Professional Documents
Culture Documents
S40B Series Service Manual-9!3!2013
S40B Series Service Manual-9!3!2013
Rev 09/03/13
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.
2
Planetary Final Drive Service Manual
Content
Introduction 4
Roll and Leak Test 5
Tightening and Torquing Bolts 7
Lubrication Information 8
Disassembly Instructions Main Disassembly 12
Cover Disassembly 14
Housing-Spindle Disassembly 15
Output Carrier Disassembly 18
Input Carrier Disassembly 19
Assembly Instructions Cover Subassembly 21
Input Carrier Subassembly 22
Output Carrier Subassembly 24
Housing-Spindle Subassembly 26
Main Assembly 30
Assembly Drawing 32
Parts List 33
Assembly Tools 35
General Information Contact Information 47
3
Planetary Final Drive Service Manual
Introduction
This manual is a step-by-step guide to the disassembly and
®
assembly of the S40B SeriesTorque-Hub units with ratios of XX:X
or lower. It is designed for the customer or mechanic who is
®
repairing this particular Torque-Hub model.
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.
4
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 Roll Test The purpose of the roll test 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.
S40B105525ZY T224477
5
The Leak Test 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
PRESSURE DURING THE LEAK TEST. Higher pressure will create
a false sealing effect in assemblies with lip-seals. The unit has a
leak if the pressure gauge reading on your leak check fitting starts
to fall after the gearbox has been pressurized and allowed to
equalize. Leaks will most likely occur at the pipe plugs, the main
seal or wherever o-rings or gaskets are located. The exact location
of a leak can usually be detected by brushing a soap and water
solution around the main seal and where the o-rings or gaskets
meet on the exterior of the unit and then checking for air bubbles. If
a leak is detected in a seal, o-ring or gasket, the part must be
replaced and the unit rechecked. Leak test at 10 psi for 20 minutes.
S40B105525ZY T173814
6
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.
2. Go to the opposite side of the bolt circle and tighten bolt “B” until
equally snug.
3. Crisscross around the bolt circle and tighten the remaining bolts.
5. Using the same sequence, crisscross around the bolt circle and
apply an equal torque to the remaining bolts.
7
Planetary Final Drive Service Manual
Lubrication Information
®
General Properties The lubricant used in most Torque-Hub drives should be
petroleum-based gear fluid containing anti-oxidation, anti-foaming
and extreme pressure additives. The lubricant should have a
minimum viscosity index of 95 cst and maintain a minimum viscosity
of 40 cst under normal operating conditions. Some applications
require special considerations; consult the machine manufacturer
and Oerlikon Fairfield for more additional information.
8
®
Maintenance 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.
9
DISASSEMBLY
10
THIS PAGE
INTENTIONALLY
LEFT BLANK
11
Planetary Final Drive Service Manual
Main Disassembly
1. Perform a roll check and a leak check prior to disassembling the unit.
2. Remove two magnetic Pipe Plugs (14) and drain oil out of gearbox.
12
5. Remove the Input Sun Gear (6).
7. Remove Flanged Bolts (11) from Ring Gear thru Hun Spindle subassembly.
9. Remove External Retaining Ring (26) from the groove on Sun Gear (7).
10. Remove Bolts (28) and remove the Locking Plate (27) from Internal Coupling (1H).
11. Lift out the Output Carrier Subassembly from Hub-Spindle Subassembly.
13
Planetary Final Drive Service Manual
Cover Disassembly
1. Remove the O-Ring (8) from groove in the Cover Plate (5) and discard it.
4. Remove Thrust Washer (9) from the groove on the Cover Plate (5).
14
Planetary Final Drive Service Manual
Housing-Spindle Disassembly
1. Set the unit on a bench so that the Spindle (1A) flange is down.
15
2. Remove O-Ring (25) from the Housing (1G) and discard it.
CAUTION: The Shim edges are sharp; wear gloves when handling or installing Shims to
prevent injury.
7. Remove Bearing Cone (1F) from spline end of the Internal Coupling (1H).
8. Turn over the unit 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.
9. Using a dead blow hammer on the Housing (1G) flange to drive the Hosing (1G) off of the
Spindle (1A).
11. Remove the Boot Seal (1U) from the Housing (1G).
16
12. Remove the Face Seal (1B) from the Housing (1G) and Spindle (1A).
13. Remove outboard Bearing Cone (1D) from the Housing (1G).
14. Using a hammer and punch drive the inboard Bearing Cup (1E) out of the Housing (1G). Be
careful not to damage the counter bore in the housing.
