We Abe PARTS AND SERVICE MANUAL ors] poem 5.1 Drawworks Specifications 5.1.1 Drum Specifications MAIN DRUM Model: i sown CE75000 i Drum Size: 19-718 inches x 35-1/2 inches Wireline Size: 4-1/8 inch Drum Ciutch: Fawick 37VC650 Brake Size: 44 inches x 14 inches w/ brake bands and brake linkage SANDLINE DRUM Model: Grown GE75000 | | Drum size: 43 inches x 42 inches | Wireline Size 9/16 inch Drum Gluten: __| Fawick 268 525 a: Brake Size: 42 inches x 8 inches w brake bands and brake linkage 5.1.2 Auxiliary Brake This unit is equipped with one (1) Eaton Mode! WCBD-424 water-cooled assist brake. 5.2 General Maintenance of Drawworks Components 5.2.1. Clutches and Quick Release Valves 5.2.1.1 Clutches The Airflex clutch shoes on this unit are fitted with neoprene tubes and drive bars. No lubrication or adjustment should be necessary. These clutches operate at air pressures between 120 and 130 psi. CAUTION: Do not operate clutches if system air pressure is less then 100 psi 6.2.1.2 Quick Release Valves For the clutches to release quickly, itis important that the quick release valves should function properly. Sometimes sticking valves may result from air system impurities. These valves should therefore be cleaned periodically. CAUTION: Never oil quick release vaives. 5.2.1.3 Brakes To ensure that brake leverage ratio wears equally, the relationship of the brake linkage ‘mechanism must be maintained the same at all times. To adjust Main Drum brakes for wear and lever position, adjust pin brake equalizer bolts (on drawing 100043168), so that both sides are in identical position, with exactly the same amount of bolt length protruding from the bottom,PARTS AND SERVICE MANUAL SY DRS-00750 DRILLING BRAWWORKS 5.3 Assembly Drawings DRAWWORKS LAYOUT. Saxon Energy Services Inc. Drawworks CE7S0DD (Eaton Brake) 100046013. 1/2, Drawworks Assembly CE7S0DD. 100046013. 2/2, Drawworks Assembly CE7SODD. 100046086. Maindrum Shaft Assembly CE750DD. 100046122. Sandline Shaft Assembly CE7S0DD. 100043168. Brake Shaft Assy Maindrum CE750SD. 100046546. Brake Shaft Assy Sandline. CE750DD. 100042508. 1/2 Right Angle Gearbox Assy CE750DD ODS. 4100042508. 2/2 Right Angle Gearbox Assy CE7S0DD ODS. 100042085, Reversing Box Assembly CE750SD. Revoe-Sepi0s e-3Equipment Drawings2 spout = can ——! ore a @ = a ee a] i 4 4 somes cons | be ; “gene 240 fae 2 i Be ||| BE. Bese ae TR Epes 3 a OD, Meee le aaa sas Sauer 1D ree ne ean IO MS aa 61 ow : —_—_——— OFF mts So ‘mers Se ee iva fof Steet oe eel CengRAL vores: Sietercieas, [ame ———— oe | ace amma nage ome ee 5 ae Eee eS aon fy ns MAINDRUM SHAFT ASSEMBLY CE75000 ers iy a ~ me] = Ses Tr tooosso8s [9‘ous pa sue srw A 1 a ‘ : : ne BE Psa = eee ] PERS Rae ie ee pee ae] rae ee er Hi TBR de arpgg oe ft a feee tite eee on cain ' i |, I soe OFF ORILLER'S. SIDE en a 88 05 GENERAL NOTES: mg us Stam