Industrial Gearbox Service Manual
Contents
1. 18 Shaft Mounted Components Gear Sets Increase reliability and strength of a gear wheel mounted on a shaft 19 Prevent and repair keyway wear 20 Repair badly worn keyways 21 Repair worn shafts 22 Couplings Protect the spline assembly to prevent unnecessary fretting 24 Repair spline backlash 25 Prevent couplings moving due to loose setscrews 26 Increase the load capacity for flange couplings 27 Mounting Gearbox to Motor Prevent loosening of gearbox and motor mounting bolts 28 Gearbox Application Product Table 30 Contents 2 Industrial2. Bonding a sleeve on the worn shaft with LOCTITE 620 Retaining Compound STEPS 1 Determine an appropriate size of sleeve and machine the shaft to match 2 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 3 Apply a bead of LOCTITE 620 to the circumference of the shaft 4 Assemble sleeve onto the shaft 5 Wipe off excess 6 Apply the same product between the sleeve and the gear wheel Rebuilding the worn shaft with LOCTITE Fixmaster Superior Metal and bonding the gear wheel onto the shaft with LOCTITE 603 Retaining Compound 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 ODC Free Cleaner amp Degreaser 4 Apply a layer of LOCTITE Fixmaster 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 603 Retaining Compound to the components 8 Assemble using normal procedures SHAFT MOUNTED COMPONENTS GEAR SETS CHALLENGE RESULTS SOLUTION 1 SOLUTION 2 24 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 25 Protecting the spline assembly to prevent unnecessary fretting CAUSE n Wear will occur wh
3. 76764 Loctite Heavy Duty Anti Seize Metal free anti seize for use up to 2400 F 20 g stick 1 2 lbs 41205 51606 Maintenance Cleaners General cleaning of external surfaces Loctite Natural Blue Biodegradable Cleaner amp Degreaser Large parts cleaner water based 24 fl oz 82249 Cleaning and degreasing of machined parts Loctite Pro Strength Degreaser Solvent cleaner 15 oz aerosol 1578099 Cleaning and degreasing of surfaces prior to bonding Loctite ODC Free Cleaner amp Degreaser General parts cleaner prior to bonding solvent based 15 oz aerosol 22355 16 fl oz pump spray 20162 1 gallon 20260 Surface Protection Rust treatment Loctite Extend Rust Treatment Rust treatment coating 10 25 oz aerosol 30539 Corrosion protection Loctite Maxi Coat Long term corrosion protection 12 oz aerosol 51211 GEARBOX APPLICATION PRODUCT TABLE NOTES
4. RESULTS Prevent loosening and corrosion of the housing and cover fasteners to ensure gasket reliability Prevent corrosion and seizure of split gearbox alignment pins CAUSES n Cover fasteners that are rusted and seized make gearbox maintenance difficult and create additional labor associated with drilling and tapping the fastener hole n Fasteners can work loose when subjected to torque vibration thermal expansion and shock loads n Once the fasteners become loose the preload for the gasket will be lost and the gasket will fail n Dowel pins can rust and seize into component making disassembly very difficult 12 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 13 Seal threaded assemblies with LOCTITE 567 or 561 Thread Sealants STEPS 1 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply a bead of LOCTITE Thread Sealant to the leading threads of the male fitting 3 Assemble parts and allow to cure Prevent leaks from threaded fittings of lubrication and cooling systems Lubrication System Prevent oil leaks on oil drain plug oil inlet housing ventilation oil pump oil filter and gauge Cooling System Prevent leakage on the coolant pump pressure and temperature control unit and all pipe work CAUSES n Traditional thread sealants are susceptible to leaks n Pressure and temperature changes within a gearbox system can aggravate any leak n Vibration between
