320
(mineral oil) for lubrication of gears and bearings. Minimum and maximum gear oil operating temperatures for these regions is
-5°C (23°F) to 120°C (248°F). Please contact your Digga specialist for the recommended Gear Oil if operating outside this range.
OPERATING IN NORTH AMERICA
The Planetary Drive Unit in the Trencher when operating in North America uses the Gear Oil CHEVRON MEROPA ISO 320
(mineral oil) for lubrication of gears and bearings. Minimum and maximum gear oil operating temperatures for this region is
-18°C (-0.4°F) to 107°C (225°F). Please contact your Digga specialist for the recommended Gear Oil if operating outside this range.
● Continuous operating temperature must not exceed 80°c.
● During extended stationary periods (one month or more), the unit should be run monthly to immerse all internals in oil, thereby
preventing corrosion.
● Oil should be changed when hot, to prevent a build up of sludge deposits. Flush interior of unit with uid recommended by oil
companies.
● Check for leaks regularly and if an oil leak is detected contact your nearest DIGGA Dealer for remedy instructions.
● Use only the prescribed oil when relling. Valvoline EPG ISO 320 Gear Oil.
● DO NOT mix oil of different viscosity, NOT even those of the same brand.
● NEVER mix mineral and synthetic oils.
● Cleanliness is necessary when changing oil.
OIL CHANGED SCHEDULE
IMPORTANT
• First oil change MUST be carried out within the rst 50 hours of use under MODERATE OPERATING CONDITIONS. Thereafter,
every 500 hours.
• Change the gear oil after the rst 30 hours of SEVERE OPERATING CONDITIONS*. (i.e. severe ambient temperature conditions of
+40°C or below 0°C, trenching in hard ground.) Thereafter, every 300 hours.
• Contact your nearest DIGGA Dealer for Gear Oil change procedure.
THE GEARBOX OIL CAPACITY IS ENGRAVED ONTO THE SERIAL TAG LOCATED ON THE TRENCHER
PM-000111-A Trencher: Service and Repair Manual - November 2014
PLA NETARY SU BASSEMB LY........................................................................................................................ 9
UNIT REASSEMBLY....................................................................................................................................... 10
All parts should be inspected as they are removed from unit. Scribe or mark a line across the assembly mounting case, ring gear, and cover
joints on outside of gearbox to assure proper orientation of assembly, oil ll/ drain plug, motor mounting, etc., as the unit is reassembled.
1. Remove chain, boom, sprockets and seal protector.
2. Remove outer ring of bolts (refer to diagram below) from gearbox assembly. Lift gearbox assembly clear of frame. Remove drain plug and
drain oil.
3. Remove inner ring of bolts and nyloc nuts (Refer to pages 6 and 7). Remove hydraulic motor from gearbox assembly.
4. The primary planetary assembly is now ready for removal. Lift outer ring gear, sun gear and gear set from the output housing.
5. Remove key steel from keyway. Loosen lock nut using the required tool and remove locknut.
CAUTION: RETAINING RING IS NO LONGER RETAINING OUTPUT SHAFT. TAKE PRECAUTIONS IF THE UNIT IS MOVED
BECAUSE THE SHAFT MAY FALL OUT.
6. With output shaft down through a centre hole in hydraulic press table and unit supported by case, press shaft out by applying load to top
end of shaft (internal end) until it passes through inner shaft bearing. Outer shaft bearing will come out of unit attached to shaft.
CAUTION: CARE SHOULD BE TAKEN NOT TO INJURE FEET OR DAMAGE OUTPUT SHAFT DURING THIS PROCEDURE.
The unit is now disassembled into groups of parts and/or subassemblies. The area requiring repair or service should be identied by thorough
inspection of the parts after they have been washed in solvent.
PM-000111-A Trencher: Service and Repair Manual - November 2014
REFER TO APPROPIATE EXPLODED VIEW DRAWING (Page 58-65)
BIGFOOTMINI BIGFOOTBIGFOOT XD
1. Inspect inner and outer bearing cups and cones. If either is damaged, the complete bearing assembly will need replacing.
2. Remove inner and outer bearing races from output housing with the appropriate tool.
3. Clean all foreign material from oil plug located on bottom of output housing. Add a small amount of pipe thread compound to thread on plug
before installing it back into case.