aye | MGA BSIFCONN Oo Wen RAR Fe Pac an 8 he me DRILLER'S SIDE SE === Soin eoie Fe SANDLINE SHAFT ASSEMBLY CE75000 a ear wT 100046122 _2 » « ‘ . NB. ED OU ee ria . a ete te as 1 arp ues [ftom fl He Paenefebetarmaorier ri n a Ee eee Lehi lee oe z fe Hiren i re] . re Slpwre quiero sac : 5 - im ot a fren 4 \ cena ANG AO - |o ce 5 " {iin chroser 0 nome ese 2 owe 6, HOR. yee. ‘@8 © ARAKE SHAFT ASSY MAINDRUM CE7S0SD as vo _T™ vo00a5i68 TJ2 » “ . ‘ 2 OU ERD cu . ‘ : : : he ) FReee eos : ee Fee . os + = seta aaa Sofa 184 ee a +" Peo ates eee te Se tet Pee ae res So Ete . freee Hate ria Keine = ee he ee eae 5 5 a . BOD G@R OD el eRANthi2 GENERAL NOTES: 1, GEN 0 RID wen UD BP 2 eT wt 1D AD a RO BRAKE SHAFT ASSY SANDLINE CE7S000 wos [aa _[ 1o004646 14 Z 1 L « 7 s a ‘ il 3 i 2 SANDLINE ORUM SHAFT MAIN DRUM SHAFT ORUMSIZE #13" x 42" ORUMSIZE 620° x BRAKE SIZE 8" x 42" DRUM GROOMING 1-1/ ; BRAKE RIMS 8” x 42° BRAKE SIZE 11" x 44" BRAKE LINING 20 PCS 8" x 1° x 12" BRAKE RIMS 11" x 44” BRAKE COOLING SPLASH COOLED BRAKE LINING 20 PCS 11" x1-1/8" x 12° BRAKE COOUNG WATER COOLED SPROCKET 1 3/4" TRIPLE - 357 ALUISION $5610 SPROCKET 1.1/2" TRPLE - cuUTCH 26c8605- J 5 ane es SeRes 60 Berita HAW #120-TRIPLE-14 Fi LUTCH S7¥C6E0 | W/AIANUAL DISCONNECT SPROCKET 1 1/2" TRPLE = 21T— ‘SPROCKET TRIPLE| E71_3/a" ~597 ° eae Ss teas RIGHT ANGLE GEARBOX 29/28 REVERSING BOX 2:1. RAIN ROTARY CLUTCH 16vc60 EATON BRAKE 424WCBD ‘THIS DRAWING IS FOR INFORMATION eee PURPOSES ONLY AND IS NOT'T0 BE omer sue | A AUS, seca ee rarer ISSUED FOR CONSTRUCTION, — peg SRW —_ NON (0) assy NSE HS EE 10 line hookloads~ 400,000 Lbs drilling FINAL DESIGN MAY VARY FROM. ee! SAXON ENERGY SERVICES INC. 8 line hookloads~ 375,000 Lbs drilling SALES ILLUSTRATION. ee CE750DD_(EATON BRAKE) - -/- - PROPOS, - 3 SHEE —F r ee SSE SseE CS ueSEECEE 7 eee 3TOM Pie ae —e et tt “ 1 oH ‘ siaintuae onan . Hl GCOSLIO ATEHESSY SHYOMMNEO PR ala al BE meee ana Hi a a Sioa wo eA ND OnE TE TAMAR 9 A HL SOE acu sere /1 2 1ST BLA SI wie he SON TGK ‘ «ws aren om Oma ND lm = SHON WES il D x | @ t 4] AS. 2 it 1 | ‘ Hi ca @ ii 4 ih | i 2 th 1 ft wd a 7 — iff + = the Bete ae oll acs t + oO | fe He seas fe | a oy = Hee te 6 — tee : Hy \ H = ~Sapaaureestet eect S s EB i = eee ee 1 lla| = Pt ae v ul a » & ¥ mera tea i el TBO BOON. ‘ »_IFNooWsY ,FNOOUTI_ + s 8 MEW A-A(ROTAIE) fe sae 0 saree) © i NOTE FOR WOUNT FATON BRAKE: ae Pe noi (i # FG f2 ab 96 ‘cia 97 To 0 wr SON LD 10 on GENERAL Nou: 5. wl SCONE Dayo eH EURO 2 ER WA 8 HA WELD Notes: Ss NE ONE AL wa oH 3 COMBOS CT rs ow re oe ra SAL Wb EES Y OMY ADS See) Be ORAWWORKS ASSEMBLY CE75O D0 aa [100046013z SE fries || a s iat Lip ame ee aa 4. wy 1047 Po av. Ja ; dag ON | oh sonst sree amt rox Fae F PROCEDURE FOR SETTING GEAR BACKLASH {ok mgm MON SLED OF 8 Tic sous shud Er aC a HS CA Care (si eS DS 2. mst sas ENG 8 HOHE HO HUT a en