Torque-Hub Electric Drive E01HA010A2300
Contents
1. Kit Number Qty Description G3 1 INPUT RING AME035HR01 Input Ring Kit G20 1 COVER O RING G27 1 MAIN BEARING RETAINING RING G14 1 MAIN BEARING G14 1 MAIN BEARING G32 3 TANGED THRUST WASHERS G25 3 PLANET THRUST WASHERS AME035C201 G15 1 SHAFT BEARING Gearbox Output Planet Kit SHAFT BEARING RETAINING G28 1 RING G9 3 OUTPUT PLANET GEAR G20 1 COVER O RING G26 3 PLANET BUSHING G27 1 MAIN BEARING RETAINING RING G10 3 OUTPUT PLANET PIN 038908 11 1 BRAKE DISC Brake Disc 41 1 BRAKE KIT AME035BM02 Brake Kit 12 1 BRAKE COVER GASKET 12 1 BRAKE COVER FILLER STRIP AMEO35MH03 M7 2 MOTOR MOUNTING BOLTS A23 Motor Hardware Kit M8 2 WASHERS AMEO35MH04 M7 2 MOTOR MOUNTING BOLTS A24 Motor Hardware Kit M8 2 WASHERS Continued on Next Page 30 Kit Number Qty Description BRUSH AND TERMINAL SERVICE Me KIT AME035MB04 Brush and Bearing Kit MOTOR BESRING AAS 7 1 BEARING RETAINING RING 13 1 ELECTRIC MOTOR AME035MA08 A23 Motor Kit 17 1 MOTOR LIP SEAL 13 1 ELECTRIC MOTOR AME035MA09 A24 Motor Kit 17 1 MOTOR LIP SEAL AMEOSSMEOI 13 12 1 COVER KIT A23 A24 Motor Cover Kit 31 Motor Maintenance Procedure Appendix A Section 1 Glossary of Parts Section 2 Trouble Shooting Section 3 Disassembly Section 4 Inspection and Service Section 5 Reassembly Section 6 Servicing Guidelines 32 Motor Maintenance Procedure Section 1 Glossa2. 1 3003 9NI14M9 143913 SUJO TIV weise am 3A 934 35 OIAAWIS 38 01 Yyi30 35001 TW 1001 ONISSIYA ATOMNISSV JON WNVIONI 311 INANI ONIH3 39403 AB ON 311 BO 3215 10015 uwm im onix SI ee ee 100 Y 90 10 90 SUTINWMO VW 031412385 0 SSIINN 05 57 2 Y OL N 115 Oriy 3NO 41 Mailing Address Shipping Address Fax E mail Website Planetary Electric Drive Repair Instructions With more than 90 years of experience Fairfield Manufacturing Co Inc has become the largest U S non captive producer of gears custom gear assemblies planetary final drives and related gear products Fairfield Manufacturing Co Inc headquartered in Lafayette Indiana USA is distinguished by our extensive design manufacturing and applications engineering capabilities Our 500 000 square foot plant is a modern fully equipped manufacturing facility that includes a full service heat treat department Our philosophy of synchronous engineering is a partnership that matches our best and brightest people with your people to evaluate your unique requirements and develop products and assemblies that meet your needs For more information contact Fairfield Manufacturing Co Inc today Fairfield Manufacturing Co Inc U S 52 South P O Box 7940 Lafayette IN 4
3. Before pressing the Output Planet Shaft G10 into the Spindle G1 make sure the Output Planet gear G9 spins freely Press the Output Planet Shaft G10 into the Spindle G1 until it bottoms out Make sure the Output Planet Gear GQ turns freely after the Planet Shaft is pressed in Repeat Steps 5 11 for the other two Output Planet Gears G9 Turn the Spindle G1 over so that the carrier end is down Using a flat plate or rod press the Motor Shaft Seal G17 into the center bore so that it is flush with the face of the Spindle G1 This concludes the Spindle Subassembly 22 Planetary Electric Drive Service Manual Hub Subassembly 1 Put Hub G2 table with the tapped holes facing down 2 Using a flat plate in conjunction with a pressing tool press in the Seal G16 so it is 060 inch inside the edge of the hub NOTE The Seal has a thin outer shell that can be easily damaged if not installed with care It is a good idea to start the Seal into the bore with a rubber mallet before pressing 3 Flip the Hub G2 over 4 Using the appropriate pressing tool T 174356 press the Main Bearing G14 into the bore until it bottoms out This concludes the Hub Subassembly 23 Planetary Electric Drive Service Manual Input Carrier Subassembly Use the Input Planet Shaft G6 as a pressing tool to install the Planet Bushing G26 into the bore of each Planet Gear G5 The shaft will help guide the b