BIGFOOT XD HIGHFLOW
7
DRIVE ASSEMBLY: HYDRIVE - HYDRIVE XD
REFER TO APPROPIATE EXPLODED VIEW DRAWING (Page 66-69)
HYDRIVEHYDRIVE XD
1. Inspect inner and outer bearing cups and cones. If either is damaged, the complete bearing assembly will need replacing.
2. Remove inner and outer bearing races from output housing with the appropriate tool.
3. Clean all foreign material from oil plug located on bottom of output housing. Add a small amount of pipe thread compound to thread on plug
before installing it back into case.
PM-000111-A Trencher: Service and Repair Manual - November 2014
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PLANETARY SUBASSEMBLY
Rotate planet gear to check for any abnormal noises or roughness in the primary planet bearings. At the same time, inspect planet gears for any
damage or worn teeth. If replacement or further inspection is required, proceed as follows.
1. Remove circlips from top plate and remove plate.
2. Slide planet gears from carrier.
CAUTION: THE NEEDLE ROLLER BE ARINGS ARE NOT CAGED THEREFORE CAN FALL FREE.
3. Remove bottom plate.
4. Check primary planet shafts, top and bottom plates, centre thrust washer, needle rollers and gears for any abnormal wear.
5. Replace any worn items.
NOTE: IF THE PL ANET SHAFTS ARE WORN, THE COMPLETE CARRIER ASSEMBLY MUST BE REPLACED. THE POSTS
SHOULD NOT BE REPLACED IN AN EXISTING CARRIER.
6. Assembly: Fit centre thrust washer, t bottom plate, t gears, insert needle rollers into gears using lubricating oil, t top washer and install
circlips to posts place gear set into ring gear and place sun gear into gear set, ensure all turns freely.
9
UNIT REASSEMBLY
1. Start with output housing assembly. Turn case upside down and position on table. Bottom seal end should be facing upward and install
bearing cup with appropriate tooling.
2. Install bottom seal applying a smear of Loctite 243 thread locker to outside of seal and t using appropriate tooling. Ensure seal is ush
with the housing. Wipe off excess Loctite. Grease inner face of seal with EP grease.
3. Invert outer housing to upright position and place over securely positioned output shaft with splines facing upward. Using the appropriate
tooling, assemble the output housing onto the output shaft.
4. Install bearing race to output housing with appropriate tooling. Install bearing ensuring correct installation technique. Only drive the
bearing home via the inner cone of bearing. Hitting outer roller cage will damage the bearing.
5. While holding output shaft with one hand, rotate case to be cer tain it turns freely and smoothly. The slight resistance felt, if any, is due to
shaft seal load (drag) on output shaft. Nut tension – 125ft/lbs (approx) (“Bearing Preload Chart P.18” for correct lock nut tension.)
6. Insert key after tensioning locking nut.
7. Clean and ensure inner section of housing and bearings are free from foreign matter.
8. Lightly grease a new o-ring and install it into o-ring groove in case.
9. Fit gear set and sun gear to the output housing. Line up bolt holes and t ring gear. Make sure the ring gear sits at on the
10. Grease a new o-ring and install it into the groove of hydraulic motor. Refer back to scribe marks made across external joints prior to
11. Re t gearbox assembly making sure original scribe marks are aligned and t all outer bolts.
12. Attach hydraulic hoses and test operation.
13. Ret seal protector, sprocket, boom and chain.
NOTE: IF THE BEARINGS HAVE BEEN REPL ACED, IT IS LIKELY THAT A NEW KEYWAY WILL HAVE TO BE CUT IN THE LOCKNUT.
NOTE: BE CERTAIN THAT THE O-RING STAYS SEATED IN GROOVE DURING STEP DURING ALL ASSEMBLY STAGES.
housing. Top up gear oil level to top of gear set.
Disassembly Procedure. Line up scribe marks so that orientation of motor mount holes and oil plug are back to their original positions and
ret motor.
PM-000111-A Trencher: Service and Repair Manual - November 2014
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ALWAYS ENSURE THAT THE HYDRAULIC MOTOR IS PRIMED WITH HYDRAULIC FLUID PRIOR TO USE FOLLOWING
ANY REPAIRS TO THE TRENCHER, OR THE PARENT MACHINE IF A LEAK IS DETECTED WHILE CONNECTED TO THE
TRENCHER. DO NOT ALLOW THE TRENCHER TO RUN WITHOUT OIL AT ANY TIME.