15. Turn the Housing (1G) over and drive the outboard Bearing Cup (1C) out of the Housing. Be
careful not to damage the counter-bore in the housing.
17
Planetary Final Drive Service Manual
Output Carrier Disassembly
1. Unbend the tang of Lock-Tanged Washer (2I) from the Bearing Nut (2H) and remove the
Bearing Nut (2H) from the Planet Shaft (4K).
3. Remove Lock Pin (2J) from the slot of the Carrier (4A) and Planet Shaft (4K).
5. Slide out the Planet Gear Subassembly from the window of the Carrier (4A).
6. Remove Thrust Washer (2F) from the window of the Carrier (4A).
7. Remove Bearing Cones (4D) from the bore of the Planet Gear (4B).
8. Remove Bearing Cups (4C) from the bore of the Planet Gear (4B).
9. Remove Thrust Spacer (4F) from the bore of the Planet Gear (4B).
10. Remove Retaining Ring (4E) from internal groove of the Planet Gear (4B).
11. Repeat the steps 1 through 9 for the remaining two Planet Gears (4B).
18
Planetary Final Drive Service Manual
Input Carrier Disassembly
1. Unbend the tang of Lock-Tanged Washer (2I) from the Bearing Nut (2H) and remove the
Bearing Nut (2H) from the Planet Shaft (2K).
3. Remove Lock Pin (2J) from slot of the Carrier (3A) and Planet Shaft (2K).
5. Slide out Planet Gear Subassembly from the window of Carrier (2A).
6. Remove Thrust Washer (2F) from the window of the Carrier (2A).
7. Remove Bearing Cones (2D) from the bore of the Planet Gear (2B).
8. Remove Bearing Cups (2C) from the bore of the Planet Gear (2B).
9. Remove Thrust Washer (2E) from the bore of the Planet Gear (2B).
10. Remove Retaining Ring (2G) from the internal groove of the Planet Gear (2B).
11. Repeat steps 1 through 9 for the remaining two Planet Gears (2B).
19
ASSEMBLY
20
Planetary Final Drive Service Manual
Cover Subassembly
2. Grease and install Thrust Washer (9) onto Cover (5). The grease should hold washer in
place for assembly.
5. Grease and install Thrust Washer (17) onto Cover (5). The grease should hold washer in
place for assembly.
6. Grease and install O-Ring (8) into groove on Cover (5). Insure that the O-Ring (8) is fully
seated against the inner diameter.
21
Planetary Final Drive Service Manual
Input Carrier Subassembly
1. Place Planet Gear (2B) onto press table. Install Retaining Ring (2G) into the groove of the
Planet Gear (2B).
3. Apply grease and install Thrust Washer (2E) onto the bore of the Planet Gear (2B)
4. Use Tool T-159309 and install Bearing Cups (2C), with wide face into bore of the Planet
Gear (3F). Insure that Bearing Cup has seated completely against Retaining Ring and
Thrust Washer in the respective sides.
5. Install Bearing Cone (2D) into Bearing Cup (2C) on both sides of the Planet Gear (2B).
6. Apply grease and install Thrust Washer (2F) on planet shaft bore top side in Carrier (2A)
planet gear window.
7. Slide Planet Gear (2B) assembly into planet window of Carrier (2A).
8. Align planet shaft bore in Planet Gear (2B) with Thrust Washer (2F) bore and Carrier (2A)
planet shaft bore.
22
9. Inspect Planet Shaft (2K) for nicks and burrs. Insure that planet shaft hole and planet shaft
are free from debris, burrs, sharp corners. Start the Planet Shaft (3E) on the wide side of the
Carrier (2A). Install Planet Shaft (2K) through large diameter in the carrier hole and through
planet gear bearing inner race by aligning the lock pin slot in both carrier and planet shaft.
10. Install Lock Pin (2J) into lock pin slot in Carrier (2A) and Planet Shaft (2K).
11. Install Tanged Lock Washer (2I) onto Planet Shaft (2K).
12. Clean threads on Planet Shaft and Bearing Nut. Apply Loctite-263 and install Bearing Nut
(2H) onto Planet Shaft (2K) by using tool T-136699 Tighten Bearing Nut (2H) and measure
rolling torque of planet gear using a fish scale. Torque Bearing Nut (2H) until 1.5 – 2 lbs of
drag is achieved while rolling Planet Gear (2B).
