Industrial Gearboxes Service Manual
Contents
1. Rebuild and repair the bearing housing seat with Loctite Hysol 3478 Superior Metal See page 12 Removal of cured chemical gaskets from dismantled flange surface with Loctite 7200 Gasket Remover Cleaning and degreasing of surfaces prior to bonding with Loctite 7063 Cleaner and Degreaser Make any size or shape gasket For flexible covers and covers with large bolt spacing use Loctite 5910 Flange Sealant For rigid assemblies use Loctite 518 Flange Sealant See page 20 See page 58 Prevent bearing spin and fretting with Loctite 603 or Loctite 641 Retaining Compound See page 30 oil seal and housing with Loctite 248 Threadlocker Loctite 480 or Loctite 435 Instant Adhesive See page 28 L Secure and prevent leakage between Prevent keyway wear with Loctite 243 Repair housing cracks porosities and defects with Loctite Hysol 3471 Metal filled Epoxy See page 8 Prevent pinion and all other gear movement with Loctite 648 Retaining Compound See page 36 Threadlocker or repair keyway wear with Loctite 660 Retaining Compound See page 44 Prevent corrosion seizure and boltloosening with Loctite 243 or Loctite 248 Medium Strength Threadlocker See page 14 and 18 BLS LLL Seal rigid parts without gasket shimming using Loctite 518 or Loctite 128068 See page 16 Seal and lo2. New components e Apply a Loctite Medium Strength Threadlocker to eliminate any future wear of the key or keyway Steps 1 Clean the keyway and key with Loctite 7063 Cleaner and Degreaser 2 Apply several drops of Loctite 243 Threadlocker into the keyway or Loctite 248 Threadlocker onto the key 3 Insert the key into the keyway 4 Wipe off any excess adhesive 9 Allow the adhesive 6 hours to cure before assembling the gear wheel For further technical details refer to selection chart on page 67 al Use a thin coat on the bottom and a thicker layer on the ap of 0 25 mm use Loctite 660 inutes 1g back into service SOLUTION 3 y in existing shaft and gear are badly worn it may be necessary to cut new keyways In this case the old keyway should led with metal filled epoxy ts with Loctite 7063 Cleaner amp Degreaser apply Loctite Hysol 3478 Superior Metal into the keyway of both the shaft and gear 12 hours curing time line the cured adhesive to the original dimensions of the shaft and bore of the gear new keyway in the shaft and gear n No 1 above to refit the key Worn components e The assembly is restored and ready for service without a major overhaul e The key is secured into the keyway CHALLENGE gt Secure the key in the keyway on new equipment gt Prevent micro movements that lead to wear gt Repair worn keyways SOLUTION e Please
3. YOUR ADVANTAGE e Quick return to service e Reduce scrap by salvaging and extending the life of gearbox housing and cover ie I i i i L L gt Prevent bearing spin corrosion and housing damage Cause e Bearing outer races are prone to spinning within their housings resulting in damage to the housing regardless of whether or not they have been pressed or shrink fitted in place e The air space between a bearing and housing is an area susceptible to rust and fretting corrosion thus causing damage to the parts Housings SOLUTION e Apply a film of Loctite 641 Retaining Compound to the outside diameter of the bearing e Loctite 641 Retaining Compound is a medium strength allowing for easy disassembly during future overhauls e Alternatively use Loctite 603 for a high strength joint or Loctite 640 for longer assembly time Steps 1 Clean the mating surfaces with Loctite 7063 Cleaner amp Degreaser Note Loctite 603 is oil tolerant and cleaning is less critical 2 Apply a film of Loctite Retaining Compound to the outside diameter of the bearing 3 Assemble using normal techniques 4 Functional cure in 6 hours at room temperature For further technical details refer to selection chart on page 68 gt YOUR ADVANTAGE e Bearing movement is eliminated e Bearing can be easily removed with standard tools e Corrosion is eliminated because the air space between the bearing and
4. 2 Clean parts with Loctite 7063 Cleaner amp Degreaser 3 Check the spline area for uniformity 4 Apply Loctite Hysol 3478 Superior Metal to the spline shaft and disperse the product uniformly over the spline circumference Note For wear between socket and shaft below 0 25 mm use Loctite 660 Retaining Compound in combination with Loctite 7649 Activator 5 Immediately push the spline shaft into the socket and remove excess adhesive 6 Allow the adhesive to cure before putting the equipment back into service e Assembly is restored and ready for service without major overhaul M 0 CHALLENGE Ms aa gt Prevent couplings from moving due to loose set screws gt Secure coupling assembly screws against working loose gt Ensure optimum assembly life in on site conditions Cause e Couplings are commonly held in place by a key and a set screw e Coupling assemblies are subjected to vibration and high loads which can cause threaded fasteners to loosen e Typically couplings are assembled on site for this reason it is difficult to ensure that tightening specifications are followed gt YOUR ADVANTAGE SOLUTION Secure all threaded fasteners on couplings using Loctite 243 or 248 Medium Strength Threadlocker Steps 1 Clean the components with Loctite 7063 Cleaner amp Degreaser 2 Apply Loctite 243 or 248 Medium Strength Threadlocker to all threaded fasteners 3 Align the coupl