NOSE ROLLER BEARING REPLACEMENT
FIG 1FIG 2FIG 3
1. To replace the nose roller
bearing, rstly remove circlip
using a pair of straight circlip
pliers Fig 1.
NOTE: A HAMMER IS NOT RECOMMENDED FOR THIS PROCEDURE AS IT CAN DAMAGE THE
NEW BEARING.
2. Use a press to push the
bearing out ensuring the
pipe underneath is larger
than the bearing Fig 2.
SCRAPER SHOE REPLACEMENT
SCRAPER SHOE
The Scraper shoe is designed to be interchangable should it get damaged or a different chain is tted
to the trencher. To replace simply remove the 3 nut and bolts holding it in place. Replace the shoe and
tighen the bolts using hand tools.
MAINTENANCE
3. When pressing the new bearing in ensure the drift used is
the correct size. ie; The drift must sit against the outside shell of
the bearing being careful not to damage the ring that holds the
bearing together, make sure the bearing is sitting against the lip
on the opposite side of the nose roller and replace circlip.
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MAINTENANCE
SPROCKET REPLACEMENT FOR BIGFOOT
Firstly remove ½” bolt holding the auger, then remove auger.
FIG 1
Using a 3/16” Allen key loosen the 2 grub screws in the
retaining collar and slide collar off the shaft. (shown in Fig 1).
SPROCKET REPLACEMENT FOR HYDRIVE
Firstly remove ½” bolt using a spanner, remove the
spocket washer and then slide sprocket off the shaft.
(shown in Fig 3).
PM-000111-A Trencher: Service and Repair Manual - November 2014
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FIG 3
Slide the sprocket off the shaft and replace with new sprocket. It is
FIG 2
recommended Anti-seize be applied to shaft before replacement of
sprocket (Shown in Fig 2)
FIG 4
Slide the sprocket off the shaft and replace with new sprocket. It is
recommended Anti-seize be applied to shaft before replacement of
sprocket (Shown in Fig 4)
MAINTENANCE
NOTE: IF THE SPROCKET CANNOT BE REMOVED BY TAPPING WITH A HAMMER THEN A PULLER MAY HAVE TO BE USED.
IMPORTANT: SHUT DOWN TRENCHER & MACHINE BEFORE ANY ADJUSTMENTS ARE MADE
HYDRAULIC HOSE CONNECTION
SUPPLY FROM MACHINE
1. The Trencher chain must rotate
in an anti-clockwise direction (when
viewed from the Motor side of the
Trencher). The Supply Line from the
Parent machine must be connected
to the ‘A’ port on the Trencher Motor
BOOM ADJUSTMENT
1. Use spanner supplied to
wind adjuster nut clockwise
for loosening, anti-clockwise
for tightening
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MAINTENANCE
CHAIN ADJUSTMENT
1. To either adjust chain or remove chain – remove the ½" Bolts
holding spanner to outer boom. (FIG 1)
2. Use spanner supplied to wind adjuster nut clockwise for
loosening, anti clockwise for tightening. (FIG 2)
FIG 1
3. To achieve the correct chain tension: Adjust the tension on the lower
chain section at the midway point between the sprockets to allow 20mm
to 30mm of vertical movement. (FIG 3)
PM-000111-A Trencher: Service and Repair Manual - November 2014
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Chain
midway point
between sprockets
20mmto30mm
FIG 2
FIG 3
SEAL REPLACEMENT
MAINTENANCE
Before the seal can be replaced remove
retaining collar and sprocket as shown in
sprocket replacement. Then remove the
key and seal protector. Place a screwdriver
between outside of seal and inside of
housing. Tap gently with a hammer until
the seal can be levered out Fig 1. Inspect
the inside of the housing for damage and
if damaged or burred, clean up with emery
cloth.
NOTE: MAKE SURE ALL GEAR OIL IS DRAINED AT THIS POINT.
Before the seal can be replaced run
some grease around the inside lip of the
seal for lubrication to the shaft. Ensure
there are no burrs on the shaft between
the end of the shaft and the end of the
housing. File if necessary. Using loctite
243 (or equivalent) run a small bead
around the outside of the seal see
Fig 2.
