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CT45 Torque-Hub®

Assembly-Disassembly Manual

3/18/2010 REV2
While every precaution has been taken in the preparation of this document, Fairfield Manufacturing assumes no liability with
respect to the use of the documentation described herein, or for any act or omission of Fairfield concerning this
documentation.

Features and specifications are subject to change without notice.

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Table of Contents

Introduction ...................................................................................................................... 4
Roll and Leak Testing ...................................................................................................... 5
Brake Testing .................................................................................................................. 6
Tightening and Torquing Bolts ......................................................................................... 7
Lubrication Information .................................................................................................... 8
Main Disassembly ........................................................................................................... 9
Input Brake Disassembly ............................................................................................... 11
Coupling Disassembly ................................................................................................... 13
Hub-Spindle Disassembly.............................................................................................. 14
Second Stage Carrier Disassembly ............................................................................... 15
First Stage Carrier Disassembly .................................................................................... 16
Cover Disassembly ........................................................................................................ 17
Cover Subassembly ...................................................................................................... 18
First Stage Carrier Subassembly ................................................................................... 20
Second Stage Carrier Subassembly .............................................................................. 21
Hub-Spindle Subassembly ............................................................................................ 22
Coupling Subassembly .................................................................................................. 24
Main Assembly .............................................................................................................. 25
Input Brake Subassembly .............................................................................................. 27
Assembly Drawings and Parts Lists .............................................................................. 31
Assembly Tools ............................................................................................................. 43

A few specialized assembly tools are used in the assembly of this gearbox. The tool diagrams included in this
manual are intended for the customer who may wish to have the tool made. It is not necessary to have the tools
in order to build this gearbox.

Fairfield Manufacturing Company, Inc.


P.O. Box 7940
U.S. 52 South
Lafayette, Indiana 47903
Phone 765-772-4000 Fax 765-772-4001
www.fairfieldmfg.com
MMVI

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Introduction
This manual is a step-by-step guide to the disassembly and assembly of CT45 Torque-Hub
units, and is designed for the customer or shop mechanic who is repairing this particular model
of Torque-Hub.

Users of this manual should note that each part mentioned is followed by an identification
number enclosed in parentheses. These part numbers may be referred to in the Parts List
section of this manual and on the illustrated parts breakdown of this unit.

Any specialized tools normally used to assemble this unit are noted in the assembly
procedures and diagrammed in the tooling section.

Users should familiarize themselves with the procedures for roll and leak testing as well as bolt
tightening and torquing found on the following three pages before starting any repairs.

Standard safety practices should be followed during the disassembly and assembly
procedures described. Safety glasses and safety shoes should be worn, and heavy, heat
resistant gloves should be used when handling heated components. Be especially alert when
you see the word CAUTION. This indicates that a particular operation could cause personal
injury if not performed properly or if certain safety procedures are not followed. The word
NOTE is used to bring attention to the user of certain procedures or helpful hints that will aid in
the disassembly and assembly steps.

4
Roll and Leak Testing
Torque-Hub units should always be roll and leak tested before disassembly and after assembly
to make sure that the unit’s gears, bearings, and seals are working properly. The following
information briefly outlines what to look for when performing these tests.
NOTE: The brake must be released before performing the roll test. This can be accomplished
by using the procedures for testing the brake on the next page or by screwing 11 M5 x 20
socket head cap screws into the inner plate. The bolts must be removed before a brake test
can be performed.

The Roll Test


The purpose of the roll test is to determine if the unit’s gears are rotating freely and properly.
The gears should rotate in the unit when a constant force is applied to the roll checking
apparatus. If more drag is felt in the gears only at certain points, then the gears are not rolling
freely 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 digits on the ID tag.

The Leak Test (Main Unit)


The purpose of a leak test is to make sure the unit is airtight. 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.

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The Brake Test

Note: Brakes used in this gearbox are intended as static input brakes only. They are not to be
used for dynamic braking.
Using the model number CT45A130F4117 as a reference, the underlined letter gives the brake
option. Options are D, E, F, or 0.

D Input Brake -- 3250 lb-in (367 Nm) Static (6 spring)


Full Release 110 psi (8 bar)
Maximum Release Pressure 3000 psi (210 bar)

E Input Brake -- 4335 lb-in (490 Nm) Static (8 spring)


Full Release 140 psi (10 bar)
Maximum Release Pressure 3000 psi (210 bar)

F Input Brake -- 5960 lb-in (673 Nm) Static (11 spring)


Full Release 200 psi (14 bar)
Maximum Release Pressure 3000 psi (210 bar)

0 -- No Brake Included

If a brake does not release at these pressure values it has to be inspected, and repaired or
replaced.

NOTE: Failure to perform this test could result in a damaged or ineffective brake.

6
Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that
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.

1. Tighten (but do not torque) bolt “A” until snug.


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.
4. Use a torque wrench to apply the specified torque to bolt “A”.
5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to
the remaining bolts.

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Lubrication Information

8
Disassembly Procedures

Main Disassembly

1. Perform a roll check and a leak check prior to disassembling the unit. On units that have brakes eleven
M5X20 socket head screws need to be screwed into the brake to disengage it in order to perform a roll check.

