Torque-Hub® Planetary Final Drive CW130 Series Service Manual
Contents
1. 1A rests on it Ensure there is enough gap to lower the Housing 1G down pe m 10 Use a dead blow hammer on the Housing 1G flange to drive the inboard Bearing 1C 1D off of the Spindle 11 Lift the Spindle subassembly 1A out of the Housing 1G 12 Remove the Face seal 1B halves from the Housing 1G and from the Spindle 1A 13 Using a hammer and punch drive the inboard Bearing Cup 1C out of the Housing 1G Be careful not to damage the counter bore in the housing 14 Turn the Housing 1G over and drive the outboard Bearing Cup 1C out of the Housing Be careful not to damage the counter bore in the housing 15 Remove the Bearing Cone 1C from the Spindle 1A This concludes the Housing Spindle Disassembly 22 Planetary Final Drive Service Manual Input Brake Disassembly 1 Set the Spindle 1A on the bench with the flange side up 2 Install M6 1 0x16mm bolts 17M through the Thrust Plate 17K and into the Brake Piston 17A and tighten incrementally to compress the brake springs 17L 17D and take pressure off of the Retaining Ring 174 3 Remove the Retaining Ring 17J from counter bore of the Spindle 1A and remove Brake Piston 17A assembly with Springs 17D 17L and Thrust Plate 17K 4 Remove M6 bolts 17M from the Brake Piston 17A incrementally to release the tension of the springs slowly 5 Remove the Brake Thrust Plate 17K 6 Remove the Brake Springs 17L 17D2. squarely against the Housing 5 as shown Use sudden and even pressure to pop push the Toric Ring under the Retaining Lip 3 of Los UN T Je EEE ya y NOTE It is important for the O ring as well as the housing bore to be wet with Alcohol during this process Visually inspect the positioning of the O Ring and Seal Ring relative to each other as well as relative to the housing Always make sure that everything is seated symmetrically NOTE Misaligned seals and improperly seated O Rings can cause leakage or premature failure If small adjustments are necessary do not push directly on the Seal Ring 1 use the Installation tool 9 to push down or use the Adjustment Tool 11 to pull up NOTE Never use sharp instruments such as screwdrivers They can cause permanent damage to the O Ring and or Seal Ring which may lead to rapid failure For twists or obvious bulges in the O Ring or if the Seal Ring is riding up on the O Ring and cannot be adjusted always remove the seal half and repeat the procedure beginning with the cleaning process 14 After a successful installation always wait a few minutes for the Alcohol to completely evaporate before assembling The Alcohol is necessary as a lubricant during the installation process but for assembly the area must be clean and dry in order for the O Ring to properly crush into its final position After the two seal halves have been installed in their respective housin
3. 9 into input coupling Apply 10 in lbs torque While trying to rotate tool pump the handle on the hydraulic hand pump and increase the pressure until the brake releases The brake is released when you are able to rotate the tool ROLL CHECK TOOL Record the release pressure If the brake does not release within limits shown in the brake chart on page 6 check to see if it has the proper number of springs using the SPRING CHECKING PROCEDURE Increase to maximum pressure refer to brake chart on page 6 and hold at that pressure for one minute If the brake does not leak or lose pressure the unit has passed the brake test If the brake loses pressure attempt to repair the leak using the leak repair procedure at end of this procedure While brake is still released roll check the unit for one revolution of the output member by rotating the tool Bleed off pressure slowly while rotating the ROLL TEST Tool Record the pressure at which the brake locks up Using a clean rag wipe off excess fluid from around the brake port and install the pipe plug BRAKE 10 DIGIT IN FULL MODEL BRAKE NUMBER RELEASE RELEASE pe ase MAXIMUM BRAKE CODE PART OF PRESSURE PRESSURE pressure PRESSURE TORQUE INPUT NUMBER SPRINGS MIN psi MAX psi psi psi in Ibs BRAKE E 902442B 27 179 276 294 3000 15 460 Continued on Next Page SPRING CHECKING PROCEDURE Install bolts into holes in
