Torque-Hub Planetary Final Drive CW18 Series Service Manual
Contents
1. 5 eo RP C fe Description SPINDLE FACE SEAL BEARING CUP BEARING CONE BEARING NUT HOUSING STUDS PIPE PLUG THRUST SPACER PLANET GEAR CYLINDRICAL ROLLER BEARING EXTERNAL RETAINING RING INTERNAL RETAINING RING RING GEAR O RING COVER SUB ASSEMBLY COVER PLATE INPUT SHAFT CARRIER SUB ASSEMBLY CARRIER THRUST WASHER BEARING NEEDLE PLANET SHAFT GROOVE PIN PLANET GEAR COUPLING THRUST WASHER THRUST WASHER SUN GEAR DOWEL PIN PISTON BRAKE SUB ASSEMBLY PISTON BRAKE BRAKE THRUST PLATE STATOR ROTOR 52 Number Qty Description 18E 1 INTERNAL RETAINING RING 18F 1 O RING 18G 1 O RING 18H 1 BACKUP RING 181 1 BACKUP RING 18J 1 SPACER 18R SPRING 22 1 PLASTIC PLUG 21B 1 EXTERNAL RETAINING RING 22 1 RETAINING RING 24 1 ADAPTOR MOUNT 25 1 O RING 26 2 DRIVE SCREW 27 13 20 BOLT 30 1 THRUST WASHER NOTE For Spring 18R quantity refer to the Brake Chart under Brake Test on page 6 53 Planetary Final Drive Repair Instructions Assembly Tools 163056 ROLL CHECKING FIXTURE 990 r P FITTO DET 103 WELD 100 ALTER DET 103 BY CUTTING TO LENGTH 403 ONE MSTL CARB GRIND NI 01 ONE WELDMENT SJ 75 SQUARE BROACH FAIRFIELD TOOL NAME Part NO 2100102. TOOL 7176834 60 T176703 BEARING CONE PRESSING TOOL 500 15 THRU MILL FOUR SLOTS TWO HOLES 180 APART EQ SPACED LGC AS SHOWN LOC AS SHOWN TIMKEN CONE 4 259749 7 500 ONE CARS TME FORCE THE FUTURE LAFAYETTE INDIANA Usa ALL LOOSE DETAJLE TO BE STAMPED WITH THER RESPECTIVE ALL COMMEMS EXCEPT CUTTING EDGES TOLERANCE DIVENGIONS UMLTST OTHERWISE SPIC FIED xxx KIM 4004 UNLESS OTHERWISE SPECIF ED ALL CHAMPERS Os sas RADI Oe 61 T176285 ASSEMBLY LOCKNUT WRENCH 812 DRILL THRU HOLE AS SHONN 1 756 DRILL THRU 41 HOLES EQ SPACED LOCATE AS SHOWN 4750b5 C 7 1 1 1 NO CARB 1 1 i 21 125 45 x 101 ORE M STL CARB HOM 943 8 005 MILL a SLOTS EQ SPACED 7 occ An show amp 2s0201AP Tusu 9 B S SES D HOLES EQ SPACED _ LOCATE AS SHOWN LL THRU x 250 DEEP AS SHOWN Rl m ins FOUR 4140 STL HDH DRAW Ro 28 32 ALL LOOSE TO wt SAM ED 222 BERAE COUR C ETING hair An CARMPEIS Od RADE DRAAK 10 29 90 SIAMP FAST MO LIBOSA 1 178285 62 KNURL FAIRFIELD ru
3. Continued on Next Page 22 1 Remove the O Ring 5 from groove the Cover 6A 12 and discard O Ring NOTE Skip step below if the unit has Thrust Washers glued in place 2 Remove Thrust Washers 10 and 11 from pockets in the Cover 6A 12 This concludes the Cover Disassembly 23 Planetary Final Drive Service Manual Input Coupling Disassembly Qo Continued on Next Page 24 CAUTION Safety glasses must be worn during these next step 1 Remove Retaining Ring 22 18C from bore of Coupling 9 184 NOTE Skip step 2 for Assembly with Adaptor Mount 2 Remove Retaining Ring 18B from retaining ring groove of Coupling 9 18A This concludes the Input Coupling Disassembly 25 Planetary Final Drive Service Manual Input Brake Disassembly INPUT COUPLING SUBASSEMBLY HUB SPINDLE SUBASSEMBLY INPUT BRAKE LOBED BRAKE DISASSEMBLY INPUT COUPLING SUBASSEMBLY HUB SPINDLE SUBASSEMBLY INPUT BRAKE BOLTS SPLINED BRAKE DISASSEMBLY Continued on Next Page 26 10 11 12 13 Remove Input Coupling Subassembly from the unit Place Spindle 1A such that the flange side is up CAUTION Safety glasses must be worn during these next steps Install the Input Brake Bolts through the Thrust Plate 18B and into the Brake Piston 18A and tighten incrementally to compress the brake springs 18R and take pressure off of the Retaining Ring 18E Remove the Retain
4. two HI Wolk MATL 406 DRILL THRU 531 O14 CEDEE 625 DEEP MELLS W APARI a LOC AS SHOWN 13 2 TWO 104 1 am 103 2 Inm 37516 WING cur in ur ear vens ELD ron rece T201476 LEAK TEST ADAPTER PLATE ik uza WO TEST ADAPTER PLATE THRONE OM MEL TWAL p A 40 3 090 927 MAL FIED ALL E 06 xat 06 201476 59 176834 ASSEMBLY PRESSING TOOL ONE 4140 STL HDN TO ROCKWELL C 9 466 DIA REF 9 609 45 50 UNLESS OTHERWISE CHAMFERS 06 x45 SPECIFIED ALL RADII 06 R 1750 DIA DRILL THRU SIX HOLES EQ SPACED LOC AS SHOWN STOCK SIZE PATTERN NO FAIRFIELD tee FORCE BEHIND THE FUTURE ASSEMBLE TIMKE ALL LOOSE DETAILS NUMBERS BREAK ALL E INDIANA USA Y PRESSING TOOL CUP 1540070 BE STAMPED WITH THEIR RESPECTIVE CORNERS EXCEPT CUTTING EDGES TOLERANCE ON DIMENSIONS UNLESS OTHERWISE SPECIFIED 005 SCALE FULL DAA AN MH 01 18 71 STAMP PART L10854 XX 015 Xx 030 DO NOT SCALE ERRORS SHEETS 18 SHEET NO I