4. NOTE Do not overstress these Retaining Rings when removing them Remove Thrust Plate G23 Remove Thrust Washer G25 from each Planet Shaft G6 Slide each Input Planet Gear G5 off the Planet Shaft G6 Press out Bushing G26 from the bore of each Planet Gear G5 Bushings cannot be reused when removed Remove the other Thrust Washer G25 from each Planet Shaft G6 Remove Retaining Ring G24 from Output Sun Gear G8 Slide Output Sun Gear G8 out from the center of the Input Carrier G7 Remove the three Planet Shafts G6 from the Input Carrier NOTE The Planet Shafts G6 are held in with a press fit To avoid damage to the parts use an arbor or hydraulic press to remove the Planet Shafts G6 This concludes the Input Carrier Disassembly 15 Planetary Electric Drive Service Manual Hub Disassembly 1 Remove Main Wheel Bearing G14 NOTE This part is held in the hub with a press fit To remove have the hub setting seal side up Use a plate or rod with a large enough diameter push in the inner race of the bearing Apply force to the push the bearing out This bearing will need to be replaced upon reassembly 2 Remove main Lip Seal G16 NOTE This Lip Seal G16 is also held in with a press fit Remove the Lip Seal only if the hub or seal needs to be replaced The Lip Seal will most likely become damaged during removal Try not to damage the hub bore This concludes the Hub Disassembly 16
5. Planetary Electric Drive Service Manual Spindle Disassembly Place Spindle Sub Assembly on bench with Planet Gears GQ facing up NOTE Do not damage or scratch the seal surface of the spindle G1 during disassembly Remove three Output Planet Shafts G10 NOTE These Planet Shafts are held in with a press fit Use the tapped hole in the end of the pin in conjunction with a slide hammer or similar tool to remove them Remove the Output Planet Gear G9 Thrust Washer G25 and Tanged Washer G32 out each of gear window of the Spindle G1 NOTE The Output Planet Gears G9 are a very similar in size to the Input Planet Gears G5 tag or label the Planet Gears to avoid confusion Press out Bushing G26 from the bore of each Planet Gear G9 Bushings cannot be reused when removed Remove the Main Bearing G14 from the outside diameter of the Spindle G1 Continued on Next Page 17 NOTE This bearing is held in with a press fit You will need to pry against the spindle G1 to remove it A new bearing should be used when the unit is reassembled CAUTION Safety glasses must be worn during these next steps 6 Remove the Bearing Retaining Ring G28 from the bore of the Spindle G1 7 Remove the shaft Ball Bearing G15 from the center bore 8 Press out the Motor Shaft Seal G17 from the center bore The Seal cannot be reused when removed This concludes the Spindle Disassembly 18 THIS PAGE INT
6. Retaining Ring G19 out of the groove the Housing Subassembly then grasp the loose end of the Retaining Ring G19 and pull the rest of the way out 2 Remove Cover G11 Thrust Washer G21 should remain in the inner counter bore of the Cover G11 when removed NOTE To remove the cover the motor must be removed Slide a rod through the motor shaft hole and gently tap with a rubber hammer to force the cover out 3 Remove Input Sun Gear G4 4 Remove Input Carrier Subassembly 5 Remove O ring G20 from Housing Sub Assembly Discard O ring G20 6 Remove Input Ring Gear G3 Continued on Next Page 13 NOTE The Input Ring Gear G3 is held in with a press fit on its outside diameter Insert jacking screws 1 4 20UNC grade 8 with at least 1 5 inches of thread length into each of the three tapped holes to force the ring gear out Be sure and alternate between the jacking screws to keep the ring gear from becoming misaligned in the bore The screws will push against the outer race of the main bearing This bearing will have to be replaced afterwards 7 Using a screwdriver remove Spiral Retaining Ring G27 8 Pull Hub Subassembly off of the Spindle Sub assembly This concludes the Gear Box Main Disassembly 14 Planetary Electric Drive Service Manual Input Carrier Disassembly CAUTION Safety glasses must be worn during these next steps Remove Retaining Rings G18 from each of the three Planet Shafts G6