4. from the Brake Piston 17A 7 Remove the Backup Ring 17E and the O ring 17F from grooves in the Spindle 1A 8 Remove the Backup Ring 17G and the O ring 17H from grooves in the Spindle 1A 9 Remove the Stators 17C and Rotors 17B from the spindle counter bore This concludes the Input Brake Disassembly 23 Planetary Final Drive Service Manual Output Carrier Disassembly 1 Remove Retaining Ring 3C 2 Lift off Planetary Gear bearing combination 3F from Carrier 3A post NOTE Planetary gears and bearings cannot be separated without damage If bearing or planetary gear need to be replaced both must be replaced for all instances 3 Repeat steps 1 and 2 for remaining Planetary Gear bearing combinations 4 Lift Retaining Plate 2 from Carrier 3A This concludes the Output Carrier Disassembly 24 Planetary Final Drive Service Manual Input Carrier Disassembly 1 Remove Retaining Ring 8C from Carrier 8A post 2 Remove Planetary Gear Bearing combination 8F from Carrier 8A NOTE Planetary gears and bearings cannot be separated without damage If bearing or planetary gear need to be replaced both must be replaced for all instances 3 Repeat steps 1 and 2 for remaining Planetary Gear bearing combinations 4 Remove Retaining Ring 8G from Sun Gear 8H and remove Sun Gear 8H from Carrier 8A 5 Remove Retaining Ring 8K from Sun Gear 8H and remove Bearing 8J assembly 6 Turn ov
5. is repairing this particular Torque Hub model Users of this manual should note that each part mentioned is followed by an identification number enclosed in parentheses These part numbers may be referred to in the Parts List and Assembly Drawing sections of this manual Specialized tools 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 three pages before starting any repairs Standard safety practices should be followed during the disassembly and assembly procedures described Safety glasses and safety shoes should be worn and heavy heat resistant gloves should be used when handling heated components 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 The Brake Test Continued on Next Page Planetary Final Drive Service Manual Brake Test To perform a brake check use a M12x1 5 metric fitting Install a hydraulic hand pump with pressure gauge into brake port in spindle 1A using metric thread fitting Place ROLL TEST Tool refer to table on page
6. torque The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle BOLT A equally snug 3 Crisscross around the bolt circle and tighten the remaining bolts 5 Using the same sequence crisscross around the bolt circle and apply an equal torque to the remaining bolts Planetary Final Drive Service Manual Lubrication Information General Properties The lubricant used in most Torque Hub drives should be petroleum based gear fluid containing anti oxidation anti foaming and extreme pressure additives The lubricant should have a minimum viscosity index of 95 cst and maintain a minimum viscosity of 40 cst under normal operating conditions Some applications require special considerations consult the machine manufacturer and Oerlikon Fairfield for more additional information The table below lists the recommended viscosities for various ambient operating temperatures These recommendations are based on temperature rise of 50 to 100 F at normal operating conditions Differential Planetary Simple Planetary Ambient AGMA AGMA Temperature ISO Index Lubricate ISO Index Lubricate p Number Number 40 to 5 F VG100 3EP VG100 3EP 5 to 40 F VG150 4EP VG100 3EP 40 to105 F VG220 VG320 5EP 6EP VG150 VG220 4EP 5EP 105 to 150 F VG460 7EP VG320 6EP Footnotes 1 For operation in this ambient temperature range synthetic oil is recommended with
7. a light coat of oil If necessary use Tool T219329 to press Bearing Cone 1C 1D onto Spindle 1A 10 Install Bearing Nut 1J onto Spindle 1A and tighten using locknut wrench T176285 Torque Bearing Nut 1J to 350 ft lbs in 100 ft lbs increments rotate Housing 1G in both directions and then torque Bearing Nut to 350 ft lbs Rotate Housing 1G in both directions again and torque bearing nut to 350 ft lbs Repeat this until Bearing Nut 1J does not move when 350 ft lbs of torque is applied This concludes the Housing Spindle Subassembly 32 Planetary Final Drive Service Manual Main Assembly O ES NOTE Spray component parts with a liberal amount of oil as they are being assembled 1 Place Hub Spindle Subassembly spindle flange end down 2 Install the Output Carrier Subassembly onto the spindle by aligning spindle splines with carrier splines The Carrier Lugs should engage the slots in the Bearing Nut 1J Ensure carrier lugs bearing nut slots and spindle splines are all engaged and fully seated NOTE It may take several attempts to install carrier correctly on nut slots and spindle splines Continued on Next Page 33