5. 248 Medium Strength Threadlocker Semi solid stick medium strength 19 g stick 540491 52 Loctite 290 Threadlocker Wicking for post assembly 50 mi 233 33 52 Loctite 2701 Threadlocker High strength 50 mi 234853 52 GENERAL MAINTENANCE AIDS APPLICATIONS LOCTITE SOLUTIONS BENEFITS MAINTENANCE LUBRICATION To free lubricate and clean all parts of the gearbox during assembling and dismantling To free rusted corroded and seized parts during dismantling Assembly aid for all assembly works Long term protection for fasteners and alignment pins Loctite 8201 Five Way Spray Loctite 8040 Freeze amp Release Loctite 8102 High Performance Grease Loctite 8106 Multi Purpose Grease Loctite 8012 Moly Paste Loctite 8065 C5 A Copper Anti Seize Loctite 8060 Aluminium Anti Seize Loctite 8009 Metal free Anti Seize Moisture displacer amp rust preventer Frees rusted parts High performance grease General purpose lubrication grease Moly paste brush top Semi solid stick general purpose Semi solid stick general purpose Metal free Anti seize for stainless steel MAINTENANCE CLEANERS General cleaning of external surfaces Cleaning and degreasing of machined parts Cleaning and degreasing of surfaces prior to bonding SURFACE PROTECTION Rust treatment Corrosion protection Loctite 7840 Cleaner amp Degreaser Loctite 7070 Cleaner amp Degreaser Loctite 7063 Cleaner a
6. House Clear Clear Clear Black gt 24h 6h Wood Lane End Pack size IDH no Pack size IDH no Hemel Hempstead 20 g 20 g 20 g 20 g 150 ml aerosol 90 ml pump Hertfordshire HP2 4RQ 135428 195678 871787 135250 142479 333369 Tel 01442 278100 Fax 01442 278293 www loctite co uk designates a trademark of Henkel KGaA or its affiliates registered in Germany and elsewhere Henkel KGaA 2006
7. Steps 1 Using a lathe undercut the shaft in the worn area 1 5 mm deep and leave a rough surface over the entire machined surface 2 Dovetail the ends of the worn area to lock the application into place 3 Clean parts with Loctite 7063 Cleaner and Degreaser 4 Apply a layer of Loctite Hysol 3478 Superior Metal building the surface above the final desired level 5 Allow the adhesive to cure for 12 hours at room temperature 6 Machine the repair with a diamond tipped tool to the original dimensions 7 Apply Loctite 638 Retaining Compound to the components 8 Assemble using normal procedures the sleeve and the gear wheel For further technical details refer to selection chart on page 68 and 69 eP YOUR ADVANTAGE e Taper joint is strengthened by using a Retaining Compound e Assembly is restored and ready for service without a major overhaul M N AF A J N We n gt Secure the key in the keyway on new equipment gt Prevent micro movements that lead to wear gt Repair worn keyways Cause e Alternating loads and combined loading result in micro movement wear and loose parts e Over time wear can cause keys to loosen leading to damage of the keyway SAD A o f m 4 rm M AM BB in AX Bi i ee upg Oa m MI Gay Shaft Mounted Components Gear Sets E E yo ae LI 1
8. also refer to section Prevent and repair keyway wear on page 42 43 KOL ADVANTAGE e Reduce the cost of replacement parts by salvaging and extending the life of the original components d P YOUR ADVANTAGE Couplings gt Protecting the spline assembly to prevent unnecessary fretting Cause e Wear will occur where there is friction and movement in the spline LION e Use Loctite 8012 Moly Paste proactively e Moly Paste reduces friction and wear Steps 1 Clean mating surface with Loctite 7063 Cleaner amp Degreaser 2 Coat mating surface with Loctite 8012 Moly Paste 3 Assemble parts e Prevention of wear caused by friction e Prevention of corrosion CHALLENGE gt Fixed spline repair e Repair spline backlash e Stop spline wear and failure e Reuse previously worn components Cause e Alternating loads and worst case combined loading can cause micro movement e Incorrectly specified spline drive producing overload during operation YOUR ADVANTAGE Couplings SOLUTION 1 SOLUTION 2 Bonding of a non sliding spline with backlash of Rebuilding of a non sliding spline with backlash greater up to 0 25 mm than 0 25 mm e Bonding with Retaining Compound Loctite 660 e Rebuilding with metal filled Epoxy Loctite Hysol 3478 and Loctite 7649 Activator Superior Metal Steps 1 If possible abrasive blast the surface of the spline shaft and socket
9. cut gasket use one of following products e Loctite 5922 Flange Sealant non hardening pre cut gasket dressing e Loctite 534 hardening pre cut Gasket Positioner Steps 1 Remove old gasket material with Loctite 7200 Gasket Remover 2 Clean both flanges with Loctite 7063 Cleaner amp Degreaser 3 Coat flange face on both sides cover and housing with Loctite 5922 non hardening Flange Sealant or Loctite 534 hardening Flange Sealant Note Although Loctite 534 is a hardening Flange Sealant the product allows a pre cut gasket to be positioned on a gasket surface It holds aggressively yet still allows for repositioning of the pre cut gasket 4 Position the pre cut gasket 5 Assemble and tighten as required Note Accurate re positioning component assembly and tightening should be handled in a continuous workflow without interruptions 6 Assembly is operational after 6 hours e gt YOUR ADVANTAGE e Eliminate gasket leaks e Eliminate corrosion and damage on the flange surface For further technical details refer to selection chart on page 68 j CHALLENGE Removal of cured chemical gaskets ng material it is essential to clean the flange or surface with from dismantled flange surfaces Cause e After dismantling the gearbox components the flanges must be cleaned before reassembly 1d for assembly and flange sealing 1emical gaskets is ensured CH