5. 1G over Continued on Next Page 44 13 14 15 16 17 18 19 20 Place other Bearing Cone 1 onto Spindle 1A until it is seated Bearing 1C in Housing 1G and spray with a light coat of oil If necessary use Tool T176703 to press Bearing Cone 1C onto Spindle 1A Install Bearing Nut 1E onto Spindle 1A and tighten using locknut wrench T176285 Torque Bearing Nut 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 1E does not move when 350 ft lbs of torque is applied LEAK CHECK THE FACE SEAL ASSEMBLY Install Cover subassembly using twenty Bolts 27 Turn unit over onto its side and plug brake port in Spindle with Pipe Plug 10 if unit does not have brakes Perform LEAK TEST as per instructions on page 9 Turn unit over onto Spindle 1A end and remove Cover subassembly Remove Bearing Nut 1E Apply Loctite 263 to first full threads of Spindle 1A and full threads of Bearing Nut 1E And Screw Bearing Nut 1E onto Spindle 1A down to top of Bearing Cone Be sure to rotate hub as the torque is applied to properly seat the bearing Torque the Bearing Nut 1E to 350 ft lbs Rotate the Housing 1G and recheck the Bearing Nut 1E torque to insure that the 350 ft lbs is maintained S
6. BOLT A BOLT B 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 11 General Properties Planetary Final Drive Service Manual Lubrication Information 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 AGMA AGMA Ambient ISO Index Lubricant ISO Index Lubricant Temperature Number Number 40 to 5 p VG100 3EP VG100 3EP 550 40 F VG150 4EP VG100 3EP 40 to105 F VG220 VG320 5 VG150 VG220 4EP 5EP costa Brr VG460 7EP V
7. Starting with a Stator 18C alternately stack and install Stators 18C into Lobes or Splines of Hub Spindle and Rotors internal splines 18D onto splines of Input Coupling Sub Assembly 9 Stack until there are a total of 7 Stators 18C and 6 Rotors 18D installed NOTE There should always be a stator on the top and bottom of the stack Grease and install O Ring 18G into Spindle O Ring groove Gradually feed Back up Ring 181 underneath O Ring 18G Using a small pick push one end of the Back up Ring 181 to completely seat it in the groove This ensures that the piston will not cut the Back up Ring 181 during assembly Install large Backup Ring 18H in groove on Piston 18A Grease and install large O Ring 18F in the large diameter groove towards the small Diameter end of Piston 18A on top of the large Backup Ring 18H Press Piston 18A into Spindle 1A until the small end contacts the Stator 18C Insert appropriate number of springs 18R into piston 18A Refer Brake Chart in page 6 Place Pressure Plate 18B on top of springs 18R CAUTION Safety glasses must be worn during this next step Install Input brake bolts through the Pressure Plate 18B into Piston 18A After springs 18R have been compressed enough install Retaining Ring 18E into Spindle 1A groove Remove the Input brake bolts NOTE Remove Input brake bolts from units when done otherwise brake will not function The Unit shou
8. 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 8 into input coupling Apply 25 in Ibs torque W
9. AM902446B 16 147 184 210 3000 4481 L AM902446C 19 174 217 250 3000 5288 M AM902446G 13 120 151 171 3000 3662 A 902315A 6 92 123 130 3000 2940 B 902315B 9 138 184 190 3000 4410 902315 11 168 225 230 3000 5390 G 902315C 7 107 143 150 3000 3430 Continued on Next Page SPRING CHECKING PROCEDURE Install input brake bolts into holes in 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 CHECK FOR THE CORRECT NUMBER OF SPRINGS AS PER BRAKE CHART Install the Brake Cover Plate using input brake bolts Tighten screws 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 screws from the brake piston and discard NOTE USE CAUTION WHEN REMOVING SCREWS AS THEY ARE SUBJECT TO SPRING PRESSURE MAKE SURE THE RETAINING RING IS SECURED BE