14. Repeat steps from 2 through 14 for the remaining Planet Gears (2B).
23
Planetary Final Drive Service Manual
Output Carrier Subassembly
1. Place Planet Gear (4B) onto press table. Install Internal Retaining Ring (4E) into the groove
of Planet Gear (4B).
NOTE: In step below insure to install the Spacer (4F) into the deepest bore side from the
retaining groove of the Planet Gear (4B).
2. Install Spacer (4F) into bore of the Planet Gear (4B) onto Retaining Ring (4E).
3. Use tool T-159309 and install both Bearing Cups (4C) with wide face outside into bore of the
Planet Gear (4B). Insure that the Bearing Cups are seated completely against the retaining
ring and thrust washer in the respective sides.
4. Install Bearing Cone (4D) into Bearing Cup (4C) on both sides of the Planet Gear (4B).
5. Apply grease and install Thrust Washer (2F) on planet shaft bore top side in Carrier (4A)
planet gear window.
24
6. Slide Planet Gear (4B) assembly into planet window of Carrier (2A) with Retaining Ring (4E)
towards internal spline.
7. Align planet bore in Planet Gear (4B) with Thrust Washer (2F) bore and Carrier (4A) planet
shaft bore.
8. Inspect the Planet Shaft (4K) for nicks and burrs. Insure that the planet shaft hole and Planet
Shaft (4K) are free from debris, burrs, and sharp corners. Start the Planet Shaft (4K) on the
wide side of the Carrier (4A). Install Planet Shaft (4K) through the large diameter in the
Carrier (4A) hole and through Planet Gear (4B) bearing inner race by aligning the lock pin
slot in both Carrier (4A) and Planet Shaft (4K).
9. Install Lock Pin (2J) into lock pin slot in Carrier (4A) and Planet Shaft (4K).
11. Apply Loctite-263 and install Bearing Nut (2H) onto Planet Shaft (4K) by using tool T-136699
.Tighten Bearing Nut (2H) and measure rolling torque of Planet Gear (4B) using a fish scale
Torque Bearing Nut (2H) until 1.5 – 2 lbs of drag is achieved when rolling Planet Gear (4B).
13. Repeat steps from 1 through 13 for the remaining Planet Gears (4B).
25
Planetary Final Drive Service Manual
Housing Spindle Subassembly
1. Place Hub (1A) on table such that long hub end is up.
2. Using alcohol and a clean rag, wipe off bearing locations on the Housing (1G) and the
Spindle (1A).
3. Press one Bearing Cup (1E) into bearing counter bore of spindle end of housing until seated
against shoulder in housing. Use Tool T-125034.
4. Turn Housing (1G) over and press one Bearing Cup (1C) using Tool T-125033 into bearing
counter bore of cover end of Housing (1G) making sure that it is fully seated against
shoulder in the housing.
5. Press Bearing Cone (1D) into Spindle (1A) with assembly pressing tool T-160835 and spray
with a light coat of oil.
6. Using alcohol and a clean rag, wipe off seal locations on the Housing (1G) and Spindle (1A).
7. All of the Sealing components, seal ring, energizers, housing and installation tool, must be
clean and free of oil, grease, dirt or dust. Use denatured alcohol and a lint free cloth to clean
all of these areas.
26
8. Ensure there are no nicks or burrs on the installation radius that could damage the seal
during installation.
9. Place one half of the Face Seal (1B) into the seal counter-bore of the Spindle (1A).
10. Place one half of the Face Seal (1B) into the seal counter-bore of the Housing (1G).
12. Using alcohol and a clean rag, thoroughly clean the metal faces of both halves of the Face
Seal (1B) then coat with gear oil. Do not allow face seal to contact bench or get damaged
when flipping over.
13. Press Bearing Cone (1F) onto Internal Coupling (1H). Place Internal Coupling onto Hub
(1G).
14. Lift Hub (1G) and lower onto Spindle (1A), while lowering engage Carrier-coupling (1H)
splines onto spindle (1A) splines. As splines begin to engage, stop lowering the hub (1G).
Look to check for correct alignment of the Face Seal (1B). Slowly lower the hub (1G) while
slowly rotating the hub (1G). If while rotating the hub (1G) the Face Seal (1B) rotates,
STOP, RE-ALIGN the Face Seal (1B) and continue to lower the Hub (1G) while checking the
alignment of the Hub (1G) to the Face Seal (1B).