8. a pour point of 10 F lower than the minimum ambient temperature 2 For operation in this ambient temperature range synthetic oil is recommended for proper lubricant life at elevated temperatures Continued on Next Page Maintenance Oil Fill Level Oil amounts for each series of Torque Hub drives are indicated in the appropriate series literature An initial oil change should be made after the first 50 hours of operation Subsequent oil changes should be made at 1 000 hour intervals or annually whichever comes first Oil temperatures should be not higher than 160 to 180 F for continuous operation and no higher than 200 F for intermittent operation For special applications high horsepower high speeds or wide temperature changes please consult Oerlikon Fairfield When the Torque Hub unit is mounted horizontally unless otherwise specified the gearbox should be filled half full of oil Consult the appropriate series literature for approximate fill volumes Vertically mounted Torque Hub units may require special lubrication procedures Please contact Oerlikon Fairfield for vertically mounted applications This concludes the Check Procedure instructions 11 THIS PAGE INTENTIONALLY LEFT BLANK 12 Continued on Next Page Planetary Final Drive Service Manual Face Seal Installation The seal installation tool can be purchased from MORCOR LTD at Sales OMORCORLTD com part number MG11270 To begin the
9. cerlikon fairfield lt gt Wee i wA La b WA LIVES AS LK VIWA INIA AE LR LAA LL SUN A k E vi NH Torque Hub Planetary Final Drive CW130 Series Service Manual Rev 01 30 2014 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 General Information Planetary Final Drive Service Manual Content Introduction Brake Test Roll and Leak Test Tightening and Torquing Bolts Lubrication Information Face Seal Installation Main Disassembly Cover Disassembly Housing Spindle Disassembly Input Brake Disassembly Output Carrier Disassembly Input Carrier Disassembly Cover Subassembly Input Carrier Subassembly Output Carrier Subassembly Housing Spindle Subassembly Main Assembly Input Brake Subassembly Input Assembly Parts List Assembly Tools Contact Information Planetary Final Drive Service Manual Introduction This manual is a step by step guide to the disassembly and assembly of the CW130 Torque Hub units It is designed for the customer or mechanic who
10. dle Carefully remove the Retaining Ring from the Spindle Using two eyebolts threaded into opposite holes in the Brake Piston remove the Brake Piston from the Spindle Check O rings Backup Rings and brake cavity in Spindle for damage If no damage is found reinstall the Input Brake according to the Input Brake Installation Procedure in the assembly instructions chapter and perform pressure test again If brake still leaks contact the Oerlikon Fairfield service department NOTE Failure to perform this test may result in damaged or ineffective brake parts The Roll Test Continued on Next Page Planetary Final Drive Service Manual Roll and Leak Test Torque Hub units should always be roll and leak tested before disassembly if possible and after assembly to make sure gears bearings and seals are working properly The following information briefly outlines what to look for when performing these tests rotating consistently easily and properly Release the brake by applying 400 Psi to the brake port To perform a roll test use the recommended tool from the or something equivalent to apply constant rotational force to the input of the gearbox If more drag is felt in the gears only at certain points then the gears are nat 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 the unit seem to
11. e 7 Repeat steps for remaining Planetary Gear sets This concludes the Output Carrier Subassembly 29 THIS PAGE INTENTIONALLY LEFT BLANK 30 Planetary Final Drive Service Manual Housing Spindle Subassembly Spindle Sub Assembly Using alcohol and a clean rag wipe off bearing locations on the Housing 1G and the Spindle 1A Press one Bearing Cup 1C 1D into bearing counter bore of spindle end of housing until seated against shoulder in housing Use Tool T219274 Turn Housing 1G and press one Bearing Cup 1C 1D using Tool T219274 into bearing counter bore of cover end of Housing 1G making sure that it is fully seated against shoulder in the housing NOTE Generally seals should not be reused Using alcohol and a clean rag wipe off seal locations on the Housing 1G and the Spindle 1A Place Spindle 1A with flange side down onto press table and press Bearing Cone 1C 1D onto bearing surface of Spindle 1A Apply P 80 thix or alcohol to seal diameter of Spindle A Install Face Seal 1B on Spindle 1A and Housing 1G per Face Seal Installation Instructions Carefully place Housing 1G onto Spindle 1A so that two halves of Face Seal 1B contact each other Do not allow Face Seal 1B to contact bench or get damaged when flipping Housing 1G over 31 9 Place other Bearing Cone 1C 1D onto Spindle 1A until it is seated in Bearing Cup 1C 1D in Housing 1G and spray with