5. Gasket for flexible flanges such as inspection covers STEPS 1 Remove old gasketing material and other heavy contaminants with LOCTITE Chisel Paint Stripper 2 Clean both flange surfaces with LOCTITE ODC Free Cleaner amp Degreaser 3 Apply a continuous bead of LOCTITE 518 Flange Sealant or LOCTITE Instant Gasket Circle bolt holes with sealant if appropriate 4 Assemble parts and tighten as required 5 Allow to cure Prevent gasket failure between the upper and lower housing of a split gearbox Prevent leaks between the inspection cover bearing cover input output flange and housing Ensure close tolerance control of the assembly Sealing of damaged surfaces CAUSE n The use of cut gaskets is associated with several inherent problems such as gasket relaxation shrinkage extrusion and breakage that can lead to leaks When the existing gasket needs to be used as a shim use LOCTITE 534 Hi Tack Gasket Dressing Stick STEPS 1 Remove old gasket material with LOCTITE Chisel Paint Stripper 2 Clean both flanges with LOCTITE ODC Free Cleaner amp Degreaser 3 Coat flange face on both sides cover and housing with LOCTITE 534 Hi Tack Gasket Dressing Stick 4 Position the pre cut gasket 5 Assemble and tighten as required Note Accurate repositioning component assembly and tightening should be handled in a continuous workflow without interruptions n Elimination of common cut g
6. Gearbox Service Manual Industrial Gearbox Service Manual 3 Gearbox Application Diagram Rebuild and repair the bearing housing seat with LOCTITE Fixmaster Superior Metal See page 6 Remove baked on gaskets with LOCTITE Chisel Paint Stripper Clean and degrease surfaces with LOCTITE ODC Free Cleaner amp Degreaser See page 8 Prevent bearing spin and fretting with LOCTITE 603 or LOCTITE 641 Retaining Compound See page 5 and 16 Secure and prevent leakage between oil seal and housing with LOCTITE 248 Threadlocker Stick LOCTITE 480 or LOCTITE 435 Instant Adhesive See page 14 Prevent corrosion seizure and bolt loosening with LOCTITE 243 or LOCTITE 248 Medium Strength Threadlockers See page 10 Seal and lock fittings at any angle with LOCTITE 567 or LOCTITE 561 Thread Sealants See page 12 Seal rigid parts without gasket shimming using LOCTITE 518 Flange Sealant See page 8 Prevent mounting bolts from loosening or corroding with LOCTITE 2760 High Strength Threadlocker See page 28 Prevent pinion and all other gear movement with LOCTITE 620 Retaining Compound See page 19 Rebuild a worn shaft using LOCTITE Fixmaster Superior Metal See page 18 Increase the torque capacity of the flange coupling with LOCTITE 680 Retaining Compound See page 27 Repair housing cracks porosities and defects with LOC
7. for post assembly 50 ml 29031 4 Prevent bearing spin Loctite 603 Retaining Compound High strength oil tolerant 50 ml 21441 5 Loctite 640 Retaining Compound High strength 50 ml 64031 5 Loctite 641 Retaining Compound Medium strength 50 ml 21458 5 Repair and rebuild worn bearing housing Loctite Fixmaster Superior Metal Ferro silicone based epoxy with outstanding compressive strength 1 lb kit 97473 6 Loctite 2760 Threadlocker High strength primerless 50 ml 32525 6 Housing and Cover Assembly Prevent gasket failure between upper and lower housing split gearbox prevent leaks Loctite 518 Flange Sealant General purpose up to 0 25 mm gap fill 300 ml kit 22424 8 Loctite 534 Hi Tack Gasket Dressing Stick Increase the reliability of cut gasket seals 19 g stick 39156 8 Removal of cured chemical gasket Loctite Chisel Paint Stripper Aggressive gasket remover 18 oz 79040 9 Housing and cover fasteners alignment pins Loctite 243 Threadlocker Medium strength oil tolerant 50 ml 1329467 10 Loctite 248 Medium Strength Threadlocker Stick Semisolid stick medium strength 19 g stick 37087 10 Loctite 2760 Threadlocker High strength 50 ml 32525 10 Loctite Heavy Duty Anti Seize Metal free high lubricity 1 2 lb 51606 10 Lubrication and Cooling System Threaded fittings for lubrication and cooling system Loctite 567 T