7. Shooting 34 Motor Maintenance Procedure Section 3 Disassembly BRAKE CONNECTOR FIELD CONNECTION BRAKE COVER SCREWS BRAKE COVER Remove the 2 brake cover screws and set aside These screws will be needed to release the brake Remove the brake cover Remove the gasket 11 and the filler strip that is in the groove of the commutator end head 9 Install the 2 cover mounting screws into the threaded holes in the brake assembly and tighten to manually release the brake Refer image in the Manual Disengage Procedure on page 8 Remove the 3 screws holding the brake assembly 10 to the motor Carefully remove the brake assembly brake disc and reaction disc from the motor by sliding off of the shaft Remove the screws holding the commutator end head 9 in place and remove the commutator end head from the frame and field assembly 1 The armature 3 will be attached to the commutator end head Pull back the brush springs in the commutator end head 9 pull the brush back and rest the springs on the side of the brush The brushes should move freely within the holders Use an arbor press to remove the armature 3 from the commutator end head assembly 9 Remove the snap ring 7 and bearing 8 from the commutator end head Discard the bearing This concludes the Disassembly 35 Motor Maintenance Procedure Section 4 Inspection and Service Carefully blow out any accumulated carbon dust and dirt fr
8. enclosed in parentheses These part numbers may be referred to in the Parts List section of this manual and on the illustrated parts breakdown of this unit Any specialized tools normally used to assemble this unit are noted in the assembly procedures and diagrammed in the assembly tools section Users should familiarize themselves with the procedures for roll and leak testing as well as bolt tightening and torquing found on the following two pages before any servicing of the assembly Standard safety practices should be followed during the procedures described Safety glasses and safety shoes should be worn Be especially alert when you see the word CAUTION This indicates that a particular operation could cause personal injury if not performed properly or if certain safety procedures are not followed The word NOTE is used to bring attention to certain procedures or helpful hints that will aid in the disassembly and assembly process DISCLAIMER This manual will cover how to completely assemble and disassemble this EO1H Electric drive Torque Hub unit However if the unit is under warranty you should contact your Fairfield customer service representative for a replacement unit The warranty will no longer be valid if the unit is disassembled by non Fairfield personnel The Roll Test The Leak Test Planetary Electric Drive Service Manual Roll and Leak Test Torgue Hub units should always be roll and leak tested before disassemb
9. of servicing fill the unit with ISO grade 68 oil or oil of a similar viscosity 80W gear oil or 20W engine oil The gearbox will need to be filled with 10 oz of oil 10 oz of gearbox oil will fill the gearbox cavity approximately half full To check the oil level rotate the wheel so that the cover plugs are at 12 o clock and 3 o clock Allow the oil to settle Slowly loosen the 3 o clock plug If oil begins to come out then the oil level is sufficient If no oil is noticed at the 3 o clock plug location then remove both plugs Slowly add oil at the 12 o clock plug location until oil begins to seep out of the 3 clock plug location Reinstall and tighten plugs to 40 in Ibs Planetary Electric Drive Service Manual Manual Disengage Procedure MANUAL RELEASE HOLES NOTE In the event of a power loss to the Torque Hub the parking brake will engage as a safety precaution Should the unit need to be towed or pushed to an area where it can be serviced or recharged the operator will need to manually disengage the parking brakes The following procedure outlines how this is to be done CAUTION If the machine is on any incline the wheels must be adequately blocked prior to manually disengaging the brakes Failure to do so may result in injury or even death 1 Make sure the E stop plunger is pushed in and the key is removed from the ignition Switch 2 Remove the 2 Back Cover Bolts B1 The Brake Cover Bolts are also the release bolts f