15. *****NOTE! The Face Seal is properly aligned: when the Hub (1G) can be rotated without
rotating the Face Seal (1B) and the upper half of the Face Seal (1B) is partially installed into
the hub (1G). With the Face Seal (1B) properly aligned and not rolled over finish lowering
the hub (1G) until completely down against the Face Seal (1B).
16. Place Bearing Plate (1L) onto end of Shaft (1A). Install 4 Bolts (1J) (equally spaced) through
Bearing Plate into Shaft. Tighten Bolts (1J) to 200 in.-lbs. in 50 in.-lbs. increments Rolling
Hub (1G) until Bolt torque holds at 200 in.-lbs.
27
17. Measure depth from the face of the Bearing Plate to the surface of the Shaft. Subtract the
average thickness of the Bearing Plate. Add .004 to this difference to get required shim pack
thickness. Round the dimension down to get a correct shim pack thickness.
CAUTION: The Shim edges are sharp; wear gloves when handling or installing Shims to
prevent injury.
18. Place the shim pack on the end of the Shaft (1A), place the Bearing Plate (1L) on the Shim
Pack (1I). Install Bolts (1J) with Loctite 272 through Bearing Plate and into the Shaft. Tighten
Bolts evenly and roll the Hub to seat the bearings. Torque Bolts (1J) to 30-35 ft.-lbs., safety-
wire in pairs.
28
THIS PAGE
INTENTIONALLY
LEFT BLANK
29
Planetary Final Drive Service Manual
Main Assembly
NOTE: Spray component parts with a liberal amount of oil as they are being assembled.
1. Clean the internal threads of Internal Coupling (1H) and of Bolts (28).
2. Lower Output Carrier Subassembly into Internal Coupling (1H), in mesh with the splines.
3. Place Retainer Plate (27) into the groove of the Carrier and onto Internal Coupling (1H).
Install Bolts (28) through Retainer plate (27) into Internal Coupling (1H) with Loctite-243 and
torque to 130-150 in-lbs.
4. Install Retaining Ring (26) into groove of Sun Gear (7). Install Sun Gear (7) into mesh with
Planet Gear (4B) against Spindle (1A).
5. Install Ring Gear (18) onto Hub (1G) aligned with Dowel Pin (13) and into mesh with Planet
Gears (4B). Install 20 Flanged Bolts (11) through Hub (1G) with Loctite-243. Torque them to
220-250 ft-lbs.
6. Install Carrier Sub Assembly to mesh with Ring Gear (18) and Sun Gear (7) spline.
7. Install Sun Gear (6) to mesh with Planet Gear (2B) and against Output Sun Gear (7).
30
Continued on Next Page
9. Install Bolts (12) through Cover into Ring Gear (18) and torque them to 35-45 ft-lbs.
10. Install Pipe Plugs (14) with thread sealant into Cover.
11. The unit should now be leak and roll checked as per instructions on page 5 and 6. 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.
31
Planetary Final Drive Service Manual
Assembly Drawing
32
Planetary Final Drive Repair Instructions
Parts List
33
Number Qty Description
15 1 ID PLATE
16 2 SCREW DRIVE
17 1 THRUST WASHER
18 1 RING GEAR
25 1 O-RING
26 1 EXTERNAL RETAINING RING
27 3 RETAINER PLATE
28 6 BOLT
1X 1 PIPE PLUG
1T 1 PIPE PLUG
1K 2 MAGNETIC PIPE PLUG
1V 3 PIPE PLUG
1U 1 SEAL BOOT
1P 1 BEARING CARRIER
34
Planetary Final Drive Repair Instructions
Assembly Tools
35
T125034 – BEARING CUP ASSEMBLY ADAPTOR
36
T164786 – ALIGNMENT PIN FOR ASSEMBLY
37
T136699 – .750 DRIVE LOCKNUT WRENCH
38
T163327 – SPLINED LOCATOR RING
39
T159309 – LOADING PLUG AND BASE FOR ASSEMBLY
40
T160835 – ASSEMBLY PRESSING TOOL
41
T158152 – LOADING PLUG AND BASE FOR ASSEMBLY
42
T158338 – ASSEMBLY PRESSING TOOL
43
T147871 – N-12 LOCK NUT WRENCH
44
T173814 – LEAK TEST ADAPTOR
45
T212150 – ROLL TEST TOOL
46
Planetary Final Drive Repair Instructions
Contact Information
Website www.oerlikon.com/fairfield
47
Oerlikon Fairfield
U.S. 52 South / P.O. Box 7940
Lafayette, IN 47903 USA
765-772-4000
www.oerlikon.com/fairfield
48