8. the gearbox and lubrication cooling system leads to stress on the pipe work n Less oil consumption thereby reducing the risk of the gearbox running low on lubricant n When cured LOCTITE Thread Sealants are resistant to oil and water glycol and ensure zero leakage n Thread sealants prevent fittings from loosening yet allow easy disassembly with normal hand tools n Elimination of the potential hazards and cleanup associated with oil leaks n Elimination of seized fittings because moisture and air have been sealed out n Elimination of rust and corrosion within the thread space n Contaminants prevented from getting into the oil through the gaps in the threads n Reduced coolant consumption LUBRICATION AND COOLING SYSTEM CHALLENGE SOLUTION RESULTS 14 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 15 FOR METALLIC OIL SEALS Fill the air spaces by applying LOCTITE 243 or 248 Medium Strength Threadlocker to the outside diameter of the oil seal STEPS 1 Clean the bonding surfaces of the oil seal and the gearbox with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply the adhesive recommended for the different kinds of oil seals to the outside diameter of the oil seal Note In the case of a cassette seal apply adhesive onto the cleaned shaft as well 3 Press the oil seal into position using normal techniques and wipe off any excess Prevent leaks between the gearbox housing and oil se
9. 7 Prevent couplings from moving due to loose setscrews Ensure optimum assembly life in on site conditions CAUSES n Couplings are commonly held in place by a key and a setscrew n Coupling assemblies are subjected to vibration and high loads which can cause threaded fasteners to loosen n Typically couplings are assembled on site for this reason it is difficult to ensure that tightening specifications are followed Secure all threaded fasteners on couplings using LOCTITE 243 or 248 Medium Strength Threadlocker STEPS 1 Clean the components with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply LOCTITE 243 or 248 Medium Strength Threadlocker to all threaded fasteners 3 Align the coupling and assemble 4 Tighten each fastener within 5 minutes of assembly n All fasteners are secured in place n Prevention of misalignment and coupling failure Upgrade the load capacity of existing flange drive couplings Reuse worn flange couplings CAUSES n The transmittable torque of a flange drive coupling is limited by the friction of the surfaces n Overloading causes slippage and wear of the coupling surface Use LOCTITE 680 High Strength Retaining Compound on the flange face to increase the torque capacity Increase torque capacity without any mechanical changes STEPS 1 Clean the surfaces with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply a thin film of LOCTITE 680 High Str
10. 7 n Assembly is restored unitized and ready for service without a major overhaul n Easy and fast repair method compared to alternative repair methods n Joint between housing and bearing outer race is strengthened by using Loctite adhesive Rebuild worn housing surface with LOCTITE Fixmaster Superior Metal STEPS 1 Machine the housing by undercutting in the bore by 1 5 mm in the worn area leaving the surface rough 2 Clean parts with LOCTITE ODC Free Cleaner and Degreaser 3 Mix and apply a layer of LOCTITE Fixmaster Superior Metal and force it into the rough surface finish Build the surface above the final desired level 4 Allow the adhesive to cure for 12 hours at room temperature 5 Machine the repair to the required dimensions typically a press fit using diamond cutting inserts 6 Clean the rebuilt surface and the outer bearing ring with LOCTITE ODC Free Cleaner amp Degreaser 7 Retain the joint between the housing and the outer bearing race with LOCTITE 2760 Threadlocker Repair and rebuild worn bearing housing CAUSES n Worn components lead to micro movement and additional wear n Load produces axial forces that are higher than original calculations n Spun bearing caused by seizure or inappropriate loads CHALLENGE SOLUTION RESULTS HOUSING 8 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 9 Use LOCTITE 518 Flange Sealant Use LOCTITE Instant