10. 7903 7940 2309 Concord Road Lafayette IN 47909 Main 765 772 4001 Applications Engineering 765 772 4011 Sales and Service 765 772 4010 Applications Engineering apps fairfieldmfg com Sales sales fairfieldmfg com www oerlikon com fairfield 42 THIS PAGE INTENTIONALLY LEFT BLANK 43 cerlikon fairfield Oerlikon Fairfield U S 52 South P O Box 7940 Lafayette IN 47903 USA 765 772 4000 www oerlikon com fairfield 44
11. ENTIONALLY LEFT BLANK 19 ASSEMBLY Planetary Electric Drive Service Manual Spindle Subassembly Place the Spindle G1 on the bench with the carrier portion facing up NOTE Do not damage or scratch the seal surface of the Spindle G1 during assembly Install Input Ball Bearing G15 into the Spindle bore G1 CAUTION Safety glasses must be worn during these next steps Using Retaining Ring Pliers install Retaining Ring G28 into the groove in the Spindle G1 bore Using the appropriate pressing tool T 182377 press on Main Bearing G14 until it is fully seated Use the Output Planet Pin G10 as a pressing tool to install the Planet Bushing G26 into the bore of each Planet Gear G9 The shaft will help guide the bushing into the bore as well as prevent damage from the press Place Tanged Thrust Washer G32 into each planet window of the Spindle G1 Make sure the tang sits in the cast groove on the inside of the window Continued on Next Page 21 10 11 12 13 14 Place a Thrust Washer G25 onto the Output Planet Gear G9 Line up the bores as best as you can Use grease to hold the Thrust Washer in place Slide the Output Planet Gear G9 into the window with the Tanged Thrust Washer G32 until the bores line up Insert Output Planet Shaft G10 into the Planet Shaft hole of the Spindle G1 and through the bores of the Thrust Washers G25 amp G32 and the Planet Gear G9
12. cerlikon fairfield Torque Hub Electric Drive E01HA010A2300 E01HA010A2400 Service Manual Rev 10 19 12 4 While every precaution has been taken in the preparation of this document Fairfield Manufacturing Co Inc assumes no liability with respect to the use of the documentation described herein or for any act or omission of Fairfield Manufacturing Co Inc concerning this documentation Torque Hub is a registered trademark of Fairfield Manufacturing Co Inc Features and specifications are subject to change without notice Disassembly Instructions Assembly Instructions Motor Maintenance Procedure General Information Planetary Electric Drive Service Manual Content Introduction Roll and Leak Test Tightening and Torquing Bolts Lubrication Information Manual Disengage Procedure Motor Disassembly Gearbox Main Disassembly Input Carrier Disassembly Hub Disassembly Spindle Disassembly Spindle Subassembly Hub Subassembly Input Carrier Subassembly Gearbox Main Assembly Motor Assembly Parts List Appendix A Assembly Tools Contact Information Planetary Electric Drive Service Manual Introduction This manual is a step by step guide to the disassembly and assembly of the E01H Electric drive Torque Hub units It is designed for the customer or shop mechanic who is repairing this particular Torque Hub model Users of this manual should note that each part mentioned is followed by an identification number