10. AS SHOWN 4 Using a chisel split open the bearing nut through the larger drilled bore as shown below USING CHISEL SPLIT OPEN THE BEARING NUT THROUGH THE LARGER DRILLED HOLE Continued on Next Page 30 10 11 12 13 14 15 Remove Bearing Nut 1E out of Hub Spindle Subassembly Discard Bearing Nut 1E A new locknut must be used for reassembly Turn the unit over and carefully place the unit on a support base until the Spindle 1A rests on it Ensure there is enough gap to lower the Housing 1G down USING DEAD BLOW HAMMER ON THE HOUSING DRIVE THE BEARING CONE OFF THE SPINDLE SUPPORT SPINDLE USING SUPPORT BASE Use a dead blow hammer on the Housing 1G flange to drive the inboard Bearing Cone 1F off of the Spindle Lift the Spindle 1A out of the Housing 1G Remove the Face Seal 1B halves or Outer of Lip Seal 1B from the Housing 1G Remove the Bearing Cone 1D 1F from the Spindle 1A Remove the Bearing Cone 1C from the Spindle 1A Using a hammer and punch drive the inboard Bearing Cup 1C 1E out of the Housing 1G Be careful not to damage the counter bore in the housing Turn the Housing 1G over and drive the outboard Bearing Cup 1E out of the Housing Be careful not to damage the counter bore in the housing Remove the other Face Seal 1B half or the remaining inner sleeve of Lip Seal 1B from the Spindle 1A This concludes the Housing Sp
11. hammer CAUTION Safety glasses must be worn during these next steps Install Retaining Ring on each planet post of Spindle 1 Install the O ring 5 from between the Housing 1G and the Ring Gear 4 6 Place Ring Gear 4 6 into Housing Spindle Subassembly with spline end of Ring Gear 4 6 towards Cover 6 ends of Housing 1G Install Input Carrier Subassembly into Ring Gear 4 6 with Intermediate Sun Gear 12 facing down If applicable install Sun Gear 7 into input carrier planet gear mesh Align pipe plugs 1U to proper location per print and install Cover Subassembly 6A onto Housing 1G Apply Loctite 243 to bolts 27 and install them into Housing 1G through Ring gear 4 6 and Cover Subassembly 6A Continued on Next Page 47 INPUT COUPLING SUBASSEMBLY HUB SPINDLE SUBASSEMBLY BOLTS LOBED BRAKE DISASSEMBLY INPUT COUPLING SUBASSEMBLY HUB SPINDLE SUBASSEMBLY INPUT BRAKE BOLTS SPLINED BRAKE DISASSEMBLY Continued on Next Page 48 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 NOTE Use an air gun to clean up the brake and make sure there are no chips inside Place unit on bench such that Spindle 1A flange side is up Insert Coupling Sub Assembly into Spindle 1A bore and onto Input Shaft 7 Install Spacer 18J into brake bore of the Hub Spindle Assembly applicable only for Splined Brake assembly
12. 034 T 219294 T181663 BRAKE ASSEMBLY CONCENTRICITY FIXTURE Ne 005 AT 24562775 Wt din EU 5 65 T184035 BRAKE ASSEMBLY CONCENTRICITY FIXTURE 66 T188489 BRAKE ASSEMBLY CONCENTRICITY FIXTURE fil 20 x 63 4 PACED 2290 DIA Sy 18 7503 1A 1 n il U d SS a SSS D7 l m 10 3 PENE 525 67 205279 LEAK TEST ADAPTER PLATE 68 179926 ASSEMBLY PRESSING TOOL 65 NOH LS OF I IRO N NS AW SSS PEAT SA OL us ris 3wo 2 0 02 Y NO NAYOHS Er 432945 03 5 lel 1140 WO EPE 69 Mailing Address Shipping Address Fax E mail Website Planetary Final 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 i
13. 2 STOCK SIZE OR PART NUMBER LAFAYETTE INDIANA ROLL CHECKING FIXTURE GEARED FOR EXCELLENCE USA LOOSE DETAMS BE STAMPED WITH THEIR RESPECTIVE NUMBERS BREAK ALL CORNERS EXCEFT CUTTING EDGES TOLERANCE ON DIME XXX IN 5005 XX 015 X 00 SIONS UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED ALL CHAMPERS 06 X 45 RADII 06 R SCALE DO NOT SCALE DRAWING REPORT ERRORS DRAWN 4 9 05 SIZE SHEETS SHEET NO STAMP PART NO ME STAMP TOOL NO T 163056 54 T180149 LEAK TEST ADAPTER 38 18 PIPE UNLESS CTMEMWISE SPECIFIED ML CHAMPERS O6 245 RADI 1 FL Matin 500 9 n 3 Lo 53 DIA DRILL THRU B B 2S 014 CBORE 425 DEEP 22 HOLES 8 180 LOC AS SE CAN 707 15 THD DIA REF V Two METL e rar nou scarto ros LAFAYETTE WA 9 T LEAK TEST ADAPTER ALL LOOSE TO MC STAPT wT TER FR Ly pe rra Ses tH HG Lem E FULL oo wor se uum mer pep aos fe ES E 100021 36 T 180149 55 T184729 LEAK TEST ADAPTER rr WFID TN PLA