2. Take out the five Magnetic Pipe Plugs (1H) and drain the oil from the unit. Note the condition and volume of
the oil.

3. Remove the twelve cover Bolts (15).

4. Lift the Cover (14) or Cover Subassembly off of the unit.

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5. Remove the Thrust Washer (13) from on top of the first stage Carrier (10A). It may have stuck to the Cover
(14) when it was removed.

6. Remove the O-ring (21) that goes between the Cover (14) and Ring Gear (5).

7. NOTE: This step only applies to units not ending in “D” or “DP”. Remove the Thrust Washer (12) from on top
of the first stage Carrier (10A). It may have stuck to the Cover (14) when it was removed.

8. Take out the first stage Sun Gear (11).

9. Lift out the First Stage Carrier Subassembly.

10. Remove the second stage Sun Gear (9).

11. Remove the Second Stage Carrier Subassembly. The third stage Sun Gear (8B) will come out with the
Carrier (8A).

12. Take out the two Bolts (7) holding the Hub (1G) to the Ring Gear (5).

13. Lift the Ring Gear (5) off of the unit.

14. Remove the O-ring (4) that was between the Hub (1G) and Ring Gear (5).

15. Take out the two Dowel Pins (6) from the Hub (1G).

16. Remove the five External Retaining Rings (3C) that are holding the third stage Planet Gears (3A)
in place.

NOTE: The Roller Bearings (3B) are pressed onto the Spindle (1A) and locked into the Planet Gears (3A). If the
Planet Gears are damaged, or the Roller Bearings are damaged or worn then both parts must be replaced.
The Planet Gears are also a matched set and if one is damaged all must be replaced.

17. Pry the Planet Gears (3A) off of the Spindle (1A) posts. Be careful to not damage the Thrust Spacer (2).

18. Take the Thrust Spacer (2) out of the gearbox.

19. Remove the Coupling Subassembly.

Removal of the Mounting Adapter (if applicable)


NOTE: The Mounting Adapter is not shown in exploded view drawing, and there are multiple configurations of
which only the first type is described here. See page 39 for more information.

20. Turn the gearbox so that the Spindle (1A) side is up. Remove the four Bolts (27).

21. Take out the Mounting Adapter (25).

22. Remove the O-ring (26).

This concludes the Main Disassembly.

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Input Brake Disassembly
This assembly has 2 styles of brakes. The indicator is the 9th digit in the model number. If the digit is an alpha
character the brake has splines on the outside diameter of the stators.
If the digit is a number the brake has lobes on the outside diameter of the stators.

Splined option

Omit this section if the unit being disassembled has no brake.

WARNING: Make sure 11 M5X20 Socket Head Screws (1A1) have been tightened down into the brake before
beginning this procedure.

1. Using snap ring pliers remove the Internal Retaining Ring (1A2) that holds the input brake in
place.

2. Lift the Piston (1A5) Subassembly out of the Spindle (1A). If the Piston Subassembly will not lift out insert the
Coupling back into the Spindle. Use a dead blow hammer on the Coupling to lightly tap the Piston
Subassembly out of the Spindle. Remove the Coupling and Retaining Ring when the Piston is removed.
NOTE: An alternative method for doing this is to pressurize the Spindle brake port with low pressure air or
hydraulic oil.

3. Remove the Anti-Extrusion Rings (1A6 and 1A9) and O-rings (1A7 and 1A8) from the Spindle (1A).

4. Remove the brake Inner Plates (1A10) and Outer Plates (1A11) from the Spindle (1A).

5. Take out the End Plate (1A12) from the Spindle (1A).

6. Back out all 11 Socket Head Screws (1A1) part of the way from the Piston (1A5). Then finish backing the
Screws out.

7. Take the Thrust Plate (1A3) and Springs (1A4) out of the Piston (1A5). If the Brake (17) uses less than a full
complement of springs, mark the position of the springs as a reference to ease the reassembly.

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Lobed option

Omit this section if the unit being disassembled has no brake.

WARNING: Make sure 11 M5X20 Socket Head Screws (8D) have been tightened down into the brake before
beginning this procedure.

1. Using snap ring pliers remove the Internal Retaining Ring (9) that holds the input brake in place.

2. Lift the Piston (8A) Subassembly out of the Spindle (1A). If the Piston Subassembly will not lift out insert the
Coupling back into the Spindle. Use a dead blow hammer on the Coupling to lightly tap the Piston
Subassembly out of the Spindle. Remove the Coupling and Retaining Ring when the Piston is removed.
NOTE: An alternative method for doing this is to pressurize the Spindle brake port with low pressure air or
hydraulic oil.

3. Remove the Anti-Extrusion Rings (4 and 7) and O-rings (5 and 6) from the Spindle (1A).

4. Remove the brake Inner Plates (3) and Outer Plates (2) from the Spindle (1A).

5. Back out all 11 Socket Head Screws (8D) part of the way from the Piston (8A). Then finish backing the
Screws out.

7. Take the Thrust Plate (8C) and Springs (8B) out of the Piston (8A). If the Brake (17) uses less than a full
complement of springs, mark the position of the springs as a reference to ease the reassembly.