10. gearbox housing fasteners to ensure reliability of the gasket between the upper housing and the base gt Prevent corrosion and seizure of split gearbox alignment pins Cause e Fasteners can work loose when subjected to torque vibration thermal expansion and shock loads e Once the fasteners become loose the preload for the gasket AN will be lost and the gasket will fail 2 e Dowel pins can rust and seize into component making disassembly very difficult 243 or 248 Medium Strength Threadlocker to the housing fastener 2701 for high strength or on stainless steel and plated fasteners 09 Heavy Duty Anti Seize onto the dowel pin ket is in use ensure only a very thin layer of Anti Seize is applied For further technical details refer to selection chart on page 67 sistent disassembly eners from loosening 7063 ia 1 ls E E lager Crna klaasis r EF CHALLENGE lt N gt Prevent gasket failure between aly the upper and lower housing of a split gearbox oc 3 518 Flange Sealant Circle bolt holes with sealant if appropriate FI r e Sealant for large gearbox flanges Loctite 128068 is designed to cure assembly gt Ensure close tolerance control 5 required of the assembly Allo ir G il to d L I gt Sealing of damaged surfaces rther technical details ection chart on page 68 e YOUR ADVANTAGE iit forces from on
11. strengthened by using a Loctite Retaining Compound e Shaft is repaired to provide full surface contact For further technical details refer to selection chart on page 68 Shaft Mounted Components Bearings CHALLENGE SOLUTION 1 SOLUTION 2 Moderate scoring Heavy scoring e Strengthen the joint between the damaged e Fill the grooves with Loctite Hysol 3478 Superior kt shaft and the bearing with Retaining Gompound Metal to rebuild a uniform surface and ensure that AETI Loctite 603 the bearing will be mounted on a smooth shaft gt Repair of axial score marks on cylindrical shafts a gt Strengthen the retaining joint on worn shafts Steps Steps 1 Remove any raised burs 1 Remove any raised burs 2 Clean the parts with Loctite 7063 2 Clean parts with Loctite 7063 Cleaner and Degreaser Cleaner and Degreaser 3 Apply Loctite Hysol 3478 Superior Metal into the 3 Apply a bead of Loctite 603 Retaining Compound groove Build the surface slightly above the desired to the circumference of the shaft diameter 4 Press the bearing onto the shaft using normal 4 Allow the adhesive to cure for 12 hours at room techniques temperature 5 Wipe off excess material 5 Grind the excess material with abrasive paper 6 Apply Loctite 7649 Activator to the rebuild area of the shaft 7 Apply Loctite 603 to the inner bearing race and assemble For further technical details refer to selection chart on page 68 and 69 E
12. 278 40 keyway wear Loctite 248 Medium Strength Threadlocker Semi solid stick medium strength 19 g stick 940491 44 Loctite 248 Medium Strength Threadlocker Semi solid stick medium strength 19 g stick 540491 40 Protecting the spline Loctite 8012 Moly Paste Moly paste brush top 453 g 504236 45 Loctite 660 Quick Metal Retaining High strength gap filling up to 0 25 mm 50 mi 229232 42 assembly Compound Repair spline backlash Loctite 660 Quick Metal Retaining High strength gap filling up to 0 25 mm 50 mi 229232 46 Loctite Hysol 3478 Superior Metal Ferro silicon carbide based epoxy with 452 g 886366 42 Compound outstanding compressive strength Loctite Hysol 3478 Superior Metal Ferro silicon carbide based epoxy with 452 g 886366 46 Gear mounted on Loctite 660 Quick Metal Retaining High strength gap filling up to 0 25 mm 50 ml 229232 42 outstanding compressive strength a cylindrical shaft Compound Prevent coupling moving Loctite 243 Threadlocker Medium strength oil tolerant 50 mi 135278 48 Loctite Hysol 3478 Superior Metal Ferro silicon carbide based epoxy with 452 g 886366 42 Set screws outstanding compressive strength Loctite 248 Medium Strength Threadlocker Semi solid stick medium strength 19 g stick 940491 48 Increase torgue capacity Loctite 638 Retaining Compound High strength 50 mi 234795 50 Flange couplings MOUNTING GEARBOX TO MOTOR Mounting fastener Loctite 243 Threadlocker Medium strength oil tolerant 50 mi 135278 52 Loctite
13. 5 min 180 min 90 min 180 min 150 min Compressive strength 82 7 70 N mm 70 N mm 60 N mm 70 N mm 124 N mm 70 N mm 90 N mm Operating temperature Upto 120 C Upto 120 C Upto 120 C Upto 120 C Upto 120 C Upto 120 C Upto 120 C Upto 120 C Pack size IDH no 1149 500 g 500 g 500 g 900 g 452 g 500 g 500 g 265628 229176 229175 229174 195891 886366 229173 195826 Instant Bonding Surface Preparation Dissimilar materials needs to be bonded Do you need an activator v M Ws Increase cure speed on passive surfaces Dakar UNIVERSAL GENERAL APPLICATION TOUGHENED HIGH TEMPERATURE such as stainless steel aluminium plated or passivated metals OFFICIAL SUPPLIER 401 454 435 480 Recommended for bonding on rebuilt surfaces with Loctite Hysol 3478 Superior Metal Especially for Plastic Rubber Plastic Rubber Plastic Rubber Metal Plastics Solvent based Solvent free Porous Substrates Porous Substrates Porous Substrates 7649 7240 Operating temperature o o o o Appearance a BERETS HOMIE UNE ADMD SS NDE Ap tee 90 The data contained herein are intended as reference only Please contact your local Henkel Technical Support Group for assistance and recommendation on Fixture time on steel Transparent Blue green specifications for these products 5 20 sec 5 20 sec 5 20 sec 60 120 sec green liquid liquid Viscosity mPa s Evaporation time 110 Gel 200 300 Je 2 eales Henkel Loctite Adhesives Ltd Colour On part life A Technologies