FCN ED ENE 2 WER WLU ad THE quad 97 Sr ee EK DE (50 RIGHT ‘ANGLE GEAR BOX ASSY CE75000~|* OFF DRIER SIDE a —| ee soousois fo 0) 4 eae» ® . . EW DOT. NO OUT 2 ‘ Esa ae . tee A. a ne + : =a So — ee see SSeS ee a. oe hal BE deuce sence =, — saa = 8 os : 2 Haw! : a oom 20 8 cannon 2 “PEL ape = ; AG a ih = A: 7 Hout a f EPH = 4 ®® @ @ OO OOO@OY 4s ® Se GENERAL NOTE Nore: 1 ma Gre 1g REO woe OU Ps mone as OLS We wea a HER REVERSING BOX ASSEMBLY CE750S0 “wT sooazos T110 line hookloads~ 400,000 Lbs drilling ALUSION $5610H SERIES 60. 550 HP CHAN COMPOUND W/MANUAL, DISCONNECT SPROCKET 1 1/2" TRIPLE - 75T- CHAIN #120-TRIPLE- 14 SPROCKET 1 1/2 TRIPLE - 21T- 3 eEeeay SANDLINE DRUM. SHAFT DRUMSIZE 613" x 42" BRAKE SIZE 8" x 42" BRAKE RIMS 8° x 42" BRAKE LINING 20 PCS B” x 1” x 12" BRAKE COOLING SPLASH COOLED 1 i 1 NAIN-DRUM SHAFT DRUWSIZE 620" x 36” DRUM GROOVING 1-1/8" BRAKE SIZE 11" x 44” BRAKE RIMS 11" x 44” BRAKE LINING 20 PCS 11" x1-1/8" x 12° BRAKE COOLING WATER COOLED J pot 13/4" TRILE - 357 HAIN f4140—TRIPLE~ 112 a SIVC650 “we i /f im goa RIGHT ANGLE cearoox_/) 29/28 ROTARY CLUTCH 16vC60 ‘THIS DRAWING IS FOR INFORMATION PURPOSES ONLY AND IS NOT TO BE ISSUED FOR CONSTRUCTION. 8 line hookloads~ 375,000 Lbs drilling FINAL DESIGN MAY VARY FROM. SALES ILLUSTRATION. REVERSING BOX 2:1. RAI 13/4" -59T EATON BRAKE A2AWCBD SPROCKET TRIPLEL_ 0 NOT SCALE CROWN S11 Suppo Puce SL ar, apcran Tee Pr anak (403) 215-5500 SAXON ENERGY SERVICES NC DRAWWORKS CE7SODD (EATON BRAKE} petedfeet| daa ae - See = 7 7 7“ * ' s »_NOOUET ANDOU 5 . sa hse a fe ® — n ee = A Q @ 2 = 7 Feige} fs . i 5 ee a ee ae a . z A = L ae ae = 3 sae = anit i 4 ee = ‘| GENERAL NOTES: J ree 2 Wat HN, 80 PW, ES: 1 nso oR. MOUS ee COMME LE 2 ates Tt 08 SSAC nie race 0 cme wt ce Seo a7 oe [Sel ere fort —earor_ bas Pr Te ht 5 t—— 7 mas — fie one | DORAWNORKS ASSEMBLY CE75000 i nena He a = Pies of e ioooss013 Io‘ _——— nist, ote . 1 . 7 SS i = y serene : o ~ ~ \\ “eH ; % 4, { hi i i, ~ 33 = ie wl soclaae © i ~ = 4 2. L i i == _-4{ | = ® I voy | YEN AAO ‘GENERAL NOTES: 2 ane wwe, a I, WELD NOTES: 1 OS OE CWS, WE 6 1/4 ALE PE 2 cations wo ou oF cam {UAC ttt PESIES elt Wk OB Sis. a ‘NOTE FOR MOUNT EATON BRAKE: SECU 6:8 Fa ca fe One Fe 6 tsa Sebo aon apo: Seges fal Gata | py Speman | nd Senate, RRRTERE exis] DRAWHORKS ASSEMBLY CE75000 et au at a eaaaee seen Sree ola “sa_T 1000160130ead i ‘ ‘ yt a Le = 4 ie a : ee = a nl | oY : 4 , £ ee =a Fi =i ot 2 A a ee ® i i seen eo ogo we « 5 ® Q @ 2 FS AR in me ction I 8 ma a 5 BRE ns 6 : D@ ( (ellie Cz fay et ) go, Se oe F t oe Sofas 6 sean : ae oO pre V [= ee Fon 7 | ci : ae x =z £ # a L. : 8 eu. = say OFF DRILLER'S SIDE DRILER’S SIDE CENERAL NOS: = jot SRSA 1 on Sr en aD — ls 2 MRS wang DT a MAINDRUM SHAFT ASSEMBLY CE750D0 discs Ses sseae sree eee see ee ee sauce “ae Ts in _[ 1o0oeeoes ToEse cael ‘ ae ange a | ; , er | yee : doit |o PS v4 | Fae ; @ +o L-@ 5 7 9 : i i‘ © 8 ® © i in} \ LZ) i B Sacra acrcerd erect be We nas - zs a seein OFF DRILLER’S SIDE DRILLER’S SIDE id ihe, cenceal_ noes: ea | Snes F i an 0 ee wore Mes I, oe HN SANDLINE SHAFT ASSEMBLY CE7500D we PP yo0046122 02 " * . . 