This concludes the Input Brake Disassembly.

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Coupling Disassembly

This section only applies to units with a model code ending in “D”.

1. NOTE: This step only applies to units that have a Brake (17). Remove the Retaining Ring (20B)
from the outside of the Coupling (20A).

2. Take out the Retaining Ring (20F) that is holding the Input Shaft (12) in place. Remove the Input
Shaft.

3. Take out the Washer (20D) and Spring (20E).

4. Remove the Retaining Rings (20F) and (20C) from the center of the Coupling (20A).

This concludes the Coupling Disassembly

This section only applies to units with a model code ending in “DP”

1. NOTE: This step only applies to units that have a Brake (17). Remove the Retaining Ring (20B)
from the outside of the Coupling (20A).

2. Take out the Input Shaft (12) from the Coupling (20A).

3. Remove the Retaining Rings (20F) and (20C) from the center of the Coupling (20A).

This concludes the Coupling Disassembly

This section only applies to units with a model code not ending in “D” or “DP”.

1. NOTE: This step only applies to units that have a Brake (17). Remove the Retaining Ring (20B)
from the outside of the Coupling (20A).

2. Remove the Retaining Ring (20C) from the center of the Coupling (20A).

This concludes the Coupling Disassembly

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Hub-Spindle Disassembly

1. Set the unit on a bench so that the Spindle (1A) flange is down. Grind out the staked Locknut (1J) material
from the Spindle.

2. Using the tool shown on page 42 or a hammer and punch back the Locknut (1J) off of the Spindle (1A). It
may be necessary to heat the Locknut with a torch to expand the Locknut and break down the Loctite. A new
Locknut must be used for reassembly.

3. Turn the unit over so it rests on the Spindle (1A) posts. Use a dead blow hammer on the Hub (1G) flange to
drive the inboard Bearing Cone (1D) off of the Spindle.

4. Lift the Spindle (1A) off of the Hub (1G).

5. Pull the Face Seal (1B) halves out of the Hub (1G) and off of the Spindle (1A).

6. Using a hammer and punch drive the inboard Bearing Cup (1C) out of the Hub (1G). Be careful not to strike
the counterbore where the Cup locates.

7. Turn the Hub (1G) over and drive the outboard Bearing Cup (1C) out of the Hub. Be careful not to strike the
counterbore where the Cup locates.

8. Remove the outboard Bearing Cone (1D) from the Spindle (1A).

This concludes the Hub-Spindle Disassembly.

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Second Stage Carrier Disassembly

1. Using snap-ring pliers remove the three Retaining Rings (8F) from the Carrier (8A).

2. Pry the three Planet Gears (8D) off of the Carrier (8A) posts.

NOTE: The roller bearings cannot be removed from the Planet Gears (8D). If either is damaged both must be
replaced.

3. Remove the Retaining Ring (8C) from the third stage Sun Gear (8B).

4. Take out the third stage Sun Gear (8B).

This concludes the Second Stage Carrier Disassembly.

Notes:

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First Stage Carrier Disassembly

1. Using a hammer and punch drive one of the Roll Pins (10E) down into the Planet Shaft (10D) until it bottoms
out in the Shaft. NOTE: Make sure the pin is driven completely into the shaft or damage to the carrier may
occur when the Planet Shaft is removed.

2. Hold on to the Planet Gear (10F) and push the Planet Shaft (10D) out of the Carrier (10A). The Thrust
Washers (10B) will slide off the Shaft as it is removed.

3. Using a hammer and punch drive the Roll Pin (10E) out of the Planet Shaft (10D).

4. Remove 19 Needle Bearings (10C) from the inside of the Planet Gear (10F).

5. Repeat steps 1-4 for the remaining two Planet Gears (10F).

This concludes the First Stage Carrier Disassembly.

Notes:

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Cover Disassembly

This section only applies to units that have a model number ending in “D”.

1. Remove the two Bolts (15C) that hold the Disengage Cap (15D) in place.

2. Take out the Disengage Cap (15D) and Disengage Rod (15E).

3. Remove the two Bolts (15C) that hold the Cover Cap (15B) in place and take the Cover Cap out of the Cover
(14).

4. Remove the O-ring (15G) from around the shoulder of the Cover Cap (15B).

5. Take out the O-ring (15F) from inside the Cover Cap (15B).

6. Remove the Pipe Plug (15H) from the Cover (14).

This concludes the Cover Disassembly

This section only applies to units that have a model number ending in “DP”.

1. Take out the four Bolts (15C) holding the Cover Cap (15B) in place.

2. Remove the Cover Cap (15B) from the Cover (14).

3. Remove the O-ring (15G) from the groove in the Cover Cap (15B).

This concludes the Cover Disassembly

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Assembly Procedures

Cover Subassembly

This section only applies to units that have a model number ending in “D”.