14. CE 375 18 NPT PIPE 406 DIA DRILL 887 DIA CRORE X 625 DEEP TWO HOLES 1807 APART LOC AS SHOWN UNLESS OTHERWISE SPECIFIED ALL CHANFERS 06 RADI DS R pow WC REWORK 575 16 THD 4 2 Jub X THD DIA REF TWO MSTL 2 sa mma 105 2 sre __ mrs rms ven ee array x FAIRFIELD sur rore oco me rurume LAFAYETTE INDIANA USA ASSEMBLY LEAK TEST LOOSE TO K STAMPED AITH DOENE TOLERATE CPV LAE 005 019 x 56 T182969 ROLL CHECK TOOL EXTERNAL INVOLUTE SPLINE DATA APPROVED BY LANTI 08220292 FLAT ROOT SIDE FIT TOLERANCE CLASS SPECIAL ACT CIRC TOGTH TAS MAX ACT CIRC TOOTH THS 153582 TOOLS T8913 BARBER COLMAN DRIVING DOG 1151114 BARGER COLMAN DRIVING HEAD T 77 BARRER COLMAN HEADSTOCK CENTER 1125984 HOB PB OTA PRILL THRU 14 HOLES EQ SPACED Loc TURN FOR DIA SFIT 10 101 BARGER COLMAN DET DIA UNLESS OTHERWISE SPECIFIED ALL CHAMFFRS 06 46 RADII 05 MAX CWO pr op REWORK CLNO MATL 250 20 525 DEEP 4 HOLES SPACED FAIR ELD mHE FORCE 7HE FUTURE LAFAYETTE INDIANA usa ALL LOOSE DETAILS SE STAMPE
15. D WITH RESPECTIVE NUMBERS BREAK ALL CORMERS EXCEPT CUTTING EDGES TOLERANCE G DIMERRIONS UNLESS OTHERWISE SPECIFIED XXX 005 018 57 198122 BRAKE ASSEMBLY CONCENTRICITY EXTERNAL INVOLUTE SPLINE DATA PER 3 392 1 1970 APPROVED EY HAYWAR2 _ 06 27 97 FLAT ROOT SDE 57 TOLERANGE GLASS NORMAL DIAMEIRAL PIIC H DIAMETER BASE CIRCLE DIAMETER PIN DIAMETER MN MEAS OVE PINS MEAS OVER PINS REFI TOOT IKS EFF C RC TOOTH TKS MN ACT CRS TOOTH IKS MAX ACT TOOTH TKS REF USE HO 7 72 76 172176 2 500 HOB 12002400 307 T 89132 DRIVING DOG 1 151115 DRIVING HEAD 17 61227 HEADSTOCK CENTER 250 20 THRU ___ 4 HOLES EG SPACED f L TE AS SHOWN 2 375 B C BELL CENTERS BOTH ENDS 1 2498 1 7493 3 2005 0 9 281 THRU HOLE 4 HOLES EQ SPACED TED AS SHOWN 2 375 21 33 1125 HEX HEAD ACROSS FLATS LAFAYETTE ANA usa BRAKE ASSEMBLY CONCEHTFICITY FXTJRE Aii VODIEQIIB SAM POD PRAE ELI C ETIMO ESET LS Adi 04 A8 RADE 20 ILA REPORT 188081 B REDESIGNED HEAD NRF 242792 I c SWETNG SIANP FAST STAMP w9TIuE2352Vv 1198122 58
16. FORE 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 input brake bolts into holes in the Brake Piston Tighten screws in such a way to ensure the Brake Cover Plate remains straight while being compressed into brake cavity of Spindle 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 Reference Sample Model CW18 X The X is the brake option Model Code Consult Oerlikon Fairfield for other brake options NOTE Failure to perform this test may result in damaged or ineffective brake parts The Roll Test 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 the unit s gears bearings and seals are working properly The following information briefly outlines what to look for when performing these tests The purpose of the roll t
17. G320 6EP Footnotes 1 For operation in this ambient temperature range synthetic oil is recommended with 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 12 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 13 Planetary Final Drive Service Manual Seal Installation The seal installation tool can be purchased from MORCOR LTD at Salesp MORCORLTD com part number MGT045 To begin the procedure
18. Place Spindle 1A with flange side down onto press table and apply thy 80 or alcohol to seal diameter of Spindle 1A Slide the inner sleeve out of the Seal assembly 1B Insert Inner Sleeve 1B into seal press tool T219294 Being careful not to scratch the Seal 1B surface Place the seal press tool with Seal 1B on to the Spindle 1A Press seal tool with inner Sleeve 1B on to spindle 1A When the Seal 1B flange makes contact with the Spindle 1A flange the Seal 1B is fully seated With clean rag wipe off the Seal 1B diameter Spray the O D of the outer Seal 1B with alcohol and wipe with a clean rag Make sure not to touch the O D of the Seal 1B after it is clean and dry Place outer Seal 1B into Housing 1G seal bore with spring side down Align and place seal installation tool over the Seal 1B Press the seal into the Housing 1G using the seal press tool T219294 When the seal press tool makes contact with the Housing 1G the Seal 1B is fully seated Carefully place Housing 1G onto Spindle 1A so that two halves of Lip Seal 1B contact each other Do not allow Face Seal 1B to contact bench or get damaged when flipping Housing 1G over Skip to Step 21 NOTE Skip below steps 12 through 19 if unit has two part lip seal 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