2 OUR i ay eee re ie a “pe BHA + = . EE : @@ 2 + Ql swe ee Ae aN 23 Ac tt ots 8 GENERAL NOTES: 2 MMS tN UD HO, 22 2 Zz 3 Lei il Saag acta ses | "Gn “ime | —GRAKE SHAFT ASSY MANDRUM CE750SD ha w wooos3i68 [14 » * . 4 2 LDOUBE, N aUR 2 ‘ Sian : . Shetty = Eee ees aa foam hath =] Flames tr ttre car coe + Leet = See HE ne ee reac : panei ete sce ee : Ebene to] Sa) ee er ane ae Abe sn me fess a at Te = 1 1 Qa I e I oN ® @ 8 yy iid a WW ch "i ie if u |_ © Fy @u i i 1 | * GOD i aan | 1 QD ane a ® VW Ac ® || & GENERAL NOTES: {lea GUE 0 aD eM AAU Be sie RAKE SHAFT ASSY SANDUNE CE75000 Pec va_T™ 190006546 TtDow wes nr sows sce 990 Fenn Woof PROCEDURE FOR SETTING GEAR BACKLASH ke a aun oi “ie an ete a GENERAL Non pene Riera eee eee! 1. MATRCOFRPATIN ¥0 BC PRENOCD WHEN REQURED OY HP. 4,8 2 moms my ‘stm as Ses een ee ee ‘eine (Sor) ose stern oc aces Es a-ak MSE A ag Ng | ————_—_— Tews I RGHT ANGLE GEAR BOX ASSY CE7SO0D ova ara rena men Sa 80" El raion ie OFF_DRIAER SIDE ym ow eo ‘a * 1000466 9 Dou. aD THE ASSY E7000 |*ne “J se0evador QS0S23) MW3SS¥ XOG INISNIAIY 5S ha —T a v (comers ase ace 3 nies wt ott @ "so 9 apa ai SE ‘a tow 0 ‘a: net a HE 2 KES 3108 SIO WERE ae oH BO QD GOO or QQQOOD OO @ @O@Equipment ManualSY DRS-00750 DRILLING RIG PARTS AND SERVICE MANUAL, | ORAMAORKS 5.4 Component Manufacturer Supplied Information EATON. VC (Clutch) Elements. Technical Information, EATON. VC (Clutch) Elements. Installation, Operation and Maintenance. EATON. CB (Clutch) Elements. Installation, Operation and Maintenance, EATON. Airflex WCB Water Cooled Tensioners. Installation, Operation and Maintenance. EATON. Airflex WCB2 and WCBD Brakes. Technical Information. EATON. Rotorseals B3 (et al). Installation, Operation and Maintenance. Revoe-Sop08 3.8lI i | i # s/s} elelelela siajgalete AE 5) alsa 1 ae XSI G TaN Nelda BRENDON KOU= : Ll i I ib B q dl: a zi il % als aii : 2 : = : rm ff if a ls Si, | He 5 ali iFE:CN Single Wide VC Eler Airflex’ — ons S S E.TN FOS reas wh Airrflex’ single wide ve Elements a i th hil nun Ai iH= H i f I iS i z ae es Ho a rid A ie: Hadden) |b HERE evergeass EB. AURA Pibf i ROSE TES i HI i : oy | i / eats Hai ih al 7 SME | HE i I 3 | = ih | ale Be aE.N ah Alrflex’ ve ciutch Apptication ‘ut eT ban Ree nS Airflex’ ve ctutch Application mean lsfaaiseialaE.1-N 4 Hes a _ | i A ike tl at = cee aii ‘Ub Here al ki £: : ae ul z lee et | ay <}ejele = ajo|a}s| = EisieiaiR) |B} oem oe aa] | TORR Airtlex’_vc ciuteh application se ease Rasa T ae | se8 Sag all "TY ARERR 1aAirflex’ ve ciutch application soe « bee ale ae i illo