1. Apply pipe thread sealant to the Pipe Plugs (1H) and (15H) and install them into the Cover (14).

2. Grease an O-ring (15G) and place it on the underside of the Cover Cap (15B) flange.

3. Grease and insert an O-ring (15F) into the groove in the Cover Cap (15B) making sure it is seated correctly.

4. Insert the Cover Cap (15B) into the center opening of the Cover (14) and align the bolt holes.

5. Install two Bolts (15C) into the Cover Cap (15B).

6. Position the Disengage Cap (15D) onto the Cover Cap (15B) and install two Bolts (15C) to hold it in place.
Torque all four bolts to 8-10 ft-lbs.

7. Turn the Cover (14) over and install the Disengage Rod (15E) into the Cover Cap (15B).

This concludes the Cover Subassembly.

This section only applies to units that have a model number ending in “DP”.

1. Install an O-ring (15G) into the groove in the Cover Cap (15B).

2. Install the Cover Cap (15B) into the Cover (14).

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3. Insert the four Bolts (15C) to hold the Cover Cap (15B) in place. Torque the Bolts to 8-10 ft-lbs.

This concludes the Cover Subassembly.

Notes:

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First Stage Carrier Subassembly

1. Apply a liberal coat of grease to the inside of one Planet Gear (10F).

2. Line the inside of the Planet Gear (10F) with 19 Needle Rollers (10C).

NOTE: The last roller installed must be installed end wise. That is, the end of the last roller must be placed in
between the ends of the two rollers that form the space, and then slid, parallel to the other rollers, into place.

3. Set the Carrier (10A) upright.

4. Insert a Planet Shaft (10D) approximately ½” into the Carrier (10A). Be sure to insert the end of the Shaft
without a roll pin hole into the side of the Housing with a roll pin hole. The chamfered roll pin hole in the
Planet Shaft should face up.

5. Apply a light coat of grease to two Thrust Washers (10B) and place them onto the end of the Planet Shaft
(10D) that has been inserted into the Carrier (10A).

6. Place the Planet Gear (10F) with Needle Rollers (10B) onto the Planet Shaft (10D).

7. Apply a light coat of grease to two Thrust Washers (10B) and place them onto the Planet Shaft (10D).

8. Push the Planet Shaft (10D) through the hole on the opposite side of the Carrier (10A). Use a punch or a
similar tool to align the roll pin holes in the Carrier and Planet Shaft.

9. Drive a Roll Pin (10E) into the aligned roll pin holes until it is flush with the outside of the Carrier (10A).

10. Repeat steps 1-9 for the remaining two Planet Gears (10F).

This concludes the First Stage Carrier Subassembly.

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Second Stage Carrier Subassembly

1. Insert the third stage Sun Gear (8B) splines into mesh with the splines in the Carrier (8A).

2. Using snap-ring pliers insert a Retaining Ring (8C) into the groove on the third stage Sun Gear
(8B) to hold it in place.

3. If the Bearing (8E) or the Planet Gear (8D) was found to be damaged during the disassembly both must be
replaced as the assembly of the parts is permanent. If a new Bearing and Gear are to be used proceed to the
instructions in step 4. If the same Gear and Bearing will be used skip to step 5.

NOTE: The orientation of the Bearing (8E) is with the flat end up.

4. Center the Bearing (8E) and cardboard retainer on the end of the Planet Gear (8D) with the large chamfer on
its inside diameter. Push the Bearing through the cardboard retainer and into the Gear until it snaps into the
groove in the Gear.

5. Once the Bearing (8E) has been installed into the Gear (8D) the part can be heated to 200 degrees
Fahrenheit to ease the assembly onto the post. Press the Planet Gear with the bearing installed onto the
planet post of the Carrier (8A). Use tool T-160279 shown on page 40.

6. Using snap-ring pliers install the retaining ring (8F) onto the planet post.

7. Repeat steps 3-6 for the remaining two Planet Gears (8D).

This concludes the Second Stage Carrier Subassembly

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Hub-Spindle Subassembly

1. Place the Spindle (1A) onto a bench with the planet shaft posts up.

2. Install a new Bearing Nut (1J) onto the Spindle (1A) and torque it to 200 ft-lbs (do not use any Loctite), using
the locknut wrench shown on page 42.

3. Mark on both the Bearing Nut (1J) and the Spindle (1A) a reference line to indicate the minimum final position
of the Nut.

4. Remove the Bearing Nut (1J).

NOTE: Generally seals should not be reused.

5. Wipe down the rubber bore of ½ of the Face Seal (1B) and the seal bore on the Spindle (1A) with denatured
alcohol. Also make sure the rest of the metal Seal surfaces are clean. Allow the Seal to dry and then push it
into the seal bore on the Spindle. Make sure the Seal is oriented properly so that the metal faces will contact
each other when the other ½ of the Seal is installed. Apply a light film of oil to this metal surface. Do not
apply any oil to the rubber section. Set the Spindle off to the side.

6. Set the Hub (1G) on a bench with the flange side up.

7. Press a Bearing Cup (1C) into the inboard bearing location on the Hub (1G) using the tool on page 41. An
arbor type press is best for this operation.