14. ALLENGE nblies with Loctite 577 572 or 561 Thread Sealants are resistant to oil gt Prevent leaks from threaded fittings d ensure zero leakage of lubrication and cooling systems ale nt fittings from loosening yet y disa j with normal hand tools Lubrication System e Prevent oil leaks on oil drain plug oil inlet housing ventilation oil pump oil filter and gauge glass 063 Cleaner amp Degreaser Cooling System Thread Sealant to the leading threads e Prevent leakage on the coolant pump pressure and temperature control unit and all pipe work T i and allow to cure Cause e Traditional thread sealants a susceptible to weeping e Constant pressure and temperature changes within a gearbox system can aggravate any leakage e Vibration between the gearbox and lubrication cooling system leads to stress on the pipe work Shaft Seals SOLUTION 2 ler press fit For oil seal with metallic clamping part g Loctite 435 e Fill the air spaces by applying Loctite 243 or 248 de diameter of the Medium Strength Threadlocker to the outside diameter of the oil seal gt Prevent leaks between the gearbox m jer than 60 mm use Loctite 480 housing and oil seal shaft using Loctite 435 gt Prevent movement of oil seal in housing m of the oil seal and the gearbox with Loctite 7063 Cleaner 8 Degreaser mmended for the different kinds of oil seals to the out
15. DH NO PAGE HOUSING LUBRIGATION AND GOOLING SYSTEM Defects and porosities Loctite Hysol 3471 A amp B Steel filled repair epoxy 500 g 229176 8 Threaded fittings for Loctite 577 Thread Sealant General purpose 50 mi 229342 26 lubrication and cooling Loctite 290 Threadlocker Wicking for post assembly 50 mi 233 33 8 system Loctite 572 Thread Sealant Slow cure 50 ml 229360 26 Prevent Loctite 603 Retaining Compound High strength oil tolerant 50 mi 135280 10 Loctite 561 Thread Sealant Semi solid stick controlled strength 19 g stick 940920 26 bearing spin Loctite 640 Retaining Compound High strength high temperature slow cure 50 mi 564050 10 SHAFT SEALS Loctite 641 Retaining Compound Medium strength 50 mi 195780 10 Prevent leaks between oil Loctite 248 Medium Strength Threadlocker Semi solid stick medium strength 19 g stick 940491 28 Repair and rebuild worn Loctite Hysol 3478 Superior Metal Ferro silicon carbide based epoxy with 452 g 886366 12 seal and housing bearing housing outstanding compressive strength Loctite 435 Instant Adhesive Transparent toughened fast cure 20 g 8 1 87 28 Loctite 2701 Threadlocker High strength 50 mi 234853 12 Loctite 480 Instant Adhesive Black toughened 20 g 135250 28 HOUSING AND GOVER ASSEMBLY SHAFT MOUNTED COMPONENT BEARINGS Split gearbox Loctite 243 Threadlocker Medium strength oil tolerant 50 ml 135278 14 Prevent bearing spin or Loctite 641 Retaining Compound Medium strength 50 ml 135523 30 housing fas
16. LOCTITE Industrial Gearboxes Service Manual This guide has been designed to provide quick and easy assistance to the professionals who service industrial gearboxes and look for reliability longevity and cost reduction With the help of this guide you can e Easily select the right Loctite products to help you service the wide variety of gearbox assemblies e Prevent wear proactively Pinpoint the most suitable solution for servicing worn parts or Determine the best product for your particular service or repair problem Industrial gearboxes play an important role in processing and manufacturing facilities Performance must be tailored to an endless diversity of demands and reliable operation over a long service life with minimum maintenance is a key requirement For plant professionals the ultimate goal is to maximise machinery output reliability and efficiency That s why a gearbox failure can be a costly setback to overall plant operations Proactive maintenance will minimise expensive downtime enhance reliability and dramatically cut costs Loctite products are used in gearbox manufacturing worldwide to enhance quality and extend end product life The same high quality Loctite technologies and products are also available to the people who maintain repair and service gearboxes There is a comprehensive range of Loctite products to Repair and prevent gearbox failures on site to minimise downti
17. Type of thread FINE PITCH Hydraulic amp Pneumatic Universal 542 577 Thread size Up to 3 4 Up to 3 Temperature resistance 150 C 1906 Disassembly strength Medium Medium Viscosity Low High Pack size IDH no 50 mi 50 mi 267431 229342 1 General recommendation not limiting testing other sizes All grades Cleaning of substrates with Loctite 7063 recommended At temperatures below 5 C use of Loctite 7649 Activator required COARSE PITCH Slow cure 972 Up to 3 150 C Medium High 50 ml 229360 Stick form 561 Up to 3 150 C Low Semi solid 19 g stick 540920 PLASTIC PLASTIC or PLASTIC METAL Universal 99 Up to 4 130 C Low Thread 150 m 270153 Flange Sealing Does the existing gasket need to be used as a shim NO Gap Up to 0 25 mm Rigid metal flanges 8 Flange couplings 518 548 574 Take free time cure speed Fast curing Fast curing Fast curing Temperature resistance 150 C 150 C 150 C Cure mechanism Anaerobic Anaerobic Anaerobic Viscosity Paste Semi solid Gel Pack size IDH no 300 ml 18 g stick 250 ml 435566 704920 135500 With temperatures below 5 C please use Loctite 7649 Activator Retaining Need to be able to disassemble YES Medium strength 641 668 603 Diametrical clearance lt 0 1 mm lt 0 15 mm lt 0 1 mm Temperature resistance 150 C 150 C 150 C Handling stre