ssl] iissaiea a | i |, flees ea isles eeln sae i INGE RCIBEE: i ee | TN ap rt -e a fone ste Airflex’ ve clutch application yen re 4 ct uh ln an iB | 2 BELEIELEYE:TN Femes25 Cmts tin Sin 1 Airflex” ve srake application E.T-N Airflex’ ve rake apptication ssatgueae WaHEnEHE Jeena 2 AHNalegre allah abhigalgey gmaven pewmg- Hg meumg—eapls—_asaNss rap siamese pes SONY wera ‘amano HAT OS YANY ra aT O KOYYsso pt ans peas psms.agojeny eps itu 00 ges suogsauueg em, voyseuveg ous ferns toro sts aPuENpeRpaNA-sng RsaI FSA sous ieMBguNg Aue BULBS OA KO YY Nea syawodog BanunoW On KOU |HORROLAERNUGsIRSMEHING —— sEQKUNE, sasercoumcing-sigmum-seen —— HEaKMeY era ‘SwvaUOTaED BURTON OA KOEN NLA Swreuoduog BanunOW SA XSANEquipment ManualVC 5000 Installation, Operation and Maintenance of Airflex® VC Element Assemblies E-T-N A Z\ Warning Forward this manual to the person responsible for installation, Operation and Maintenance of the product desorbed herein. Without access to this information, fauity Installation, Operation (or Maintenance may result in personal injury or equipment damage. A\causon: Use Only Genuine Aiflex® Replacernent Parts ‘The Arfiax Division of Eaton Corporation recommends tho use of genuine Airlox roplacoment pats. The use of non-genuine Airlex replacement parts could result in substandard product performance, And may void your Eaton waranty. For epimum perfomance, contact ito tn the U.S.A. and Canada: (800) 233-5926 Outside the U.S.A. and Canada: (216) 281-2211 August, 1989 (Revised: July, 1995) 203675 © Copyright Eston Corp, 1905, All ight rosarved. POF Format1.0 INTRODUCTION 44 Ld 1a ve 00 tad oughout this manual there are a number of IRD WARNINGS that must be read and adhered to in xr fo prevent possible per Sone inuny endog, danza t9 gouprent Three signal words “DANG! Re \RNING", and "C SAUTION" are used to indicate the severity of a hazard, annd are preceded by the safety alert symbc 12 nat ASDANGER - Denotes the most serious hazard, and is used when serious injury or death WILL result from misuse or fallure to follow specific instructions. ZAWARNING - Used when serious injury or death MAY result from misuse or failure to i follow specific instructions. ZX CAUTION - Used when injury or productequipment damage may result from misuse or failure to follow specific instructions, It is the responsibilty and duty of all personnel involved in the installation, operation and main- tenance of the equipment on whieh this device is used to understand the /1\ DANGER, WARNIN IG, ao CAU proce- es by which hazatdare to be avoided Description The Airfiex® air-actuated VC element assembly is specifically designed and manufactured for severe clutch or brake applications on heavy equipment where high starting loads or sus- tained slippage would normally lower clutch or brake efficiency and reduce operating life. CConstricting action and ventilated construction make high torque capacity and rapid heat dissipation possible. 