11. Except as otherwise noted all marks are trademarks and or registered trademarks of Henkel and or its affiliates in the U S and elsewhere registered in the U S Patent and Trademark Office 2013 Henkel Corporation All rights reserved 10773 LT 4872 10 13 U S A Henkel Corporation Engineering Adhesives One Henkel Way Rocky Hill Connecticut 06067 Tel 1 800 LOCTITE 562 8483 Tel 1 860 571 5100 Fax 1 860 571 5465 www henkelna com mro Canada Henkel Canada Corporation Engineering Adhesives 2515 Meadowpine Blvd Mississauga Ontario L5N 6C3 Tel 1 800 263 5043 within Canada Tel 1 905 814 6511 Fax 1 905 814 5391 Industrial Gearbox Service Manual i Industrial Gearbox Service Manual Industrial Gearbox Service Manual 1 Contents 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 Easily select the right LOCTITE products to help you service the wide variety of gearbox assemblies Prevent wear proactively Pinpoint the most suitable solution for servicing worn parts 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 ra
12. TE 290 Wicking Grade Threadlocker to the mounting bolts MOUNTING GEARBOX TO MOTOR CHALLENGE SOLUTION 1 RESULTS SOLUTION 2 30 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 31 APPLICATION LOCTITE SOLUTION BENEFITS PACKAGE SIZE PART NO PAGE Shaft Mounted Component Bearings Prevent bearing spin Loctite 641 Retaining Compound Medium strength 50 ml 21458 16 Loctite 603 Retaining Compound High strength oil tolerant 50 ml 21441 16 Loctite 660 Retaining Compound High strength gap filling up to 0 020 50 ml 66040 16 Repair worn shafts Loctite Fixmaster Superior Metal Ferro silicone based epoxy with outstanding compressive strength 1 lb kit 97473 18 Loctite 603 Retaining Compound High strength oil tolerant 50 ml 21441 18 Shaft Mounted Component Gear Sets Gear mounted on a shaft Loctite 620 Retaining Compound High temperature high strength 50 ml 62040 19 Secure keys and repair slightly worn keyways Loctite 243 Threadlocker Medium strength primerless 50 ml 1329467 20 Loctite 660 Retaining Compound High strength gap filling up to 0 020 50 ml 66040 20 Repair badly worn keyways Loctite Fixmaster Superior Metal Ferro silicone based epoxy with outstanding compressive strength 1 lb kit 97473 21 Loctite 243 Threadlocker Medium strength oil tolerant 50 ml 1329467 21 Repair worn shafts Lo
13. TITE Fixmaster Steel Putty Metal Filled Epoxy See page 4 Prevent corrosion and seizure of dowel pins with LOCTITE Heavy Duty Anti Seize See page 10 Prevent keyway wear with LOCTITE 243 Threadlocker or repair keyway wear with LOCTITE 660 Retaining Compound See page 20 Make any size or shape gasket for flexible covers and covers with large bolt spacing use LOCTITE Instant Gasket for rigid assemblies use LOCTITE 518 Flange Sealant See page 8 4 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 5 n Quick return to service n Reduce scrap by salvaging and extending the life of gearbox housing and cover Seal porosities up to 0 05 mm using LOCTITE 290 Threadlocker medium strength wicking STEPS 1 Thoroughly clean and dry the components with LOCTITE ODC Free Cleaner amp Degreaser ensuring the porosity is oil free 2 Brush LOCTITE 290 Threadlocker into the porosities 3 Allow to cure typically for 3 hours 4 Clean off excess product Repair housing and cover defects Seal oil leaks due to damaged housing CAUSES n Gearbox housings may be porous n Service or repair work may cause damage to gearbox housings and covers HOUSING Filling damaged areas with LOCTITE Fixmaster Steel Putty metal filled epoxy STEPS 1 Thoroughly clean and dry the components with LOCTITE ODC Free Cleaner amp Degreaser ensuring the repair area is o