12. er Bearing 8J assembly and remove Retaining Ring 8M then separate Bearing 8J and Bearing Carrier 8L This concludes the Input Carrier Disassembly This concludes the Disassembly instructions 25 ASSEMBLY Planetary Final Drive Service Manual Cover Subassembly Continued on Next Page 1 2 3 Insert Bearing Carrier 14B into Bearing 14A and install Retaining Ring 14D Freeze Bearing 14A assembly Install the Bearing assembly into the Cover 14 and install Retaining Ring 14C Grease the O ring 14G install it into the groove in the Cover 14 and lay sight glass into the Cover 14 making contact with the O ring 14G Grease the O ring 14G install it into the groove in the Retaining Plate 14F and install Retaining Plate 14F over Sight Glass 14E on Cover 14 and secure with Bolts 14H with Loctite Install Sight Glass Cover 14J and secure with Bolts 14K This concludes the Cover Subassembly 27 9 10 Planetary Final Drive Service Manual Input Carrier Subassembly Place Bearing 8J into oven no warmer than 250 F Carefully remove Bearing 8J from oven and insert Bearing Carrier 8L into Bearing 8J and install Retaining Ring 8M Allow assembled components to cool to ambient temperature Install Bearing assembly into Sun Gear 8H and install Retaining Ring 8K Place Sun Gear 8H into Carrier 8A by aligning the carrier s
13. gs and just prior to assembly the faces should be thoroughly cleaned with Denatured Alcohol Next apply a thin film of oil EP90 the same oil that will be used to fill the assembly to the faces of the Seal Rings with a clean lint free cloth Warning Be careful not to get oil on the O Rings The seal set is now ready to be drawn together in the assembled unit Max Variation 0 04 in 1 00 mm Check the assembled height A in a least four places spaced 90 apart This concludes the Face Seal Installation instructions 15 DISASSEMBLY Planetary Final Drive Service Manual Main Disassembly COVER SUBASSEMBLY 1 Perform a roll check and a leak check prior to disassembling the unit 2 Remove the magnetic Pipe Plugs 1H and drain the oil out of the gearbox NOTE Record the condition and volume of the oil 3 Remove Bolts 13 from the Cover Subassembly 4 Lift the Cover Subassembly off of the unit 5 Remove and discard O ring 4 Continued on Next Page 17 T 10 Hub Spindle Subassembly OUTPUT CARRIER SUBASSEMBLY INPUT CARIER SUBASSEMBLY Remove the Input shaft 11 Lift out the Input Carrier Subassembly Lift the Ring Gear 5 off of the hub spindle subassembly Separate and discard o ring 4 Remove bolts 9 holding the Output Carrier Retaining plate to the hub spindle subassembly Lift the Output Carrier Subassembly from Hub Spindle Subassembly This concludes the Main D
14. isassembly Planetary Final Drive Service Manual Cover Disassembly KY 7 zi II IS 1 s ES 1 Remove Bolts 14K and Cover Cap 14J 2 Remove Bolts 14H and Plate Retainer 14F 3 Pull Sight Glass 14E from Cover 14 remove and discard O rings 14G 4 Turn Cover Subassembly over and remove Retaining Ring 14C 5 Press Bearing subassembly from Cover 14 6 Remove Retaining Ring 14D and slide Bearing 14A from Bearing Carrier 14B This concludes the Cover Disassembly 19 Planetary Final Drive Service Manual Input Disassembly Hub Spindle Subassembly 1 Set the unit on a bench so that the Spindle 1A flange is up 2 Remove retaining ring 23D and pull out input group 3 Remove O ring 23E from groove in spindle and discard 4 Remove Retaining Ring 23F and slide Bearing Carrier 1E and Lip Seal 23C from Input Coupling 20A 5 Separate Lip Seal 23C from Bearing Carrier 1E 6 Remove Retaining Ring 20B from Input Coupler 20A and press bearing 23B off being sure to only place pressure on the inner race This concludes the Input Group Disassembly 20 Planetary Final Drive Service Manual Housing Spindle Disassembly Spindle Sub Assembly 7 Continued on Next Page 21 8 Unscrew Bearing Nut 1J and remove from Spindle 9 Turn the unit over and carefully place the unit on a support base until the Spindle