19. SURE 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 LEAK CHECK TOOL Model Code Leak Test Tool CW18A1 1xxAxxx T182969 CW18A1 1xxZxxx T188489 CW18D11xxAxxx T188489 CW18D12xx4xxx T181663 CW18D14xxBxxx T184035 CW18D18xx4xxx T198122 CW18D21xxAxxx T188489 CW18E11xxAxxx T188489 CW18E1 1xx4xxx T188489 CW18E12xx4xxx T181663 CW18E14xxBxxx T184035 CW18E17xx8xxx T163056 CW18E18xx4xxx T198122 CW18E54xxBxxx T184035 10 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 torque The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle
20. 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 diameter to see that is running true with the circumference Eliminate O Ring twist by gently pulling a section of the O Ring 2 rapidly away from the Seal Ring 1 and letting it snap back 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 Continued on Next Page 14 Continued on Next Page With all su
21. cerlikon fairfield Torque Hub Planetary Final Drive 18 Series Service Manual Rev 01 22 13 1 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 Seal Installation Instructions Main Disassembly Cover Disassembly Input Coupling Disassembly Input Brake Disassembly Housing Spindle Disassembly Output Planet Gear Disassembly Input Carrier Disassembly Cover Subassembly Input Carrier Subassembly Output Planet Gear Subassembly Input Coupling Subassembly Housing Spindle Subassembly Main Assembly Assembly Drawing 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 CW18 Torque Hub units with ratios of 51 1 or lower It is designed for the customer or mechanic who is repairing this particular Torque Hub model
22. d on Next Page 36 1 Install three Pipe Plugs 1U 14 into the Cover 6A 12 2 Grease the O ring 5 and place it in the groove in the Cover 6A 12 NOTE Skip step below if the unit has Thrust Washers glued in place di Place the Thrust Washers 10 and 11 into counter bore of Cover 6A 12 using grease to hold it in place This concludes the Cover Subassembly 37 Planetary Final Drive Service Manual Input Carrier Subassembly Apply a liberal coat of grease to the bore of the Planet Gear 8F This will enable the Needle Rollers 8C to be held in place during assembly Install Needle Rollers 8C into the bore of each of the three Planet Gears 8F NOTE The last roller installed must be installed end wise That is the end of the last roller must be placed in between the ends of the two rollers that form the space and then slide parallel to the other rollers into place Place the Carrier 8A into the tool fixture so that one of the roll pin holes is straight up Start Planet Shaft 8D with end opposite roll pin hole first through the planet shaft hole in Carrier 8A making sure that the roll pin hole in the planet shaft is straight up Using ample grease to hold them in position slide four Washers 8B onto the Planet Shaft 8D Place the Planet Gear 8F into position and push the Planet Shaft 8D through the planet gear without going all the way through carrier Continued on Next Page 38 7 Finis
23. e Force BEHIND THE FUTURE LAFAVETTE INDIANA USA TOOL AVE 0 0 ONE 4140 STL DRAW Re ASSEMBLY PRESSING TOOL FAG K130190 T2 ALL LOOSE DETAILS TO BE STAMPED WITH THEIR RESPECT NUMBERS OREAK ALL CORNEAS EXCEPT CUTTING EDGES TOLERANCE ON DIMENSIONS UNLESS OTHERWISE SPECIFIED XXX 005 xx 2015 x 209 T174699 ASSEMBLY PRESSING TOOL UNLESS OTHERWISE SPECIFIED ALL CHAMFERS 06 x45 RADI 06 R MAX L1044A1 1174699 63 inu Savec cxi Eon Jc 2012 251 57 0M ca vou saz coi cramer Tz 15254 dor 4030 x 457 MAX 655 625 115 085 15 4 LL T219294 SEAL PRESSING TOOL ILS YL Lae R O MAX BURRS Y Z 22 R10 427 Pa A 10 355 7 10 345 64 2 0 DIA DRILL THRU 6 EQ SPACED HOLES 6 00 DIA 1 bet MIE OF PANI FAIRFIELD ENGINEERED DRIVE SOLUTIONS LAFAYETTE INDIANA USA SEAL PRESSING TOOL AL1DOSE DETARS TO STAMPED WITH RESPECTIVE MUN ENS Gil COMMER EXCEPT EDGER TOLERANCE ON CIMPNTIONS UNLESS OTHERWISE XXx 35 3x 3 UNLESS OTHERWISF SPRCIRED CHAMPERS D X 45 RADI 05 F I SCALE DRAMM me SHEET NO RAS 6 10 10 1 I STAMP PART NO STAMP NO CWT12ES51JJ8