18. ck fittings at any angle with Loctite 577 or Loctite 572 Thread Sealants See page 26 Prevent the mounting bolts loosening with Loctite 2701 High Strength Threadlocker See page 52 Prevent corrosion and seizure of dowel pins with Loctite 8009 Heavy Duty Anti seize See page 14 of flange coupling with Loctite 638 See page 50 Increase the torque capacity CHALLENGE gt Repair housing and cover defects gt Seal oil leaks due to damaged housing Cause e Gearbox housings may be porous e Service or repair work may cause damage to gearbox housings and covers SOLUTION 2 Housings SOLUTION 1 Sealing porosity up to 0 05 mm using wicking grade adhesive Loctite 290 Steps 1 Thoroughly clean and dry the components with Loctite 7063 Cleaner amp Degreaser insuring the porosity is oil free 2 Brush Loctite 290 into the porosities 3 Allow to cure typically for 3 hours 4 Clean of excess product Filling damaged areas with Loctite Hysol 3471 Metal filled Epoxy Steps 1 Thoroughly clean and dry the components with Loctite 7063 Cleaner amp Degreaser insuring the repair area is oil free 2 Mix and apply Loctite Hysol 3471 onto the area to be repaired 3 Allow to cure typically for 12 hours to achieve functional strength 4 Machine to original size if required For further technical details refer to selection chart on page 69 e
19. d Components Bearings SOLUTION 2 SOLUTION 3 For gaps up to 0 25 mm e Bond using Loctite 660 Loctite 7649 Activator For gaps which exceed 0 25 mm e Rebuild with Metal filled Epoxy Loctite Hysol 3478 Superior Metal to the original diameter bond the bearing onto the rebuilt shaft with Loctite 2701 Steps 1 Clean parts with Loctite 7063 Cleaner and Degreaser Steps 2 Apply Loctite 7649 Activator to the inner bearing race 1 Using a lathe undercut the shaft in the worn area 1 5 mm deep 3 Apply a bead of Loctite 660 to the circumference of 2 Dovetail the ends of the worn area to lock the application into place and leave a rough surface the shaft 3 Clean parts with Loctite 7063 Cleaner and Degreaser 4 Assemble the components 4 Apply a layer of Loctite Hysol 3478 Superior Metal build the surface above the final desired level 5 Wipe off excess 5 Allow the adhesive to cure for 12 hours at room temperature 6 Allow adhesive to cure for 12 hours before putting the 6 Machine the repair with a diamond tipped tool to the required dimensions equipment back into service 7 Apply Loctite 7649 Activator to the rebuilt area of the shaft 8 Apply Loctite 2701 to the inner bearing race Note In the case of a shrink fit between the shaft and the bearing apply Loctite 638 Retaining Compound For further technical details refer to selection chart on page 68 and 69 gt gt YOUR ADVANTAGE e Cylindrical joint is
20. e Cause e Disassembly of bearings and gear wheels frequently causes D YO g R ADV ANT AG damage to shafts by scoring y e Bearings and gear wheels are mounted with a shrink fit If they are dismantled without application of heat friction results in axial score marks e Cylindrical joint is strengthened by using a Loctite Retaining Compound e Shaft is repaired to provide full surface contact Shaft Mounted Components Gear Sets LOETITI liit JA AI A U HALLE SOLU Bonding of gear wheels directly onto the shaft with high strength Retaining Compound Loctite 648 4 gt Increase reliability and strength of a gear ae mounted on a shaft Clean parts with Loctite eaner and Degreaser 2 Apply a bead of Loctite 648 to the circumference of the shaft 3 Press the gear onto the shaft using normal techniques 4 Wipe off excess material 5 Allow adhesive to cure for 6 hours gt Repair worn taper joints Cause e Incorrect reassembly during maintenance leading to micro movements e Overload conditions and elevated operating temperatures j For further technical details refer to selection chart on page 68 Rebuilding the worn shaft with ceramic filled epoxy Loctite Hysol 3478 Superior Metal and bonding the gear wheel onto the shaft with Loctite 638 Retaining Compound he worn shaft with Loctite 648
21. e easy future maintenance gt Protect fasteners and alignment pins against seizing and galling SOLUTION Apply Loctite 8106 Multi Purpose Grease or Loctite 8102 High Performance Grease onto any parts that need lubricating during assembly Loctite 8012 Moly Paste ensures maximum lubricity gives good resistance to extremly high loads and is ideal for protection of parts during running in or cold start SOLUTION oe A f pi Jay i SM Apply Loctite 8065 Gopper Anti Seize to non stainless external fasteners and dowel pins Use Loctite 8009 Heavy Duty Anti Seize on all metal fittings or in aggressive chemical environments e Prevent wear and cold welding during assembly and operation e Anti Seize products are used to lubricate and to permit easy disassembly e Inhibit corrosion and oxidation in chemically and thermally hostile environments mare CHALLENGE gt General cleaning of gearbox housing covers and external surfaces is a solvent based gt no residue gt General cleaning and degreasing of small surfaces like gear wheels and gearbox components ils lubrication yreaser for small components and small surfaces er is ideal for use prior to bonding as it leaves no residue ar is compatible with metal glass rubber most plastics gt Cleaning and degreasing of surfaces prior to bond
22. e part to the other Cause e Leaks occur because liquids migrate out of the joint e Damaged flanges can result in a leak path e Incomplete sealing of T joints where three parts come together upper and lower housing and Cover CHALLENGE gt Prevent loosening and corrosion of the cover fasteners to ensure the reliability of the gasket between the housing and covers gt Typical applications are fasteners for inspection cover bearing cover and input output flanges Cause e Cover fasteners that are rusted and seized make gearbox maintenance difficult and create additional labour associated with drilling and tapping the fastener hole e Fasteners can work loose when subjected to torque vibration thermal expansion and shock loads lila LEE j d Cover Assembly kuid Wain CHALLENGE gt Prevent leaks between the inspection cover bearing cover input output flange and housing gt Eliminate cut gaskets gt Optimize sealing performance of cut gaskets Cause e The use of cut gaskets is associated with several inherent problems such as gasket relaxation shrinkage extrusion and breakage which can lead to leaks Housing and Cover Assembly _ SOLUTIO N When the existing gasket needs to be used as a shim For increasing the sealing reliability and accurate positioning of the pre