15. plines with the sun gear splines and install Retaining Ring 8G With Bearing 8B in the packing sleeve locate and push the bearing 8B into the Planet Gear 8F bore Ensure the Roller Bearing Retaining Ring snaps into the Planet Gear retaining groove Heat Planetary Gear Bearing assembly by placing it in an oven no warmer than 250 F Repeat for remaining Planetary Gears sets Being careful to avoid burns remove the Planetary Gear Bearing assembly from the oven and install on the Carrier 8A planet post with bearing radius shoulder against the planet post Install Retaining Ring 8C onto the planet post retaining ring groove Repeat steps for remaining Planetary Gear sets This concludes the Input Carrier Subassembly 28 Planetary Final Drive Service Manual Output Carrier Subassembly Place Retaining Plate 2 into counter bore in Carrier 3A 2 With Bearing 3B in the packing sleeve locate and push the bearing 3B into the Planet Gear 3F bore Ensure the Roller Bearing Retaining Ring snaps into the Planet Gear retaining groove 3 Heat Planetary Gear Bearing assembly by placing it in an oven no warmer than 250 F 4 Repeat for remaining Planetary Gears sets 5 Carefully remove the Planetary Gear Bearing assembly from the oven and install on the Carrier 3A planet post with bearing radius shoulder against the planet post 6 Install Retaining Ring 3C onto the planet post retaining ring groov
16. procedure all of the sealing components Seal Rings metal rings O Rings and the housings must be clean and free of Oil Grease Dirt or Dust Always check to make sure that there are no nicks or burrs in the housing area that could damage the Load Ring during installation The use of DENATURED ALCOHOL also known as Wood Alcohol or Shellac Thinner and a lint free cloth is recommended for cleaning all of these areas NOTE Follow all Material Safety Data Sheet guidelines After all components have been wiped clean and have dried the O Rings should be placed back on the Seal Rings in their proper position The O Rings must be seated completely and tightly on the Seal Ring Always make sure that the O rings are not twisted or distorted by inspecting the mold flash seam on the outside Eliminate O Ring twist by gently pulling a section of the O Ring 2 rapidly away from the Warning Do not place the Seal Rings face down on any hard or abrasive surface to accomplish this Once the O Rings are back on the Seal Rings quickly swab out the housing with a clean lint free cloth generously soaked it with Denatured Alcohol This is to temporarily lubricate the bore Then with the same cloth quickly swab the outside O Ring area of the seal half to temporarily lubricate the O Ring 13 Continued on Next Page With all surfaces of the O Ring 2 wet with alcohol use the Installation Tool 9 to position the Seal Ring 1 and the O Ring 2
17. 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 ROLL CHECK TOOL Roll Test Tool T224101 The Leak Test Continued on Next Page The purpose of a leak test is to make sure the unit is airtight Safely lay the fully assembled unit horizontally and attach an airline to one of the port holes in the cover DO NOT EXCEED 10 PSI PRESSURE DURING THE LEAK TEST Higher pressure will create a false sealing effect in assemblies with lip seals The unit has a leak if the pressure gauge reading on your leak check fitting starts to fall after the gearbox has been pressurized and allowed to equalize Leaks will most likely occur at the pipe plugs the main seal or wherever o rings or gaskets 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 Final 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
18. the brake piston Tighten bolts in such a way to ensure the brake piston remains straight while being compressed into the brake cavity of the spindle Carefully remove the retaining ring from the spindle Slowly remove bolts from the input brake Remove the cover plate from the end of the input brake and count the number of springs in brake If number of springs matches the number in the BRAKE CHART go to the next step If the number of springs does not match the number in the BRAKE CHART above install the correct number of springs CO Oo AM CHECK FOR THE CORRECT A NUMBER OF SPRINGS PA Es Install the Brake Cover Plate using bolts Tighten bolts in such a way that to ensure the Brake Cover Plate remains straight while being compressed into the brake cavity of the spindle Install the large retaining ring into the groove in spindle 1A making sure it is seated properly Remove all remaining bolts from the brake piston and discard NOTE USE CAUTION WHEN REMOVING BOLTS AS THEY ARE SUBJECT TO SPRING PRESSURE MAKE SURE THE RETAINING RING IS SECURED BEFORE REMOVING BOLTS Re test the input brake If release and or lockup pressures still do not match the brake chart contact the Oerlikon Fairfield service department BRAKE LEAK REPAIR PROCEDURE Install bolts into holes in the Brake Piston Tighten bolts in such a way to ensure the Brake Cover Plate remains straight while being compressed into brake cavity of Spin
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