24. est is to determine if the unit s gears are rotating consistently easily and properly It should be able to rotate the gears in the unit applying constant force to the roll checker If 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 the 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 ROLL CHECK TOOL Model Code Roll Test Tool CW18Ax1xxx T184729 CW18Dx1xxx T184729 CW18Dx2xxx T180149 CW18Dx4xxx T180149 CW18Dx8xxx T180149 The Leak Test Continued on Next Page Model Code Roll Test Tool CW18Ex1xxx T184729 CW18Ex2xxx T180149 CW18Ex4xxx T180149 CW18Ex7xxx T201476 CW18Ex8xxx T205279 The purpose of a leak test is to make sure the unit is airtight To perform a leak test use the leak test fixture from the table on page 10 If the tool is not available the gearbox must be sealed to perform the test This can be accomplished by assembling the sealed input device onto the gearbox at the input end and replace one of the oil plugs with an air chuck DO NOT EXCEED 10 PSI PRES
25. for the O Ring to properly crush into its final position After the two seal halves have been installed in their respective housings 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 16 DISASSEMBLY Planetary Final Drive Service Manual Main Disassembly CW18E SERIES MODEL 18 4 CW18D SERIES MODEL Continued on Next Page 18 1 Perform a roll check and leak check prior to disassembling the unit 2 Remove the three magnetic Pipe Plugs 1U 14 and drain the oil out of the gearbox NOTE Record the condition and volume of the oil 3 Remove Bolts 27 13 from the Cover Subassembly 4 Lift the Cover Subassembly off of the unit 25 INPUT BRAKE SUBASSEMBLY HUB SPINDLE gt SUBASSEMBLY N A Z 2 INPUT CARRIER SUBASSEMBLY CWISE SERIES MODEL Continued on Next Page 19 30 25 INPUT BRAKE SUBASSEMBLY HUB SPINDLE SUBASSEMBLY 4 gt y INPUT CARRIER SUBASSEMBLY 18 amp CW18D SERIES MODEL 5 Remove the Input Shaft 7 if app
26. h pushing the Planet Shaft 8D into the Carrier 8A until roll pin holes of Planet Shaft and Carrier are aligned If necessary align roll pin holes using a 1 8 diameter punch NOTE The chamfer on the Roll Pin hole should be towards the roll pin hole in the Carrier 8 Drive the Roll Pin 8E into the roll pin hole in carrier and into the Planet Shaft 8D until the end of the roll pin is flush with the outside diameter of Carrier 8A 9 Repeat steps 4 to 8 for the remaining two Planet Gears 8 This concludes the Input Carrier Subassembly 39 Planetary Final Drive Service Manual Output Planet Gear Subassembly 1 Apply a liberal coat of grease to the bore of the Planet Gear 3A CAUTION Safety glasses must be worn during this next steps 2 Install the upper Retaining Ring 3D from groove of the Planet Gear 3A 3 Install the Roller Bearing assembly 3B carefully 4 Install Spacer Rings on to the either sides of the Roller Bearing Assembly 3B 5 Install the lower Retaining Ring 3D from groove of the Planet Gear 3A 6 Repeat steps 1 to 5 for the remaining three Planet Gears 4F This concludes the Output Carrier Subassembly 40 Planetary Final Drive Service Manual Input Coupling Subassembly a Continued Next Page 41 CAUTION Safety glasses must be worn during these next steps 1 Install the Retaining Ring 22 18C into Coupling 9 18A NOTE Skip steps 2 and 3 for A
27. hile 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 9 DIGIT IN FULL MODEL BRAKE NUMBER RELEASE RELEASE MAXIMUM BRAKE CODE NUMBER SPRINGS MAX PRESSURE INPUT psi BRAKE 1 AM902446A 11 100 138 145 3000 3754 2 AM902446B 16 144 182 210 3000 5411 3 AM902446C 19 170 214 250 3000 6386 4 AM902446G 13 118 149 171 3000 4422 J AM902446A 11 102 129 145 3000 3110 K