8. Turn the Hub over and press the second Bearing Cup (1C) into the outboard bearing location in the Hub (1G).

9. Apply a light coat of oil to a Bearing Cone (1D) and set it into the outboard Bearing Cup (1C).

10. Install the second ½ of the Face Seal (1B) into the Hub (1G) following the procedure of step 5. Be sure to
wipe out the seal bore of the Hub.

11. Turn the Hub (1G) over and install it onto the Spindle (1A). Make sure the outboard Bearing Cone (1D) is
seated on the shoulder of the Spindle.

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12. Install the inboard Bearing Cone (1D) into the Hub (1G).

13. Install the Bearing Nut (1J) onto the Spindle (1A) using the locknut wrench. Apply Loctite 277 to the first two
threads of the Nut before installation. Tighten the Nut to a torque of 750 ft-lbs, and make sure it is at or past
the reference line marked in step 3. Stake the Nut in at least two places after the final torquing.

14. Using a hammer and punch stake the Bearing Nut (1J) in three places.

This concludes the Hub-Spindle Subassembly.

Notes:

23
Coupling Subassembly

This section only applies to units with a model code ending in “D”.

1. Install the Retaining Rings (20F) and (20C) into the center of the Coupling (20A).

2. Install the Washer (20D) followed by the Spring (20E) on top of the Retaining Ring (20F).

3. Set the Input Shaft (12) into the Coupling (20A).

4. Press down on the Input Shaft (12) and compress the Spring (20E). Install a Retaining Ring (20F)
into the Coupling (20A) to hold the Shaft in place.

5. NOTE: This step only applies to units that have a Brake (17). Install the Retaining Ring (20B)
onto the outside of the Coupling (20A).

This concludes the Coupling Subassembly

This section only applies to units with a model code ending in “DP”

1. Install the Retaining Rings (20F) and (20C) into the center of the Coupling (20A).

2. NOTE: This step only applies to units that have a Brake (17). Install the Retaining Ring (20B)
onto the outside of the Coupling (20A).

3. Set the Input Shaft (12) into the Coupling (20A).

This concludes the Coupling Subassembly

This section only applies to units with a model code not ending in “D” or “DP”.

1. Install a Retaining Ring (20C) into the center of the Coupling (20A).

2. NOTE: This step only applies to units that have a Brake (17). Install the Retaining Ring (20B)
onto the outside of the Coupling (20A).

This concludes the Coupling Subassembly

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Main Assembly

1. Grease one face of the Input Spacer (2) and install it greased side down onto the Spindle (1A).

NOTE: The third stage Planet Gears (3A) are a matched set. If one Gear is being replaced then all the Gears
must be replaced. If the Bearing (3B) or a Gear is damaged both components must be replaced as the
assembly of the Bearing and Gear is permanent. If a Bearing or Gear is being replaced proceed to step 2.
Otherwise go to step 3.

2. Center the Bearing (3B) and retainer on the end of the Planet Gear (3A) with the large chamfer on its inside
diameter. Push the Bearing through the retainer and into the Gear until it snaps into the groove in the Gear.

3. Once the Bearing (3B) has been installed into the Gear (3A) the part can be heated to 200 degrees
Fahrenheit to ease the assembly onto the post. Press the Bearing and Planet Gear assembly onto a Planet
Shaft of the Spindle (1A) using the pressing tool T163165 shown on page 43. NOTE: The chamfered end of

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the Bearing goes onto the Spindle post first. Tap the tool fixture with a rubber hammer to install the planet
gear assembly. Using a regular hammer may crack the inner bearing race.

4. Using snap-ring pliers install an External Retaining Ring (3C) on the Spindle (1A) post to hold the
Planet Gear (3A) in place.

5. Repeat steps 2-4 as required for the remaining four Planet Gears (3A).

6. Grease and install an O-ring (4) onto the Hub (1G).

7. Insert two Dowel Pins (6) into the appropriate holes in the Hub (1G).

8. Align the dowel pin holes on the Ring Gear (5) with the Dowel Pins (6) in the Hub (1G), and install the Ring
Gear onto the Hub.

9. Install two Bolts (7) to hold the Ring Gear (5) and Hub (1G) together. Torque the Bolts to 18-25 ft-lbs.

10. Place the Second Stage Carrier Subassembly into mesh with the Ring Gear (5).

11. Install the Second Stage Sun Gear (9) into the mesh with the second stage Planet Gears (8D).

12. Place the First Stage Carrier Subassembly into mesh with the splines on the second stage Sun Gear (9).

13. Install the first stage Sun Gear (11) into mesh with the first stage Planet Gears (10F).

14. Grease and install an O-ring (21) onto the Ring Gear (5).

15. Set the Thrust Washer (13) on top of the First Stage Carrier Subassembly.

16. NOTE: This step only applies to units not ending in “D” or “DP”. Place a Thrust Washer (12) on top of the
first stage Sun Gear (11).