14. al Prevent movement of oil seal in housing CAUSES n As with any press fit there are small air spaces between the housing and the oil seal and this air space can create a leak path n In the case of a split gearbox housing T joints are potential leakage points n A sealed assembly eliminates leaks contamination and corrosion n Movement of oil seal during running is eliminated n The oil seal can still be easily removed with a screwdriver during the next overhaul FOR ELASTOMER OIL SEALS Fill the air spaces by applying LOCTITE 435 Instant Adhesive to the outside diameter of the oil seal For longer positioning time and oil seal diameter larger than 60 mm use LOCTITE 480 Instant Adhesive In the case of a cassette seal also bond the inside diameter to the shaft using LOCTITE 435 Instant Adhesive SHAFT SEALS CHALLENGE SOLUTION 2 RESULTS SOLUTION 1 16 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 17 FOR GAPS UP TO 0 020 0 5 mm Bond using LOCTITE 660 Retaining Compound and LOCTITE 7649 Primer STEPS 1 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply LOCTITE 7649 Primer to the inner bearing race 3 Apply a bead of LOCTITE 660 to the circumference of the shaft 4 Assemble the components 5 Wipe off excess Prevent bearing spin Prevent downtime and scrap costs CAUSES n Bearings are prone to s
15. aner amp Degreaser 4 Apply a layer of LOCTITE Fixmaster Superior Metal and build the surface above the final desired level 5 Allow the adhesive to cure for 6 hours at room temperature 6 Machine the repair with a diamond tipped tool to the required dimensions 7 Apply LOCTITE 7649 Primer to the rebuilt area of the shaft 8 Apply LOCTITE 603 to the inner bearing race Increase reliability and strength of a gear mounted on a shaft CAUSES n Incorrect reassembly during maintenance leading to micro movements n Overload conditions and elevated operating temperatures n Assembly is strengthened by using a Loctite Retaining Compound Bond gear wheels directly onto the shaft with LOCTITE 620 High Strength Retaining Compound STEPS 1 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply a bead of LOCTITE 620 to the circumference of the shaft 3 Press the gear onto the shaft using normal techniques 4 Wipe off excess material SHAFT MOUNTED COMPONENTS BEARINGS SHAFT MOUNTED COMPONENTS GEAR SETS n Cylindrical joint is strengthened by using a LOCTITE Retaining Compound n Shaft is repaired to provide full surface contact n Quick return to service n Extended shaft life n Reduce component consumption CHALLENGE RESULTS SOLUTION CHALLENGE RESULTS SOLUTION 20 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 21 Secure the key in the k
16. asket failures such as compression set shrinkage relaxation and breaks n Constant clamp load is ensured n Elimination of oil leaks between the bearing frame and frame adapter along with associated cleanup costs and hazards n Reduced oil consumption and risk of running low on oil n Eliminate corrosion on the flange surface n Ensures all potential leak paths are filled and sealed HOUSING AND COVER ASSEMBLY CHALLENGE SOLUTION 2 RESULTS SOLUTION 1 10 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 11 Apply LOCTITE 243 or 248 Medium Strength Threadlocker to the housing fasteners Use LOCTITE 2760 Threadlocker for high strength or on stainless steel and plated fasteners If locking of the fasteners is not required use LOCTITE Heavy Duty Anti Seize STEPS 1 Clean the threads and pins with LOCTITE ODC Free Cleaner and Degreaser 2 Apply LOCTITE 243 or 248 Medium Strength Threadlocker to the housing fasteners Apply LOCTITE 2760 High Strength Threadlocker if stainless steel or plated fasteners are in use 3 Apply LOCTITE Heavy Duty Anti Seize onto the dowel pin Note If a liquid gasket is in use ensure only a very thin layer of LOCTITE Heavy Duty Anti Seize is applied 4 Assemble and tighten n Correct clamp load is maintained n Elimination of rust and seizure n Easy disassembly with normal hand tools HOUSING AND COVER ASSEMBLY CHALLENGE SOLUTION