28. indle Disassembly 31 Planetary Final Drive Service Manual Output Planet Gear Disassembly 1 Place the Planet Gear Sub Assembly on bench CAUTION Safety glasses must be worn during this next steps 2 Remove the upper Retaining Ring 3D from groove of the Planet Gear 3A 3 Remover Spacer Rings from either side of the Roller Bearing Assembly 3B 4 Remove the Roller Bearing assembly 3B and carefully slide into a snug fitting tube 5 Remove the lower Retaining Ring 3D from groove of the Planet Gear 3A This concludes the Output Carrier Disassembly 32 Planetary Final Drive Service Manual Input Carrier Disassembly 80 1 Drive the Planet Shaft 8D out of the Carrier 8A pin holes forcing the Roll Pin 8E to sheer off 2 Hold on to the Planet Gear 8F and push the Planet Shaft 8D out of the Carrier 8A The Thrust Washers 8B will slide off the shaft as it is removed 3 Using a hammer and punch drive the Roll Pin 8E out of the Planet Shaft 8D and Carrier 8A 4 Remove the Needle Bearings 8C from the inside of the Planet Gear 8F 5 Repeat steps 1 4 for the remaining two Planet Gears 8F This concludes the Input Carrier Disassembly 33 5 INTENTIONALLY LEFT BLANK 34 ASSEMBLY Planetary Final Drive Service Manual Cover Subassembly CW18E SERIES MODEL COVER SUBASSEMBLY 18 amp CW18D SERIES MODEL COVER SUBASSEMBLY Continue
29. ing Ring 18E from counter bore of the Spindle 1 Remove the Input Brake Bolts from the Brake Piston 18A incrementally to release the tension off the springs slowly Remove the Brake Thrust Plate 188 Remove the Brake Springs 18R from the Brake Piston 18 Remove the Brake Piston 18A out of the Spindle 14 Remove the Backup Ring 18H and the O ring 18F from grooves in the Spindle 14 Remove the Backup Ring 181 and the O ring 18G from grooves in the Spindle 14 Remove the Stators 18D and Rotors 18C from the spindle counter bore Remove Plastic Plug 21 from Spindle 1A if applicable Remove Spacer 184 from the spindle 1A applicable for Splined Brake Assembly only This concludes the Input Brake Disassembly 27 Planetary Final Drive Service Manual Housing Spindle Disassembly HOUSING SPINDLE SUBASSEMBLY WITH LIP SEAL Continued on Next Page 28 1 Set the unit bench so that the Spindle 1A flange is down Continued on Next Page 29 2 Using a small drill bit typically 1 8 drill from the top of the bearing nut to the bottom as shown below USING SMALL DRILL BIT TYPICALLY 1 8 DRILL FROM OF THE NUT TO BOTTOM AS SHOWN 3 Using a larger drill bit typically 5 16 drill the bearing nut from the shoulder of the bearing nut to the bottom as shown below USING LARGER DRILL BIT TYPICALLY 5 16 DRILL FROM SHOULDER OF THE NUT TO BOTTOM
30. ld undergo brake test as per instructions on pages 5 6 and 7 Install Plastic Plug 22 into Spindle 1A Continued on Next Page 49 29 30 31 32 HUB SPINDLE SUBASSEMBLY NOTE Skip steps 29 30 and 31 if unit does not have Adaptor Mounting 24 Grease and Install O Ring 25 onto O Ring groove of Adaptor Mount 24 NOTE Skip step 30 if Thrust Washer 30 is glued onto Adaptor Mount 24 Install Thrust Washer 30 onto Adaptor Mount 24 Install Adaptor Mount 24 onto Spindle 1A using Bolts 26 The unit should now be leak and roll checked as per instructions on page 8 9 amp 10 The motor can be reinstalled into the gearbox for the leak check to seal it off and the unit pressurized through a pipe plug hole on the cover This concludes the Main assembly 50 Planetary Final Drive Service Manual Assembly Drawing INPUT BRAKE 26 99 Wi SUBASSEMBLY 17 HUB SPINDLE SUBASSEMBLY 6 2 2 ay 2 4 4 INPUT CARRIER 12 SUBASSEMBLY COVER SUBASSEMBLY CWISE SERIES MODEL 30 INPUT BRAKE SUBASSEMBLY HUB SPINDLE SUBASSEMBLY GA 26 24 42 INPUT CARRIER 2 12 SUBASSEMBLY 2 COVER f SUBASSEMBLY 18 amp CWI18D SERIES MODEL 51 Number 1A 1B 1C 1E 1G 1H 1U 14 18A 18B 18C 18D Continued on Next Page Planetary Final Drive Repair Instructions Parts List Qty
31. licable 6 Lift out the Input Carrier Subassembly from Hub Spindle Subassembly 7 Remove the Second Stage Sun Gear 12 8 Lift the Ring Gear 4 6 off of the Housing Spindle Subassembly 9 Remove the O ring 5 from between the Housing 1G and the Ring Gear 4 6 CAUTION Safety glasses must be worn during these next steps 10 Remove the four External Retaining Rings 3C that are holding the spindle Planet Gears 8A in place 11 Carefully pry the Planet Gears 3A off of the spindle posts Be careful to not damage the Thrust Spacer 2 12 Remove Thrust Spacer 2 from Housing Spindle Subassembly NOTE Skip steps 13 14 and 15 if unit does not have Adaptor Mount 24 Continued on Next Page 20 13 14 15 16 17 Remove Adaptor Mount 24 from Housing Spindle Subassembly by uninstalling Bolts 26 NOTE Skip step 14 if Thrust Washer 30 is glued onto Adaptor Mount 24 Remove Thrust Washer 30 from Adaptor Mount 24 Remove O Ring 25 from groove in Adaptor Mount 24 and discard O Ring Remove the Input Brake Subassembly out of Hub Spindle Subassembly Refer page 26 for Input Brake Disassembly Remove the Input Coupling Subassembly 9 out of Hub Spindle Subassembly This concludes the Main Disassembly 21 Planetary Final Drive Service Manual Cover Disassembly 27 18 SERIES MODEL COVER SUBASSEMBLY 18 amp CW18D SERIES MODEL COVER SUBASSEMBLY 2