23. e products for cost efficient easy and effective gearbox maintenance and repair Gears and gearboxes are generally robust and reliable devices However problems do occur and need to be corrected When gearboxes and ancillary equipment fails the greatest concern is getting it running again but spare parts may not always be readily available Loctite products not only provide reliable on site repair capability but emergency repair and service solutions that last or even extend the life time of equipment Contact your local Henkel representative for help to meet your specific product application needs Table of Contents INDUSTRIAL GEARBOX APPLICATIONS 6 GEARBOX COUPLING AND MOUNTING 44 eee NS p C COUPLINGS a e Prevent and repair keyway wear 44 e Protect the spline assembly to prevent unnecessary fretting 45 GEARBOX ASSEMBLY GROUPS 8 e Repair spline backlash 46 e Prevent couplings moving due to loose set screws 48 HOUSINGS 8 e Increase the load capacity for flange couplings 50 e Repair housings and covers Damaged surfaces and porosities 8 Prevent bearing spin corrosion and housing damage 10 C MOUNTING GEARBOX TO MOTOR e Repair and rebuild worn bearing housing 12 e Prevent loosening of gearbox and motor mounting bolts 52 HOUSING AND COVER ASSEMBLY 14 e Prevent loosening and corrosion to split gearbox housing fasteners 14 GENERAL MAINTENANCE AIDS 54 e Prevent gasket failure between the upper and lower housing of a spli
24. icity 453 g 904219 18 Prevent leaks between Loctite 5910 Flange Sealant High adhesion greater than 0 25 mm gap 300 ml 142491 20 covers and housing fill Loctite 518 Flange Sealant General purpose up to 0 25 mm gap fill 65 ml 135480 20 Loctite 5922 Flange Sealant Increase the reliability of cut gasket seals 600 ml 142274 22 Loctite 534 Gasket Positioner Increase the reliability of cut gasket seals 19 g stick 705075 22 Removal of cured Loctite 7200 Gasket Remover Aggressive gasket remover 400 ml 458654 24 chemical gasket Gearbox Application Product Table GEARBOX ASSEMBLY GROUP PRODUCT INDEX PACK SIZE IDH NO PAGE GEARBOX COUPLING AND MOUNTING BENEFITS APPLICATIONS LOCTITE SOLUTIONS SHAFT MOUNTED COMPONENT GEAR SETS Gear mounted Loctite 648 Retaining Compound High temperature high strength 50 mi 234880 36 Prevent and repair Loctite 660 Quick Metal Retaining High strength gap filling up to 0 25 mm 50 mi 229232 44 on a taper shaft keyway wear Compound Loctite 638 Retaining Compound High strength 50 ml 234795 38 Loctite Hysol 3478 Superior Metal Ferro silicon carbide based epoxy with 452 g 886366 44 Loctite Hysol 3478 Superior Metal Ferro silicon carbide based epoxy with 452 g 886366 38 outstanding compressive strength outstanding compressive strength Loctite 243 Threadlocker Medium strength oil tolerant 50 ml 135278 44 Prevent and repair Loctite 243 Threadlocker Medium strength oil tolerant 50 ml 135
25. ing with Loctite adhesives Surface Protection LGCTire Tifa i 2 on E Sa ke a ELT 5 ITHE m CHALLENGE CHALLENGE gt Converting existing rust on external components gt Long term protection of ferrous metals against corrosion into a stable surface gt Surface treatment for external surfaces gt Protect surfaces from future corrosion SOLUTION SOLUTION Use Loctite 7500 Rust Treatment for external components that are corroded e Loctite 7800 Zinc Spray provides cathodic protection e Can be used for long term protection or as a primer e Converts existing rust and forms a primed surface ready for painting e Loctite 7500 Rust Treatment is a non toxic aqueous liquid which dries at room temperature e Gives an aesthetically pleasing appearance e Protects surfaces from rusting Steps 1 Shake container thoroughly before use 2 Ensure that all surfaces are free of any dirt oil and loose corrosion 3 Sanding is not required 4 Apply liberally by brush roller or sponge or airless spray gun 5 Application of 2 coats is recommended for maximum durability 6 Recoat time is 60 120 minutes Allow 24 hours minimum to dry before painting r Gearbox Application Product Table GEARBOX ASSEMBLY GROUP PRODUCT INDEX GEARBOX ASSEMBLY GROUP PRODUCT INDEX APPLICATIONS LOCTITE SOLUTIONS BENEFITS PACK SIZE IDH NO PAGE C APPLIGATIONS LOCTITE SOLUTIONS BENEFITS PACK SIZE I
26. ing and assemble 4 Tighten each fastener within 5 minutes of assembly For further technical details refer to selection chart on page 67 e All fasteners are secured in place e Prevention of misalignment and coupling failure Couplings CHALLENGE A gt Upgrade the load capacity of existing flange drive couplings gt Reuse worn flange couplings Cause e The transmittable torque of a flange drive coupling is limited by the friction of the surfaces e Overloading causes slippage and wear of the coupling surface Couplings e Use Loctite 638 High Strength Retaining Compound on the flange face to increase the torque capacity e Increase torque capacity without any mechanical changes Steps 1 Clean the surfaces with Loctite 7063 Cleaner amp Degreaser 2 Apply a thin film of Loctite 638 on the entire surface of the coupling flange 3 Once you start to assemble torque bolts within 10 minutes 4 Allow to cure for 6 hours before applying full load e Improved torque capacity without mechanical changes e Eliminates micro movement and loss of joint tension e Eliminates corrosion gt Secure all the components of the motor gearbox bedplate system gt Prevent loosening under high loads and vibration gt Select the correct threadlocking grade given the different load requirements and the need for dismantling Cause e Vibration and shock load can l