AUGER ADJUSTMENT
1. The spoil removal auger has 2
settings. When a 150mm or 200mm
chain is being used the auger must
set closer to the chain. Use the bolt
hole which is closer to the auger
ights. The auger ights should be
atleast 100mm from the chain.
FIG 2FIG 3FIG 1
Proceed to t the seal by using a large punch
and gently tap the seal into place ensuring
the seal is punched in evenly (see Fig 3).
This is ver y important as any misalignment
could cause damage to the seal and promote
a leak. The seal must be ush with the end
of the housing. Replace seal protector,
key, sprocket and retaining collar. Rell the
planetary with gear oil (See lubrication for
correct amount, grade of gear oil, and oil
lling procedures).
IMPORTANT
When a 250mm or 300mm chain is
being used it is important that the
Augers is set further away from the
chain. Use the bolt hole which is
further away from the auger ights.
The auger ights should be atleast
100mm from the chain.
15
MAINTENANCE
FITTING A TRENCHER CHAIN - MINI TRENCHER / BIGFOOT / BIGFOOT XD
CAUTION: ALL WORK SAFE PRACTICES AND PROCEDURES MUST BE ADHERED TO AND APPROPRIATE PPE MUST BE WORN.
1. Start with the Trencher securely attached to a lifting device or
machine, ensure the adjustable boom is fully retracted.
2. Place Trencher on the ground, position chain in front of the
nose roller with cutting edge of the tooth facing away from the
FIGURE 1
FIGURE 2FIGURE 6
FIGURE 3
FIGURE 5
Trencher. (Figure 1)
3. Lift chain onto Nose Roller (Figure 2) - A suitable lifting device
may need to be used for the larger heavier chains
4. Slide the chain along the boom and over the drive sprocket.
(Figure 3)
5. Raise the Trencher - Ensuring the Trencher is supported and
cannot fall whilst raised from the ground - Bring both ends of
the chain under the boom. (Figure 4)
6. Bring both ends of the chain together and insert the joining pin.
The joining pin must be inserted from the correct side which is
identied by looking at the head of the other link pins and
matching it to the same side. (Figure 5)
7. Tap the joining pin fully home using a soft head mallet. (Figure 6)
8. Insert the keeper pin and bend to secure. (Figure 7)
9. Adjust the chain tension and replace spanner to side of boom.
(Figure 8)
FIGURE 7
FIGURE 8
PM-000111-A Trencher: Service and Repair Manual - November 2014
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FITTING A TRENCHER CHAIN - HYDRIVE / HYDRIVE XD
CAUTION: ALL WORK SAFE PRACTICES AND PROCEDURES MUST BE ADHERED TO AND APPROPRIATE PPE MUST BE WORN.
1. Start with the Trencher securely attached to a lifting device or
machine, ensure the adjustable boom is fully retracted.
2. Place Trencher on the ground, position chain in front of the
nose roller with cutting edge of the tooth facing away from the
FIGURE 1
FIGURE 2
FIGURE 3
Trencher. (Figure 1)
3. Lift chain onto Nose Roller (Figure 2) - A suitable lifting device
may need to be used for the larger heavier chains
4. Slide the chain along the boom and over the drive sprocket and
down past the idle sprocket. (Figure 3)
5. Raise the Trencher - Ensuring the Trencher is supported and
cannot fall whilst raised from the ground - Bring both ends of
the chain under the boom. (Figure 4)
6. Bring both ends of the chain together and insert the joining pin
The joining pin must be inserted from the correct side which is
identied by looking at the head of the other link pins and
matching it to the same side. (Figure 5)
7. Tap the joining pin fully home using a soft head mallet. (Figure 6)
MAINTENANCE
FIGURE 5
FIGURE 6
FIGURE 7
FIGURE 4
8. Insert the keeper pin and bend to secure. (Figure 7)
9. Adjust the chain tension and replace spanner to side of boom.
(Figure 8)
FIGURE 8
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BEARINGPRELOAD FORCECHART
,PD3 - PD5
S2
PD6 -PD12
S4
S4(RME)
S4
PD15 -PD22
S5S6
PD25-PD50S812035
S9.5
S1015045S12
BEARING PRELOAD CHART
FORCE (in Kg)
This is the force to keep the housing spinning slowly
at a constant speed. The force required to star t the
spinning initially will be greater. This is not the correct
reading. To ensure an accurate reading the force
direction must be held at 90 degrees. (As shown).