17. ctite 620 Retaining Compound High temperature high strength 50 ml 62040 22 Loctite Fixmaster Superior Metal Ferro silicone based epoxy with outstanding compressive strength 1 lb kit 97473 22 Loctite 603 Retaining Compound High strength oil tolerant 50 ml 21441 22 Couplings Protecting the spline assembly Loctite Moly Paste High lubricity heavy load capacity moly paste brush top 1 lb 51049 24 Repair spline Loctite 660 Retaining Compound High strength gap filling up to 0 020 50 ml 66040 25 Loctite Fixmaster Superior Metal Ferro silicone based epoxy with outstanding compressive strength 1 lb kit 97473 25 Prevent coupling movement Setscrews Loctite 243 Threadlocker Medium strength oil tolerant 50 ml 1329467 26 Loctite 248 Medium Strength Threadlocker Stick Semisolid stick medium strength 19 g stick 37087 26 Upgrade load capacity reuse worn flange couplings Loctite 680 Retaining Compound High strength 50 ml 1835201 27 Mounting Gearbox to Motor Mounting fasteners Loctite 290 Threadlocker Wicking for post assembly 50 ml 29031 28 Loctite 2760 Threadlocker High strength primerless 50 ml 32525 28 APPLICATION LOCTITE SOLUTION BENEFITS PACKAGE SIZE PART NO PAGE Housing Defects and porosities Loctite Fixmaster Steel Putty Steel filled repair epoxy 1 lb kit 99913 4 Loctite 290 Threadlocker Wicking
18. ength Retaining Compound on the entire surface of the coupling flange 3 Once you start to assemble torque bolts within 10 minutes 4 Allow to cure before applying full load n Improved torque capacity without mechanical changes n Eliminates micro movement and loss of joint tension n Eliminates corrosion COUPLINGS CHALLENGE RESULTS SOLUTION CHALLENGE RESULTS SOLUTION 28 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 29 Secure motor and gearbox to the bedplate system Prevent misalignment caused by loosening under high loads and vibration CAUSES n Vibration and shock load can loosen fasteners and mounting bolts n Loose bolts result in movement which in turn causes misalignment Apply LOCTITE 2760 High Strength Threadlocker to the mounting bolts STEPS 1 Clean threads with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply several drops of LOCTITE 2760 High Strength Threadlocker to the mounting bolts 3 Assemble and tighten as usual n Mounting bolts and fasteners are secured in place n Eliminate vibration loosening n Eliminate bolt corrosion n Prevent misalignment Apply LOCTITE 290 Wicking Grade Threadlocker to the mounting bolts after the gearbox has been leveled and aligned STEPS 1 Clean the parts with LOCTITE ODC Free Cleaner amp Degreaser 2 Align the gearbox 3 Tighten the nuts on the mounting studs 4 Apply several drops of LOCTI
19. ere there is friction and movement in the spline Use LOCTITE Moly Paste proactively to reduce friction and wear STEPS 1 Clean mating surface with LOCTITE ODC Free Cleaner amp Degreaser 2 Coat mating surface with LOCTITE Moly Paste 3 Assemble parts n Prevention of wear caused by friction n Prevention of corrosion n LOCTITE Moly Paste provides very high lubricity and heavy load capacity For repair of a non sliding spline with backlash STEPS 1 If possible abrasive blast the surface of the spline shaft and socket 2 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 3 Check the spline area for uniformity 4 Apply LOCTITE Fixmaster 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 Primer 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 n Assembly is restored and ready for service without a major overhaul COUPLINGS CHALLENGE RESULTS SOLUTION Protecting the spline assembly to prevent unnecessary fretting CAUSE n Wear will occur where there is friction and movement in the spline CHALLENGE RESULTS SOLUTION 26 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 2