13. excessive pressing force because it will be reacted by the main wheel bearings Install the Input Carrier Subassembly into mesh The Output Sun Gear G8 portion of the Input Carrier Subassembly will mesh with the Output Planet Gears G9 and the Input Planet Gears G5 mounted on the Input Carrier Subassembly will mesh with the Input Ring Gear G3 Install the Input Sun Gear G4 into the area between the three Input Planet Gears G5 Apply a coating of grease to the Cover O ring G20 and install it into the o ring groove of the Hub Subassembly NOTE It may be helpful to stretch the O ring G20 out prior to assembly to avoid pinching or shearing when the Cover G11 is assembled Apply Loctite 380 or 480 glue to Cover Thrust Washer G21 and place it in the center counter bore of the Cover G11 so that the steel face of the washer is out of the bore NOTE Make sure that both the Cover Thrust Washer G21 and the Cover G11 have good clean surfaces for the Loctite to properly adhere Center the Cover G11 in the hub bore so that the JLG logo is up Push it into the bore Install the Cover Retaining Ring G19 into the groove of the Hub Sub assembly This concludes the Gear Box Main Assembly 27 Planetary Electric Drive Service Manual Motor Assembly 1 Insert motor 13 into back of the gearbox Try to keep the end of the motor shaft from causing damage to the lip seal in the gearbox NOTE The motor may need to be ro
14. ings G18 This concludes the Input Carrier Subassembly 25 Planetary Electric Drive Service Manual Gearbox Main Assembly SPINDLE SUB ASSEMBLY HOUSING SUB ASSEMBLY z 0 z 1 Inspect seal surface of Spindle Subassembly Remove any debris that may be present 2 Apply a coating of grease to the Lip Seal G16 in the Hub Subassembly 3 Place Spindle G1 Subassembly on table with carrier side up 4 Carefully install the Hub Subassembly seal side down onto the Spindle Subassembly This installation should be a slip fit and takes place in 3 stages NOTE The hub slides together until the gear teeth of the hub hit the gear teeth of the 3 output planets GQ NOTE Find the Output Planet Gear GQ that is tight and turn it until you feel it go into mesh with the hub gear teeth apply slight downward pressure to the hub and then find the next gear that is tight and do the same NOTE Once all the Output Planet Gears 09 are in mesh apply pressure to the hub it should push on the rest of the way Continued on Next Page 26 10 11 12 Install Retaining Ring G27 into the groove on the OD of the Spindle G1 carrier This is a Spiral Retaining Ring so it will not require pliers You will need to pull the Retaining Ring G27 apart and work it into the groove Using the appropriate pressing tool T 174356 press in the Input Ring Gear G3 into the bore of Hub Subassembly NOTE Do not use
15. ly if possible and after assembly to make sure the unit s gears bearings and seals are working properly The following information briefly outlines what to look for when performing these tests NOTE The brake must be released before performing the roll test This can be accomplished by supplying 24 Volts D C to the brake connector The brake can also be released by following the manual disengage procedures outlined on page 8 The purpose of the roll test is to determine if the unit s gears are rotating consistently easily and properly You should be able to rotate the wheel or hub of the gearbox by hand If you feel more drag is felt in the gears only at certain points then the gears are not rolling consistently and easily and should be examined for improper installation or defects Some gear packages roll with more difficulty than others Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency Rotate the gearbox both clockwise and counterclockwise the same number of turns as the ratio of the unit The gearbox ratio is the same number as the last three numbers on the ID tag The purpose of a leak test is to make sure the unit is airtight You can tell if your unit has a leak if the pressure gauge reading on your leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize Leaks will most likely occur at the pipe plugs the main seal or wherever o rings or ga