1.3 13.1 All Airflex VC element assemblies are supplied with long wearing, NON-ASBESTOS friction material. 13.2 Airflex element assemblies are available for drum diameters from 11.5 inches through ‘66 inches. The element size designation indi- cates the nominal drum diameter in inches, the ‘clutch model and the width of the friction material. For example, size '38VC1200" indicates the element operates on a drum having a nominal diameter of 38 inches, is an Aiflex "VC" series clutch or brake (the soope’ of this manual) and has friction material which is 12 inches wide. eves My, 188 (POF fone Where diametral space is limited, or the torque required is greater than a single element can transmit, all sizes of Airlex VC elements can be supplied as dual units. How It Works Roferring to Figures 1 and 2, the neoprene and cord actuating tube is contained within a stee! rim which is driled for mounting to the driving component (or reaction bracket in the case of ‘a VC brake application), As air pressure is ap- plied to the air actuating tube, the tube inflates, forcing the friction shoe assemblies uniformly against the drum which is attached to the diven component. The friction shoe as- semblies, which consist of friction blocks at- tached to aluminum backing plates, are guided by torque bars which are secured to side plates. In the case where the VC element is being used as a clutch and is attached to the driving shafi, the torque flow is from the driving shaft, through the element mounting ‘component (typically an iron. spider), through the rimiside plate structure, through the torque bars fo the backing plates and friction material, where the torque is transmitted through the fricion couple to the components mounted ‘on the driven shaft (dutch drum and drum mounting component), As actuating air is exhausted, release springs and centrifugal force assure positive disengagement. Element Adjustment Airflex VC elements are completely self adjust- ing and automatically compensate for lining and drum wear. Lubrication is not required. The torque developed is dependent upon rotating speed and applied air pressure. By limiting the applied pressure, the element will act as a torque limiting device and provide ‘overload protection. To accomplish regulated or cushioned engage- ment of the element, @ flow control valve may be installed in the element air supply line and adjusted to restrict ait low to the element while allowing free flow away from the element for rapid disengagement. By adjusting the restricted flow, the rate of engagement may be varied. Note that the flow control valve does not regulate air pressure - the supply pressure must always be adequate to transmit the maximum required