20. eyway on new equipment Prevent micro movements that lead to wear Repair worn keyways CAUSES n Alternating loads and combined loading result in micro movement wear and loose parts n Over time wear can cause keys to loosen leading to damage of the keyway Repair badly worn keyways CAUSES n Alternating loads and combined loading results in micro movement wear and loose parts n Over time wear can cause keys to loosen leading to damage of the keyway n The assembly is restored and ready for service without a major overhaul n The key is secured into the keyway NEW KEYWAY IN EXISTING SHAFT AND GEAR If parts are badly worn it may be necessary to cut new keyways in this case the old keyway should be filled with metal filled epoxy STEPS 1 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 2 Mix and apply LOCTITE Fixmaster Superior Metal into the keyway of both the shaft and gear 3 Allow to cure 4 Machine the cured adhesive to the original dimensions of the shaft and bore of the gear 5 Machine a new keyway in the shaft and gear opposite the original keyway 6 Clean again with LOCTITE ODC Free Cleaner amp Degreaser 7 Apply several drops of LOCTITE 243 Threadlocker directly into new keyway and insert key 8 Wipe off excess 9 Assemble the components 10 Allow to cure SHAFT MOUNTED COMPONENTS GEAR SETS n Eliminate mirco movement which leads to fretting n Prevent keyway wallo
21. hread Sealant General purpose 50 ml 56747 12 Loctite 561 Thread Sealant Stick Semisolid stick controlled strength 19 g stick 37127 12 Shaft Seals Prevent leaks between oil seal and housing Loctite 248 Medium Strength Threadlocker Stick Semisolid stick medium strength 19 g stick 37087 14 Loctite 435 Instant Adhesive Transparent toughened fast cure 20 g 40994 14 Loctite 480 Instant Adhesive Black toughened 20 g 48040 14 Loctite 243 Medium Strength Threadlocker Medium strength oil tolerant 50 ml 1329467 14 GEARBOX APPLICATION PRODUCT TABLE Industrial Gearbox Service Manual 33 32 Industrial Gearbox Service Manual APPLICATION LOCTITE SOLUTION BENEFITS PACKAGE SIZE PART NO Maintenance Lubrication To free rusted corroded and seized parts during dismantling Loctite Freeze amp Release Freezing action plus penetrating oil 13 52 fl oz aerosol 996456 Assembly aid for all assembly works Loctite ViperLube High Performance Synthetic Grease High performance grease 14 oz cartridge 36782 Loctite Moly Paste High lubricity heavy load capacity moly paste brush top 1 lb 51049 Protection for fasteners and alignment pins Loctite C5 A Copper Anti Seize Copper based general purpose use up to 1800 F 20 g stick 1 lb 37229 51007 Loctite Silver Grade Anti Seize General purpose for use up to 1600 F 20 g stick 1 lb 37230
22. il free 2 Mix and apply LOCTITE Fixmaster Steel Putty 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 n Bearing movement is eliminated n Bearing can be easily removed with standard tools n Corrosion is eliminated because the air space between the bearing and the housing is sealed LOCTITE 641 Retaining Compound is medium strength allowing for easy disassembly during future overhauls Alternatively use LOCTITE 603 Retaining Compound for a high strength joint STEPS 1 Clean the mating surfaces with LOCTITE ODC Free 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 Prevent bearing spin corrosion and housing damage CAUSES n Bearing outer races are prone to spinning within their housings resulting in dam age to the housing regardless of whether or not they have been pressed or shrink fitted in place n The air space between a bearing and housing is an area susceptible to rust and fretting corrosion thus causing damage to the parts CHALLENGE SOLUTION 1 SOLUTION 2 RESULTS CHALLENGE SOLUTION RESULTS 6 Industrial Gearbox Service Manual Industrial Gearbox Service Manual
23. ime of equipment To speak with someone in our technical service department or to contact your local sales representative call 1 800 LOCTITE 562 8483 or 1 800 263 5043 in Canada Introduction Introduction i Gearbox Application Diagram 2 Housing Repair housings and covers Damaged surfaces and porosities 4 Prevent bearing spin corrosion and housing damage 5 Repair and rebuild worn bearing housing 6 Housing and Cover Assembly Prevent gasket failure between the upper and lower housing of a split gearbox 8 Prevent loosening and corrosion of the cover fasteners 10 Lubrication and Cooling System Prevent leaks from threaded fittings for the lubrication and cooling system 12 Shaft Seals Prevent leaks between the gearbox housing and oil seal 14 Shaft Mounted Components Bearings Prevent bearing spin 16 Repair worn cylindrical shaft