16. ng voltage between the commutator and the shaft Visually inspect the commutator for excessive wear and overheating Replace as necessary Visually inspect the brake surfaces for excessive wear Replace brake assembly 10 if necessary Visually inspect the brake connector and field connections for frayed insulation loose terminals or other damage Replace as necessary This concludes the Inspection and Service 36 Motor Maintenance Procedure Section 5 Reassembly PRESS FIXTURE m MUST PRESS AGAINST OUTER RACE BEARING END HEAD mELD STATIONARY E ASS EMELY ASSEMBLED END HEAD BEARING AND RETAINING AING PRESS AXTURE X wer PRESS AGAINST INNER RACE HELD STATEHART FIGURE 3 BEARING PRESSING GUIDELINES After inspection and servicing reassemble the wiring in the commutator end head 9 as originally found Ensure the wiring does not contact metal parts and that it allows the brushes to move unrestricted in the holders Motor terminals must be assembled as shown Figure 4 Torque bottom terminal nut to 110 140 in Ib 12 4 15 8 N m After the motor has been disassembled it is recommended that new bearings be installed because bearings may have been damaged during removal Although the bearings may appear and feel good the bearing races could be brinelled races or balls deformed and may exhibit noise and vibration problems or fail within a relatively short pe
17. om the end head and the frame and field assembly using clean oil free compressed air Replace brushes 6 that are worn below their usable length 600 in show signs of uneven wear or signs of overheating such as discolored brush shunts and brush springs Brushes should always be replaced in complete sets of four Use identical replacement parts do not substitute brush grades as the brushes are matched to the motor type and application to provide the best service Substituting brushes of the wrong grade can cause premature commutator failure excessive brush wear or unpredictable machine performance Make sure the brush box assembly 4 is tight on the commutator end head Replace brush box assemblies in the commutator end head if they are physically damaged or brush holders are loose on the brush plate Visually inspect the frame and field assembly 1 for overheating or other signs of damage Check all wiring to insure that the insulation is in good condition Verify that pole screws are torqued to 250 300 in lbs 28 2 33 9 N m Verify field resistance using a suitable onmmeter per the appropriate motor specification Verify that the field is electrically isolated from the frame using a dielectric tester Replace as necessary Visually inspect the armature 3 assembly for signs of overheating or physical damage Visually inspect the seal surface of the shaft for excessive wear Check for grounded circuits using a dielectric tester by applyi
18. or the brake The size of the back cover bolts is M5 x 0 8 x 20mm long 3 Remove the Brake Cover M1 4 Insert the Back Cover Bolts B1 into the two Manual Release holes in the brake housing Continued on Next Page 5 Tighten down bolts and the brake will disengage 6 Repeat this procedure for the other wheel drive CAUTION The disengage bolts must be removed from the brake housing after the machine is towed or pushed to its servicing location The brakes cannot be engaged with the disengage Screws in the brake housing This will cause the machine to roll when parked on an incline This concludes the Manual Disengage Procedure THIS PAGE INTENTIONALLY LEFT BLANK 10 DISASSEMBLY Planetary Electric Drive Service Manual Motor Disassembly 1 Make sure the E stop plunger is pushed and the key is removed from the ignition switch 2 Disconnect the cable from the power controller 3 Drain the oil out of the unit by removing Cover Plug G29 see page 13 note the condition of the oil 4 Remove the 2 Motor Mounting Bolts M7 and Washers M8 5 Gently remove the Motor 13 NOTE Reference Appendix A for maintenance procedures internal to the motor This concludes the Motor Disassembly 12 Planetary Electric Drive Service Manual Gear Box Main Disassembly SPINDLE SUB ASSEMBLY HOUSING SUB ASSEMBLY INPUT CARRIER SUBASSEMBLY 1 Using screwdriver the end of the