17. Place the Cover (14), or Cover Subassembly on top of the Ring Gear (5).

18. Insert 12 Bolts (15) with Loctite 243 and torque them to 18-25 ft-lbs.

19. Turn the gearbox over and insert the Coupling (20A) Subassembly into the Spindle (1A).

20. Apply thread sealant to the remaining two Pipe Plugs (1H) and insert them into the Hub (1G)

21. If the gearbox does not have a Brake (17) then the unit should now be leak and roll checked. 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. If the unit has a brake proceed to the Input Brake Subassembly instructions.

Assembly of the Mounting Adapter (if applicable)


NOTE: If the unit has a brake the brake must be installed before completing these steps.

NOTE: The Mounting Adapter is not shown in exploded view drawing, and there are multiple configurations of
which only the first type is described here. See page 39 for more information.

22. Grease and install an O-ring (26) into the groove on the Mounting Adapter (25).

23. Set the gearbox so that the Spindle (1A) is facing up.

24. Install the Mounting Adapter (25) to the gearbox using four Bolts (27). Torque the bolts to 80-85 ft-lbs.

This concludes the Main Assembly

26
Input Brake Subassembly
This assembly has 2 styles of brakes. The indicator is the 9th digit in the model number. If the digit is an alpha
character the brake has splines on the outside diameter of the stators.
If the digit is a number the brake has lobes on the outside diameter of the stators.

Splined option

Spring Locations for “D” Input Brake Spring Locations for “E” Input Brake
The darkened out circles represent the springs.

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This section should be omitted if the unit being assembled has no brake.

1. Install the required number of Springs (1A4) into the Piston (1A5). If the Brake (17) uses less than a full
complement of Springs be sure to reinstall them in the same layout as they were when removed.

2. Position the Thrust Plate (1A3) on the Piston (1A5) aligning the bolt holes.

3. Install and tighten 11 Socket Head Cap Screws M5X20 (1A1). NOTE: Start all Screws and use a press to
clamp the Piston (1A5) Subassembly together. Then finish tightening the Screws. These screws are not a
part of the bill of material.

4. Set the gearbox on its cover and insert the End Plate (1A12) on the flange at the bottom of the Spindle bore.

5. Beginning with an Outer Plate (1A11) install the Outer Plates and Inner Plates (1A10) alternately into the
Spindle (1A).

NOTE: Anti extrusion rings and o-rings should not be reused.

6. Install an Anti-Extrusion Ring (1A9) in the lower groove inside of the Spindle (1A).

7. Install an O-ring (1A8) in the same groove above the Anti-Extrusion Ring (1A9).

8. Insert an O-ring (1A7) into the upper groove inside the Spindle (1A).

9. Install an Anti-Extrusion Ring (1A6) in the same groove above the O-ring (1A7).

10. Lightly grease the cylinder walls of the Spindle (1A) to minimize any shearing of O-rings (1A7) and (1A8) and
Anti-Extrusion Rings (1A6) and (1A9).

11. Insert the Piston (1A5) Subassembly into the Spindle (1A).

12. Using snap-ring pliers install the Retaining Ring (1A2) to hold the Brake (17) into place.

13. The unit should now be leak and roll checked. 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.

14. Once the unit has been roll checked remove the 11 M5X20 socket head cap screws from the Brake (17).

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Lobed option

Spring Locations for “D” Input Brake Spring Locations for “E” Input Brake
The darkened out circles represent the springs.

29
Omit this section if the unit being disassembled has no brake.

WARNING: Make sure 11 M5X20 Socket Head Screws (8D) have been tightened down into the brake before
beginning this procedure.

1. Using snap ring pliers remove the Internal Retaining Ring (9) that holds the input brake in place.

2. Lift the Piston (8A) Subassembly out of the Spindle (1A). If the Piston Subassembly will not lift out insert the
Coupling back into the Spindle. Use a dead blow hammer on the Coupling to lightly tap the Piston
Subassembly out of the Spindle. Remove the Coupling and Retaining Ring when the Piston is removed.
NOTE: An alternative method for doing this is to pressurize the Spindle brake port with low pressure air or
hydraulic oil.

3. Remove the Anti-Extrusion Rings (4 and 7) and O-rings (5 and 6) from the Spindle (1A).

4. Remove the brake Inner Plates (3) and Outer Plates (2) from the Spindle (1A).

5. Back out all 11 Socket Head Screws (8D) part of the way from the Piston (8A). Then finish backing the
Screws out.

7. Take the Thrust Plate (8C) and Springs (8B) out of the Piston (8A). If the Brake (17) uses less than a full
complement of springs, mark the position of the springs as a reference to ease the reassembly.

This concludes the Input Brake Subassembly.