Reading is to be taken from the inner bolt pattern.
4 Kg
PM-000111-A Trencher: Service and Repair Manual - November 2014
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MINI BIGFOOT TRENCHER
SPARE PARTS
28
18
13
11
31
10
6
20
9
14
29
16
4
19
22
5
8
7
2
3
26
21
17
15
27
24
30
12
25
1
23
32
19
SPARE PARTS
MINI BIGFOOT TRENCHER - PARTS LIST
REF NO.DESCRIPTIONQTYORDER CODE
1 BOLT HEX 1/2 X 1 G8 UNC ZINC PLATED 2
2 BOLT HEX 1/2 X 2.1/2 G8 UNC ZINC PLATED 3
3 BOLT HEX 1/2 X 2 G8 UNC ZINC PLATED 5
4 BOLT HEX 1/2 X 3.1/2 G8 UNC ZINC PLATED 1
5 BOLT HEX 3/8 X 3/4 G8 UNC ZINC PLATED 2
6 BOLT HEX 5/8 X 2 G8 UNC ZINC PLATED 5
7 NUT NYLOC 1/2" ZINC PLATED 9
8 NUT NYLOC 5/8 UNC GR5 ZP 8
9 SCREW SOCKET HEAD CAP 5/8 X 1 3/4" UNC ZINC PLATED4
10 BOLT HEX 5/8 X 2.1/4 G8 UNC ZINC PLATED 1
11 SCREW SOCKET SET 3/8 IN X 3/8 IN UNC 2
12 GEARBOX ASSEMBLY - BIGFOOT OED TRENCHER - 21 GF1
13 SPRING PIN 1/4" X 1.1/2" 1
14 SEAL PROTECTOR - BIGFOOT TRENCHER 1
15 NOSE ROLLER PIN WASHER - TRENCHER COMMON PARTS 2
16 KEY STEEL 1/2" SQ X 60 LG 1
17 NOSE ROLLER SQUARE PIN - TRENCHER COMMON PARTS 1
18 DRIVE SPROCKET COLLAR - TRENCHER COMMON PARTS 1
19 DRIVE SPROCKET 1.5/8" PITCH 12 TOOTH - TRENCHER COMMON PARTS 1
20 BOOM ADJUSTER ROD 1" UNC 1
FA-000026
FA-000027
FA-000029
FA-000030
FA-000052
FA-000073
FA-000090
FA-000095
FA-000123
FA-000186
FA-000400
GB-002297
SP-000007
TR-000025
TR-000026
TR-000027
TR-000029
TR-000031
TR-000035
TR-000062
PM-000111-A Trencher: Service and Repair Manual - November 2014
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SPARE PARTS
MINI BIGFOOT TRENCHER - PARTS LIST (CONT)
REF NO.DESCRIPTIONQTYORDER CODE
21 INNER BOOM - BIGFOOT TRENCHER 1
22 SPANNER - BIGFOOT TRENCHER 1
23 NOSE ROLLER ASSEMBLY - 1 5/8" PITCH - TRENCHER COMMON PARTS 1
24 900 DANGER BAR - 65 SQ 1
25 MINI BIGFOOT - ANGLED FOOT WELDMENT 1
26 MINI BIGFOOT - OUTER BOOM ASSEMBLY - 765 LONG 1
27 MINI BIGFOOT - SIDE PLATE ASSEMBLY - 65SQ DANGER BAR 1
28 SPOIL AUGER - MINI BIGFOOT 1
29 WASHER COMMERCIAL 3/8 ZINC PLATED 2
30 WASHER SPRING 1/2 ZINC PLATED 10
31 WASHER SPRING 5/8 ZINC PLATED 12
32HEADSTART CRUMBER ASSEMBLY1
TR-000125
TR-000146
TR-000870
TR-001348
TR-001400
TR-001409
TR-001419
TR-001445
WA-000004
WA-000010
WA-000013
TR-001344
21
SPARE PARTS
BIGFOOT TRENCHER 900 DIG
33
1
38
29
PM-000111-A Trencher: Service and Repair Manual - November 2014