19. re Section 6 Servicing Guidelines Since the operating environment of industrial equipment varies widely the following are suggested for periodic maintenance inspection intervals 1 Normal Service Perform routine inspection outlined in Section 4 every 1 000 hours of drive time 2 Severe Service Perform routine inspection every 500 hours of drive time Severe service environments are listed below a Dusty or dirty locations like cement plants lumber and flour mills coal mining stone quarries etc b High temperature areas like steel mills foundries etc Environments with sudden temperature change such as in refrigeration plant etc This concludes the Servicing Guidelines 39 Planetary Electric Drive Repair Instructions Assembly Tools 1182377 ASSEMBLY PRESS TOOL 0107528200 XVN Y 90 11048 90 SYR4NVHD rn on sn ema EIC I E 003 103 00 xxx 031 912345 5 0 55374 SNOISNIMIO NO JJNVEIIOL 3003 ONILIND 193203 Su3N902 TY WWA SHIN 534535 Canvas 39 01 SUVIN BOO Vw 15 75 01 NAH 115 OPEP 9 8 V ble 55358 OL 1001 ATANISY 311 3A 4 7 5188 ON 1 BO MIS 32015 22242242422 AY y 40 T174356 ASSEMBLY PRESS TOOL 9557111 ON 001 Ais GD 140434 3175 00 101 xx 001 xxx OD 2123 Mim MiO 552379 SNOISNIMIC NO
20. riod of service Press a new bearing 8 into the commutator end head pressing on the outer race only See Figure 3 Replace the snap ring 7 in the snap ring groove Press the armature 3 commutator end into the commutator end head and bearing assembly carefully supporting the inner race of the bearing See Figure 3 Carefully release the brush springs 6 allowing the brushes to contact the commutator Make sure brush shunts do not interfere with spring movement Assemble the commutator end head to the frame and field assembly 1 and tighten the screws to 120 140 in Ibs 13 6 15 8 N m Make sure to align the field connection with the notch in the commutator end head Seal wires where they exit from commutator end head with the grommet 9 Align wires from brake assembly 10 into notch in the commutator end head Install brake disc in between brake assembly and reaction disc with hub facing towards brake assembly Install onto shaft of motor aligning wires with groove in commutator end head Secure brake assembly to commutator end head using 3 bolts Continued on Next Page 37 7 Install filler strip 11 behind the brake leads into groove of commutator end head Place gasket 11 onto the back of the commutator end head 8 Install Brake Assembly 10 9 Remove brake cover screws from brake assembly and affix cover 12 to motor using the 2 brake cover screws This concludes the Reassembly 38 Motor Maintenance Procedu
21. ry of Parts e m a N NOTE A well planned maintenance program will save many hours of future down time and expense on a piece of equipment We recommend periodic maintenance consisting of inspections of motors batteries and wiring circuitry CAUTION Eye protection should be worn during any maintenance operation This concludes the Glossary of Parts 33 Motor Maintenance Procedure Section 2 Trouble Shooting Turn off all power to unit and disconnect main battery power Disconnect motor connections from the controller Verify field continuity between the blue and red wires If available use a 4 wire ohmmeter to verify the field resistance per the applicable motor specification below Verify armature continuity between the red and black wires If available use a 4 wire ohmmeter to verify the armature resistance per the applicable motor specification below Using a dielectric tester verify that there are no shorts between the following items a Field connector pins and the case of the motor b Armature terminals and the case of the motor Field connector pins to the to the armature terminals Verify continuity in 2 pin brake connector Measure the brake resistance and verify that it is between 18 and 22 Ohms Drive Part Number Field Resistance O 75 F Armature Resistance 75 F E01HA010A2400XX 0 210 Ohms 0 037 Ohms E01HA010A2300XX 0 127 Ohms 0 051 Ohms This concludes the Trouble