Notes:

30
Assembly Drawings and Parts Lists
Non-Disengage Unit with Model Number not Ending in “P”
(Shown with Brake)

31
Non-Disengage Unit with Model Number not Ending in “P”
(Shown without Brake and with Mounting Adapter)

32
Parts List

Number Qty Description


1A 1 SPINDLE
1B 1 FACE SEAL
1C 2 BEARING CUP
1D 2 BEARING CONE
1G 1 HOUSING
1H 5 MAGNETIC PIPE PLUG
1J 1 BEARING NUT
2 1 THRUST SPACER
3A 1 PLANET GEAR SET
3B 5 CYLINDRICAL ROLLER BEARING
3C 5 EXTERNAL RETAINING RING
3D 10 INPUT SPACER
3E 10 INTERNAL RETAINING RING
4 1 O-RING
5 1 RING GEAR
6 2 DOWEL PIN
7 2 HEX BOLT UNC(.500-13, 1.25)
8A 1 CARRIER
8B 1 SUN GEAR
8C 1 EXTERNAL RETAINING RING
8D 3 PLANET GEAR
8E 3 CYLINDRICAL ROLLER BEARING
8F 3 EXTERNAL RETAINING RING
9 1 SUN GEAR
10A 1 CARRIER
10B 12 THRUST WASHER
10C 57 NEEDLE BEARING
10D 3 PLANET SHAFT
10E 3 GROOVE PIN
10F 3 PLANET GEAR
11 1 SUN GEAR
12 1 THRUST WASHER
13 1 THRUST WASHER
14 1 COVER/RING GEAR
15 12 HEX BOLT UNC(.313-18, 1.25 GR8)
18 2 DRIVE SCREW
19 1 ID PLATE
20A 1 COUPLING
20B 1 EXTERNAL RETAINING RING
20C 1 INTERNAL RETAINING RING
21 1 O-RING
22 1 PLASTIC PLUG

See page 39 for input adapter parts lists.

33
Units with a brake will also have the following part number:

17 1 INPUT BRAKE

Brake Parts List

Number Qty Description


1A1 11 SOCKET HEAD SCREW (M5X20)
1A2 1 RETAINING RING
1A3 1 THRUST PLATE
1A4 SEE PAGE 6 SPRING
1A5 1 PISTON
1A6 1 ANTI-EXTRUSION RING
1A7 1 O-RING
1A8 1 O-RING
1A9 1 ANTI-EXTRUSION RING
1A10 6 INNER PLATE
1A11 7 OUTER PLATE
1A12 1 END PLATE

34
Disengage Unit
(Shown with Brake)

35
Disengage Unit
(Shown without Brake and with Input Adapter)

36
Parts List

Number Qty Description


1A 1 SPINDLE
1B 1 FACE SEAL
1C 2 BEARING CUP
1D 2 BEARING CONE
1G 1 HOUSING
1H 5 MAGNETIC PIPE PLUG
1J 1 BEARING NUT
2 1 INPUT SPACER
3A 1 PLANET GEAR SET
3B 5 CYLINDRICAL ROLLER BEARING
3C 5 EXTERNAL RETAINING RING
3D 10 INPUT SPACER
3E 10 INTERNAL RETAINING RING
4 1 O-RING
5 1 RING GEAR
6 2 DOWEL PIN
7 2 HEX BOLT UNC(.500-13, 1.25)
8A 1 CARRIER
8B 1 SUN GEAR
8C 1 EXTERNAL RETAINING RING
8D 3 PLANET GEAR
8E 3 CYLINDRICAL ROLLER BEARING
8F 3 EXTERNAL RETAINING RING
9 1 SUN GEAR
10A 1 CARRIER
10B 12 THRUST WASHER
10C 57 NEEDLE BEARING
10D 3 PLANET SHAFT
10E 3 GROOVE PIN
10F 3 PLANET GEAR
11 1 SUN GEAR
12 1 INPUT SHAFT
13 1 THRUST WASHER
14 1 COVER/RING GEAR
15 12 HEX BOLT UNC(.313-18, 1.25 GR8)
15B 1 COVER CAP
15C 4 HEX BOLT UNC(.250-20 GR5)
15D 1 DISENGAGE CAP
15E 1 DISENGAGE ROD
15F 1 O-RING
15G 1 O-RING
15H 1 PIPE PLUG,STD-NPT
18 2 DRIVE SCREW
19 1 ID PLATE
20A 1 COUPLING
20B 1 EXTERNAL RETAINING RING
20C 1 INTERNAL RETAINING RING

37
20D 1 THRUST WASHER
20E 1 SPRING
20F 2 INTERNAL RETAINING RING
21 1 O-RING
22 1 PLASTIC PLUG

See page 39 for input adapter parts lists.

Units with a brake will also have the following part number:

17 1 INPUT BRAKE

Brake Parts List

Number Qty Description Splined


1A1 11 SOCKET HEAD SCREW (M5X20)
1A2 1 RETAINING RING
1A3 1 THRUST PLATE
1A4 SEE PAGE 6 SPRING
1A5 1 PISTON
1A6 1 ANTI-EXTRUSION RING
1A7 1 O-RING
1A8 1 O-RING
1A9 1 ANTI-EXTRUSION RING
1A10 6 INNER PLATE
1A11 7 OUTER PLATE
1A12 1 END PLATE

Number Qty Description Lobed


8D 11 SOCKET HEAD SCREW (M5X20)
9 1 RETAINING RING
8C 1 THRUST PLATE
8B SEE PAGE 6 SPRING
8A 1 PISTON
4 1 ANTI-EXTRUSION RING
5 1 O-RING
6 1 O-RING
7 1 ANTI-EXTRUSION RING
3 6 INNER PLATE
2 7 OUTER PLATE