32. rfaces of the O Ring 2 wet with alcohol use the Installation Tool 9 to position the Seal Ring 1 and the O Ring 2 squarely against the Housing 5 as shown Use sudden and even pressure to pop push the Toric Ring under the Retaining Lip 3 of 1999 T NOTE It is important for the O ring as well as the housing bore 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 Li 773 s WI If small adjustments 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 15 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
33. s 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 47903 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 70 cerlikon fairfield Oerlikon Fairfield U S 52 South P O Box 7940 Lafayette IN 47903 USA 765 772 4000 www oerlikon com fairfield 71
34. ssembly with Mount Adaptor 2 Install the Retaining Ring 18B from retaining ring groove of Coupling 9 18A This concludes the Input Coupling Subassembly 42 Final Drive Service Manual Housing Spindle Subassembly HOUSING SPINDLE SUBASSEMBLY WITH FACE SEAL 9 HOUSING SPINDLE SUBASSEMBLY WITH LIP SEAL Continued on Next Page 43 10 11 12 Using alcohol and clean rag wipe off bearing locations on the Housing 1G and the Spindle 1A Press one Bearing Cup 1E into bearing counter bore of spindle end of housing until seated against shoulder in housing Use Tool T179926 T 176834 Turn Housing 1G and press one Bearing Cup 1C 1E using Tool T179926 T 176834 into bearing counter bore of cover end of Housing 1G making sure that it is fully seated against shoulder in the housing Install two Pipe Plugs 1U in Housing 1G Place one Bearing Cone 1D 1F into the Housing 1G and if necessary and spray with a light coat of oil NOTE Generally seals should not be reused NOTE If the unit has Face Seal refer pages 14 through 16 for detailed instructions on face seal installation Then follow from Step 12 NOTE If the unit has two part lip seal follow steps below Spray the housing seal bore with alcohol then wipe with a clean rag Ensure there is no debris left in the bore Using alcohol and a clean rag wipe off seal locations on the Housing 1G and the Spindle 1A
35. take the Bearing Nut 1E in three places equally spaced into the spline This concludes the Housing Spindle Subassembly 45 Planetary Final Drive Service Manual Main Assembly HUB SPINDLE INPUT CARRIER SUBASSEMBLY SUBASSEMBLY 18 SERIES MODEL MAIN ASSEMBLY HUB SPINDLE SUBASSEMBLY INPUT CARRIER SUBASSEMBLY 18 amp CW18D SERIES MODEL MAIN ASSEMBLY Continued on Next Page 46 10 11 12 13 Place Hub Spindle Subassembly spindle flange end down Preheat bearing heating oven to 250 F Install Thrust Spacer 2 into counter bore of Spindle 14 Once oven has reached 250 F place Planet Gear Sets into oven and leave in for 15 to 20 minutes Do not leave gears in oven for more than 20 minutes as metallurgical damage can occur if gears reach 250 F Damage can occur before gears discolor Place Hub Spindle Subassembly on bench Remove Planet Gears from oven and immediately push one Planet Gear starting with large radius on bore of Cylindrical Roller Bearing 3B onto each planet post of Spindle 1A until bearing hits shoulder of planet post on Spindle 1A If Planet Gear gets stuck on post before bearing hits shoulder of planet post immediately press bearing the rest of the way on using T174699 pressing tool Keep Planet Gears Sets 3A together during assembly One set per each Spindle 14 NOTE Do not beat planet gears onto spindle posts with bar stock or
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