22. skets are located The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o rings or gaskets meet on the exterior of the unit and then checking for air bubbles If a leak is detected in a seal o ring or gasket the part must be replaced and the unit rechecked Leak test at 10 psi for 20 minutes Planetary Electric Drive Service Manual Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts extreme care should be taken to ensure the bolts are not tightened beyond their specified torque The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle BOLT A Tighten but do not torque bolt A until snug Go to the opposite side of the bolt circle and tighten bolt B until equally snug Crisscross around the bolt circle and tighten the remaining bolts Use a torque wrench to apply the specified torque to bolt A Using the same sequence crisscross around the bolt circle and apply an equal torque to the remaining bolts Oil Type and Capacity Oil Filling Instructions Planetary Electric Drive Service Manual Lubrication Information This Torque Hub unit is shipped with ISO 68 viscosity oil hydraulic fluid It is designed to utilize the same oil throughout its service life However should it need to be serviced the oil will need to be drained and replaced In the event
23. tated to line up the sun gear splines with the motor shaft splines 2 Install the 2 Motor Mounting Bolts M7 and Washers M8 Tighten to 9 11 ft lbs 3 Connect the end of the cable to the power controller 4 Fill the gearbox with oil per the type amp capacity specified on Page 7 This concludes the Motor Assembly 28 Kit Planetary Electric Drive Service Manual Parts List Number AME035HC02 Cover Kit G11 AMEO35HS01 Main Seal Kit AME035C101 Input Carrier Kit 45 1 G20 AME035C102 Input Carrier Kit 31 1 G5 G26 G25 G18 G6 G23 G24 G8 G4 G7 G20 AMEO35HH01 Hub Kit G16 G20 G2 G14 G27 Continued on Next Page Qty 4 4 4 4 2 4 4 4 3 3 6 3 3 4 4 4 4 4 4 3 3 6 3 3 4 4 4 4 4 4 4 4 4 4 4 Description COVER COVER O RING COVER THRUST WASHER COVER SNAP RING O RING COVER PLUG MAIN LIP SEAL MAIN BEARING COVER O RING INPUT PLANET GEAR PLANET BUSHING PLANET THRUST WASHERS PLANET PIN RETAINING RINGS PLANET SHAFT THRUST PLATE OUTPUT SUN RETAINING RING OUTPUT SUN INPUT SUN CARRIER COVER O RING INPUT PLANET GEAR PLANET BUSHING PLANET THRUST WASHERS PLANET PIN RETAINING RINGS PLANET SHAFT THRUST PLATE OUTPUT SUN RETAINING RING OUTPUT SUN INPUT SUN CARRIER COVER O RING MAIN LIP SEAL COVER O RING HUB MAIN BEARING MAIN BEARING RETAINING RING 29
24. ushing into the bore as well as prevent damage from the press Press three Input Planet Shafts G6 into the three holes of the Input Carrier G7 The head of the Input Planet Shaft G6 needs to sit flush in the counter bore of the Input Carrier G7 hole Insert Output Sun Gear G8 into the splined bore of the Input Carrier G7 The gear tooth end of the Output Sun Gear G8 should protrude in the opposite direction of the Input Planet Shafts G6 CAUTION Safety glasses must be worn during these next steps Using retaining ring pliers install the Retaining Ring G24 into the groove of the Output Sun Gear G8 Make sure that the Retaining Ring G24 is correctly seated in the groove and that the Output Sun Gear G8 cannot be pulled out of the Input Carrier G7 Place a Thrust Washer G25 on each side of the Input Planet Gear G5 Line up the bores as well as you can visually Place the Input Planet Gear G5 and Thrust Washers G25 onto the Input Planet Shaft G6 sticking out from the Input Carrier G7 Continued on Next Page 24 7 Repeat 5 amp 6 for the other 2 Planet Gears G5 8 Put the Thrust Plate G23 onto the three Input Planet Shafts G6 Use the three holes on the outermost bolt circle The other three holes are for a different gear ratio 9 Using the appropriate retaining ring pliers put a Retaining Ring G18 into the groove of each Input Planet Shaft G6 NOTE Do not overstress the Retaining R
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