27. me Reclaim worn or damaged assemblies to avoid scrap and replacement costs Assist in assembly installation and disassembly oO e Ensure reliability and smooth running by restoring performance to as new condition Introduction GEARBOX SERVICE MANUAL SOLVES REAL PROBLEMS The applications described in the Gearbox Service Manual are based on a bevel helical gearbox configuration They apply equally for helical gearboxes worm gear units and geared motors Applications on planetary gearboxes due to their different construction are shown in a separate illustration The Gearbox Service Manual is designed as a practical guide to provide essential information in a logical and systematic manner It is structured in major sections covering key gearbox assembly groups coupling and mounting as well as general maintenance aids The manual is based on the real world and on solving real problems you re bound to find service and repair solutions you can use every day quickly and conveniently FEASIBILITY CONFIRMED The recommendations given in this Gearbox Service Manual are based on collaboration with customers institutes and universities to establish their validity and confirm that these methods are operable practicable and indeed the best solutions for servicing and repairing gearbox assemblies PROFIT FROM RELIABILITY At Henkel we understand the problems you face in ensuring reliability safety and durability We provid
28. mp Degreaser Loctite 7500 Rust Treatment Loctite 7800 Zinc spray Large parts cleaner water based Solvent cleaner General parts cleaner prior to bonding solvent based Rust treatment coating Zinc spray shiny PACK SIZE 400 ml 400 ml 400 ml 400 g 454 g 20 g stick 20 g stick 453 g 750 mi 400 ml pump spray 400 ml pump spray 10 1 400 ml 142730 760225 142540 142543 904236 929380 32311013 504219 235330 88432 88365 88344 195814 149293 303403 142716 54 54 56 56 56 57 57 57 58 58 58 58 58 60 61 Threadlocking Are parts assembled YES Wicking grade Low strength 290 222 Thread size Up to M6 Up to M36 Temperature resistance 150 C 150 C Functional strength after 3 hrs 6 hrs Viscosity Low Medium Pack size IDH no 50 ml 50 ml 233733 231501 General recommendation not limiting testing other sizes NO Medium strength 243 248 Up to M36 Up to M50 150 C 150 C 2hrs 6 hrs Medium semi solid 50 ml 19 g stick 135278 540491 2701 Up to M20 150 C 6 hrs Low 50 mi 234853 High strength 268 Up to M50 150 C 24 hrs Semi solid 19 g stick 540907 Time to functional strength Cleaning of substrates with Loctite 7063 recommended At temperatures below 5 C use of Loctite 7649 Activator required Thread Sealing
29. ngth 30 min 30 min 8 min Viscosity mPa s 15 semi solid 125 Pack size IDH no 50 ml 19 g stick 50 ml 135523 705053 135280 Use with Loctite 7649 Activator Time to handling strength Cleaning of substrates with Loctite 7063 recommended At temperatures below 5 C use of Loctite 7649 Activator required Selection Chart Gap Bigger than 0 25mm Flexible flanges Plastic or combined plastic metal parts 128068 5699 5910 oled alle TES SS AI TESTE 150 C 150 C 200 C Anaerobic Moisture Moisture Paste Paste 300 mi 300 mi 135270 142491 NO High strength High temp High temp 640 648 lt 0 15 mm lt 0 15 mm Pose 2 Wise 90 min 5 min 450 450 50 ml 50 ml 142620 234880 YES Positioning dressing of pre cut gaskets 5922 534 Non hardening Fast curing 200 C 150 C n a Anaerobic Paste Semi solid 60 ml 19 g stick 142274 705075 638 660 lt 0 25 mm lt 0 5 mm 150 C 150 C 8 min 20 min 2 000 Paste 50 ml 50 ml 234795 229232 Selection Chart Metal filled Epoxy Which material will be repaired STEEL ALUMINIUM Standard application High perform Stand appl High perform Steel filled Steel putty Steel pourable Steel fast cure Steel under Outstanding Multi purpose High temperature kneadable stick friction comp strength 3463 3471 3472 3473 3474 3478 3475 3479 Working life 3 MIN 45 min 45 min 6 min 45 min 20 min 45 min 45 min Fixture time 10 min 180 min 180 min 1
30. oosen fasteners and mounting bolts e Loose bolts result in movement which in turn allows the gearbox system to lose its alignment irbox to Motor CLEANER REINIGER __ Lai iii oi Super Clean SOLUTION 2 Where parts need to be aligned tightened and adjusted use Loctite 290 Wicking Grade Threadlocker after final adjustment and tightening Steps 1 Clean parts with Loctite 7063 Cleaner amp Degreaser 2 Align the assembly and tighten as usual 3 Apply Loctite 290 Wicking Grade Threadlocker to surface of assembled fastener it will penetrate into the gap between the assembled threads ice Lubrication CHALLENGE CHALLENGE gt To free rusted corroded and seized fasteners during dismantling gt Light lubrication of metals during assembly and dismantling gt Assembly aid aerosol for all parts of the gearbox gt Protect machined components against corrosion ing dismantling and assembling 43 C and cause microscopic cracks in the layer of rust frees lubricates cleans to wick directly into the rust by capillary action parts of the gearbox ective anti corrosive film nce of about 10 to 15 cm for 5 to 10 seconds To pting to release the seized parts Maintenance Lubrication 9018 CHALLENGE gt Ensure easy assembly of all close fitting parts by using assembly paste l gt Ensur