38
Non-Disengage Unit with Model Number Ending in “P”
(Shown with brake)

39
Parts List

Number Qty Description


1A 1 SPINDLE
1B 1 FACE SEAL
1C 2 BEARING CUP
1D 2 BEARING CONE
1G 1 HOUSING
1H 5 MAGNETIC PIPE PLUG
1J 1 BEARING NUT
2 1 INPUT SPACER
3A 1 PLANET GEAR SET
3B 5 CYLINDRICAL ROLLER BEARING
3C 5 EXTERNAL RETAINING RING
3D 10 INPUT SPACER
3E 10 INTERNAL RETAINING RING
4 1 O-RING
5 1 RING GEAR
6 2 DOWEL PIN
7 2 HEX BOLT UNC(.500-13, 1.25)
8A 1 CARRIER
8B 1 SUN GEAR
8C 1 EXTERNAL RETAINING RING
8D 3 PLANET GEAR
8E 3 CYLINDRICAL ROLLER BEARING
8F 3 EXTERNAL RETAINING RING
9 1 SUN GEAR
10A 1 CARRIER
10B 12 WASHER,THRUST
10C 57 NEEDLE BEARING
10D 3 PLANET SHAFT
10E 3 GROOVE PIN
10F 3 PLANET GEAR
11 1 SUN GEAR
12 1 INPUT SHAFT
13 1 THRUST WASHER
14 1 COVER/RING GEAR
15 12 HEX BOLT UNC(.313-18, 1.25 GR8)
15B 1 COVER CAP
15C 4 HEX BOLT UNC(.250-20 GR5)
15G 1 O-RING
18 2 DRIVE SCREW
19 1 ID PLATE
20A 1 COUPLING
20B 1 EXTERNAL RETAINING RING
20C 1 INTERNAL RETAINING RING
20F 1 INTERNAL RETAINING RING
21 1 O-RING
22 1 PLASTIC PLUG

40
See page 39 for input adapter parts lists.

Units with a brake will also have the following part number:

17 1 INPUT BRAKE

Brake Parts List

Number Qty Description Splined


1A1 11 SOCKET HEAD SCREW (M5X20)
1A2 1 RETAINING RING
1A3 1 THRUST PLATE
1A4 SEE PAGE 6 SPRING
1A5 1 PISTON
1A6 1 ANTI-EXTRUSION RING
1A7 1 O-RING
1A8 1 O-RING
1A9 1 ANTI-EXTRUSION RING
1A10 6 INNER PLATE
1A11 7 OUTER PLATE
1A12 1 END PLATE

Number Qty Description Lobed


8D 11 SOCKET HEAD SCREW (M5X20)
9 1 RETAINING RING
8C 1 THRUST PLATE
8B SEE PAGE 6 SPRING
8A 1 PISTON
4 1 ANTI-EXTRUSION RING
5 1 O-RING
6 1 O-RING
7 1 ANTI-EXTRUSION RING
3 6 INNER PLATE
2 7 OUTER PLATE

41
Input Adapter Configurations

Type 1 Type 2 Type 3

Type 1 Parts List


25 1 MOUNTING ADAPTER
26 1 O-RING
27 2 BOLT

Type 2 Parts List


25 1 MOUNTING ADAPTER
26 1 O-RING
27 2 FLAT HEAD BOLT
28 1 THRUST WASHER

Type 3 Parts List


24 1 MOUNTING ADAPTER
25 1 O-RING
26 2 FLAT HEAD BOLT
30 1 THRUST WASHER

42
Assembly Tools

Bearing Pressing Tool for Item 8E


T160279

43
Bearing Cup Pressing Tool for Item 1C
T172204

44
Locknut Wrench for Item 1J
T182143

45
Bearing Pressing Tool for Item 3B
T163165

46
Brake Alignment Tool
T203309

47
With over 80 years of experience, Fairfield Manufacturing has become the largest U.S. non-captive producer
of gears, custom gear assemblies, planetary final drives, and related gear products. Fairfield Manufacturing,
headquartered in Lafayette, Indiana, is distinguished by our extensive design, manufacturing, and applications
engineering capabilities. Our 500,000 square foot plant is a modern, fully equipped manufacturing facility that
includes a full service heat treat department.

Our philosophy of synchronous engineering is a partnership that matches our best and brightest people with
your people to evaluate your unique requirements, and develop products and assemblies that meet your needs.

For more information, contact Fairfield today.

Mailing Address: Fairfield Manufacturing Co., Inc.


U.S. 52 South
P.O. Box 7940
Lafayette IN 47903-7940

Shipping Address: 2309 Concord Rd.


Lafayette, IN 47909

Telephone:
Main (765) 772-4000
Automated (765) 772-4002
Voicemail (765) 772-4003

FAX:
Main (765) 772-4001
Applications Engineering (765) 772-4011
Sales and Service (765) 772-4010

E-mail:
Applications Engineering apps@fairfieldmfg.com
Sales sales@fairfieldmfg.com

Website: www.fairfieldmfg.com

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