24. nge of Loctite products to Repair and prevent gearbox failures on site to minimize downtime Reclaim worn or damaged assemblies to avoid scrap and replacement costs Assist in assembly installation and disassembly Ensure reliability and smooth running by restoring performance to as new condition The Industrial Gearbox Service Manual Solves Real Problems The applications described in the Industrial Gearbox Service Manual are based on a bevel helical gearbox configuration They apply equally for helical gearboxes worm gear units and geared motors The Industrial Gearbox Service Manual is designed as a practical guide to provide information covering key gearbox assembly groups Feasibility Confirmed The recommendations given in this Industrial Gearbox Service Manual are based on collaboration with customers institutes and universities to establish their validity and confirm that these methods are operable practical and indeed the best solutions for servicing and repairing gearbox assemblies Profit from Reliability Henkel provides products for cost efficient easy and effective gearbox maintenance and repair 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 lifet
25. pinning on their shaft this results in damage n Load produces axial forces that are higher than original calculations n Cylindrical joint is strengthened by using a Loctite Retaining Compound n Shaft is repaired to provide full surface contact n Quick return to service n Extended shaft life n Reduce component consumption FOR GAPS UP TO 0 005 0 1 mm 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 ODC Free Cleaner amp 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 SHAFT MOUNTED COMPONENTS BEARINGS CHALLENGE RESULTS SOLUTION SOLUTION 18 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 19 Repair worn cylindrical shafts or gaps exceeding 0 020 0 5 mm CAUSE n Spun bearing caused by insufficient interference or inappropriate loads Rebuild with LOCTITE Fixmaster Superior Metal to the original diameter and bond the bearing onto the rebuilt shaft with LOCTITE 603 Retaining Compound STEPS 1 Using a lathe undercut the shaft in the worn area 1 5 mm deep 2 Dovetail the ends of the worn area to lock the application into place and leave a rough surface 3 Clean parts with LOCTITE ODC Free Cle
26. w n Prevent corrosion n A unitized assembly NEW COMPONENTS Proactively apply a LOCTITE Medium Strength Threadlocker to eliminate any future wear of the key or keyway STEPS 1 Clean the keyway and key stock with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply several drops of LOCTITE 243 Medium Strength Threadlocker directly into the keyway 3 Insert the key stock into the keyway Note Cover the shaft with a rag to prevent splatter when inserting the key stock 4 Wipe off any excess threadlocker SLIGHTLY WORN KEYWAYS LOCTITE 660 Retaining Compound Compound is a very thick product allows it to fill large gaps STEPS 1 Clean the keyway and key stock with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply LOCTITE 660 Retaining Compound into the keyway 3 Assemble parts and wipe off excess Note If keyway wallow is severe shims can be used on both sides of the keyways in conjunction with the LOCTITE 660 Retaining Compound CHALLENGE SOLUTION 1 SOLUTION 2 RESULTS CHALLENGE SOLUTION RESULTS 22 Industrial Gearbox Service Manual Industrial Gearbox Service Manual 23 Repair worn shafts CAUSES n Incorrect reassembly during maintenance leading to micro movements n Overload conditions and elevated operating temperatures n Assembly is strengthened by using a Loctite Retaining Compound n Assembly is restored and ready for service without a major overhaul
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