31. side diameter of the oil seal ette seal apply adhesive onto the cleaned shaft as well ion using normal techniques and wipe off any excess Cause e As with any press fit there are small air spaces between the housing and the oil seal This air space can create a leak path A VN U R ADV ANT AG E e Inthe case of a split gearbox housing T joints LOU TA to selection chart on page 69 are potential leakage points A sembly eliminates leaks contamination and corrosion oil seal ig running is eliminated e easily removed with a screwdriver during CHALLENGE gt Prevent bearing spin gt Repair worn cylindrical shafts gt Prevent downtime and scrap costs Cause e Bearings are prone to spinning on their shaft this results in damage e Load produces axial forces that are higher than original calculations e Spun bearing caused by insufficient interference or inappropriate loads Depending on the extent of wear the following adhesives are recommended For gaps up to 0 05 mm e Retain joint using Loctite 603 oil tolerant high strength or Loctite 641 medium strength easy to dismantle Retaining Compound Steps 1 Clean parts with Loctite 7063 Cleaner and Degreaser 2 Apply a bead of Loctite 603 or Loctite 641 to the circumference of the shaft 3 Mount the bearing onto the shaft using normal techniques 4 Wipe off excess material 5 Allow adhesive to cure for 6 hours _ Shaft Mounte
32. t gearbox 16 e Prevent loosening and corrosion of the cover fasteners 18 MAINTENANCE LUBRICATION 54 e Prevent leaks between the gearbox covers and housing 20 e Free lubricate and clean all parts of the gearbox during e Removal of cured chemical gaskets from dismantled flange surfaces 24 assembling and dismantling 54 ne i LUBRICATION AND COOLING SYSTEM 26 e Free rusted and seized parts during dismantling 55 oe TART e Assembly aid for all assembly jobs 56 e Prevent leaks from threaded fittings for the lubrication and cooling system 26 KAS KA M e Long term protection for fasteners and alignment pins 57 e Lubrication Fittings Oil drain plug oil inlet housing ventilation gauge glass MAINTENANCE CLEANERS 58 kd Cooling Fittings Flange pump coarse filter pressure 6 General cleaning of external surfaces 58 PS ARKSEALS aw v tit A i e Prevent leaks between the gearbox housing and oil seal 28 SURFACE PROTECTION a 60 e Rust Treatment Converting existing rust into a stable base 60 SHAFT MOUNTED COMPONENTS BEARINGS 30 e Corrosion Protection Long term protection of ferrous 61 e Prevent bearing spin or repair worn cylindrical shaft 30 metals against rusting e Repair of axial score marks on cylindrical shaft at the position of a bearing 34 PRODUCT INDEX 62 SHAFT MOUNTED COMPONENTS GEAR SETS 36 e Increase reliability and strength of a gear wheel mounted on a taper shaft 36 e Prevent and repair keyway wear 40 SELECTION CHART 67
33. tener repair worn cylindrical Loctite 248 Medium Strength Threadlocker Semi solid stick medium strength 19 g stick 540491 14 shaft Loctite 603 Retaining Compound High strength oil tolerant 50 ml 135280 30 Loctite 2701 Threadlocker High strength 50 mi 234853 14 Loctite 660 Qucik Metal Retaining High strength gap filling up to 0 25 mm 50 mi 229232 32 Compound Loctite 8009 Heavy Duty Anti Seize Metal free high lubricity 453 g 504219 14 Loctite 638 Retaining Compound High strength 50 ml 234795 32 Prevent gasket failure Loctite 518 Flange Sealant General purpose up to 0 25 mm gap fill 65 ml 135480 16 between upper and lower Loctite Hysol 3478 Superior Metal Ferro silicon carbide based epoxy with 452 g 886366 32 housing split gearbox Loctite 128068 Flange Sealant Slow cure where long assembly time is 300 ml 135245 16 outstanding compressive strength needed Loctite 2701 Threadlocker High strength 50 ml 234853 32 Cover fastener Loctite 243 Threadlocker Medium strength oil tolerant 50 ml 135278 18 Repair score marks on Loctite Hysol 3478 Superior Metal Ferro silicon carbide based epoxy with 452 g 886366 34 Loctite 248 Medium Strength Threadlocker Semi solid stick medium strength 19 g stick 540491 18 cylindrical shaft outstanding compressive strength Loctite 2701 Threadlocker High strength 50 ml 234853 18 Loctite 603 Retaining Compound High strength oil tolerant 50 ml 135280 34 Loctite 8009 Heavy Duty Anti Seize Metal free high lubr
34. the housing is sealed Housings SOLUTION CHALLENGE e Rebuilding of the worn surface of the housing with Loctite Hysol 3478 Superior Metal ars E 1 Using a machining centre undercut the housing bore by 1 5 mm gt Repair and rebuild worn bearing in the worn area leaving the surface rough housing 2 Clean parts with Loctite 7063 Cleaner and Degreaser 3 Mix and apply a layer of Loctite Hysol 3478 Superior Metal and force it into the rough surface finish Build the surface above the final desired level Cause 4 Allow the adhesive to cure for 12 hours at room temperature 5 W Pend io mi Read 5 Machine the repair to the required dimensions in general press fit using diamond cutting inserts Bee ero movement an 6 Clean the rebuilt surface and the outer bearing ring with Loctite 7063 soon weal 7 Retain the joint between the housing and the outer bearing race with Loctite 2701 e Load produces axial forces that are higher than original calculations e Spun bearing caused by seizure or inappropriate loads For further technical details refer to selection chart on page 68 and 69 e YOUR ADVANTAGE e Assembly is restored unitised and ready for service without a major overhaul e Easy and fast repair method compared to alternative repair methods e Joint between housing and bearing outer race is strengthened by using Loctite Anaerobic Adhesive gt Prevent loosening and corrosion of split
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