torque. Refer to the OPERATION section of this manual for air piping configurations. © Copyright Eaton Corp., 1989. All rights reserved.SINGLE NARROW & SINGLE WIDE b_— Element Drum Hub Spider DUAL NARROW Outboard Element ) + a z __ _ ss —— Brake Reaction ee Outboard Bracket Fig. 8 Element 21.4 Figure 6 illustrates a typical marine main propuision application. in this ertangement, the element is attached to a pinion adapter plate and the drum and drum hub are attached to a quill shaft. A manifold is attached to the | ? outboard end of the element for bearing PA + support of the quill shaft. 7 Pinion pe Adapter Manifold —-| Plate Fig. 3 ———Pinion 2.1.2 Figure 4 illustrates the gap-mounting arrange- ment with an axial locking device. The axial rad 4 locking device restricts the relative axial of motion between the driving and driven shafts. ow This arrangement is typically used where a ‘Shaft synchronous motor armature with plain bear- ings must be held on magnetic center. Uy 2.4.9 Figure 5 illustrates @ typical VC brake applica tion, The drum and drum hub are attached to the shaft which is to be stopped. The element is attached to a rigid reaction bracket. Fig. 6 4 © Copyright Eaton Corp., 1989. Al rights reserved. vc 5000 Fevesc Joy, 1885 POF fem)TABLE 1 - FASTENER ASSEMBLY TORQUE SN = SINGLE NARROW SW = SINGLE WIDE DN = DUAL NARROW DW = DUAL WIDE D = DRY TORQUE - FT-LB. (Nm) LUBED TORQUE - FT-LB. (Nm) (80 WT. MOTOR OIL OR ANTI-SEIZE) ELEMENT TO SPIDER/ Size SIDEPLATETORIM © TORQUE DRUM TO HUB TORQUE SN11.5VC500 3/8-16NC GR 2 D15 (20) 1/2-13NC. GR2 38151) SN14VC5001/2-43NC GR2 DgB8(51) — /2-13NC GR 2 D 38 (51) SNIGVC600 —1/2-13NC GR 2 D 38 (51 3/4-10NC GR 2 193 (126) SN20VE600 1/2-18NC GR2 0 38 (51 3/4-40NG GR 2 193 (128) SN24VC650 —_5/8-11NC GR2 D77 (108) 3/4-10NC GR2 Loa (126 SN2BVG650_5/B-11NG GR 2 D77 (104) -3/4-10NC GR 2 Cos (126 SN33VG650 Y4-10NG GR 2 (93(126) 3/4-10NC GR 2 99 129) SNI7VC650 &/4-10NG GR 2 L93(126) 34-10NG GR 2 £93 (126 SN42VC650 3/4-10NC GR 2 193(126) — 3/4-10NC GR 2 93 (126) DN11.5¥C500 3/8-16NC. GR 2 D15(20) 1/2-19NC GRE © 109 (148) DN14VC500 1/2-13NC GR B Dar (18) 1/2-18NC GR D 38 (61) DNieVG600 1/2-13NC GR 2 D861) —-3/4-10NG GR B L245 (332) DNZOVE600— 1/2-13NC GRB De7 (118) —-3/4-10NC GRE. L214 (286) DN24VE650 5/8-1INC GR2 D77 (104) 8/4-10NC GR 2 99 (126) DN28VCE50 —5/B-1INC GR2 D7 (104) 8/4-10NG GR 2 93 (126) DNSBVCE50 —a/4-10NC GR 2 193126) 3/4-10NC GR 2 93 (126) DNS7VCE50 3/4-10NC GR 2 193(126) —3/4-10NC GR 2 193 (126) DN42VC650 _3/4-10NC GR 2 C93 (126) 3/4-10NC GR 2 93 (128) SW14VC1000 1/2-13NC. GR 2 D851) —1/2-18NC GRE L109 (148) SWIGVC1000 1/2-13NC GR 2 D3a(61) —-B/4-10NC GR2 £93 (126) SW20VG1000 1/2-13NC GR 2 D38G1) —_B4-10NC GR2 £93 (126) ‘SW24VC1000 _5/8-11NC GR 2 D77 (104) —_3/4-10NC GR 2 93 (126) ‘$W28VC1000 _6/8-11NC GR 2 B77 (104) —_B/4-10NC GR2 93 (126) SWS2VC1000 _5/8-11NC GR 2 D77 (104) 3/4-10NC GR2 93 (126) SW38VG1200 3/4-10NC GR 2 Ls (126) 93 (126) SW42VC1200 3/4-10NC GR 2 93 (126) 193 (126) SW46VG1200 7/8-9NC GR 2 L408 (148) L463 (221) SW52VC1200 7/8-0NC GR2 L108 (148) 163 (221) SW51VG1600 7/8-9NC GR 2 E109 (148) C163 221) SWEOVC1600 1-8NC GR 2 L463 (221) 1 172-6NC GR2 566 (767) SW66VC1600 1 ¥/4-7NC GR 2 £925 (441) 1 1/2-6NC GI C566 (767) DWI6vC1000 1/2-13NC GR 8 087(118) — 3/4-10NC GRB L245 (932) Dw20vG1000 1/2-13NG GR 8 087 (118) 3/4-10NC GRS L245 (332) Dwe4VvG1000 _5/B-11NG GR 8 D174 (236) 3/4-10NC GR 8 L245 (332) DW28VC1000 _5/8-11NC GR 8 D174 (206) 3/4-10NC GR 8 24s (332) DW32VC1000 §/8-11NG GR 8 D174 (296) 3/4-10NC GR 8 L245 (332) DWS8VC1200 3/4-10NC GR 8 L245 (832) 3/4-10NC GRB L245 (332) DW42VC1200 3/4-10NG GR 8 L245 (832) 3/4-10NC GR 8 L246 (332) DW46VC1200 7/8-9NC GR 2 L409 (148) 1-8NC GR L510 (692) Dws2VC1200 7/8-9NC GR2 L109 (148) 1-8NC GR 8 1510 (692) DWSIVC1600 7/8-9NC GR 2 L109 (148) 1-8NC GR 8 £510 (692) DweovE1600 1-8NC GR 2 L163 @21) 1 1/2-6NC Gre L566 (767) DW66VC1600 1 1/4-7NC GR 2 1326 (441) 1 W2-ENC GR2 566 (767) EHH ian _____ HEX SIZES (in) size [oLT__NuT IZE Nut ize Bot NC pte 16 /aNC nate f-1/anCf-7/8 fvenc ba B4 Y/8NC tl NC Bla ONC N66 ASG ANC W716 Bu VC 5000 Revised: July, 1995 (POF Format)Bracket 248 Dial Indicator 242 243 2 vo 500 | Inside Micrometer Fig. 9 Fabricate a rigid bracket for supporting a ial incicator and attach to the spider. See Figure 8 Thoroughly dean the flange O.D. and the face of the drum hub where alignment readings are to be taken, Rotate the spider and take paralel alignment readings off the drum hub flange O.D. If both shafts can be rotated together, the alignment readings are less influenced by any surface inregularies. LXca When recording parallel alignment readings, “sag” of the indicator! indicator bracket must be accounted for. ‘Angular alignment readings can be made by accurately measuring the gap between the spider and drum hub faces with an inside micrometer. if a dial indicator is used, make ‘sure to monitor and correct for any axial move- ment of the shaft. To reduce the influence any surface iregularies may have on the angular alignment readings, index the spider 90 degrees after taking the iniial set of readings. Take an additonal set of readings and index the spider another $0 degrees. Continue in this ‘manner unti four sets of readings have been taken, For misalignment correction, use the average of the four readings at each position. in other words, average the four top readings, the four bottom readings, and each of the four side readings. Shim and shift the base of the movable shaft to Correct the misalignment. After tightening the base, recheck the alignment and correct if necessary. Make sure to check for a “sof foot” ondliion. Dowel or chock into postion after satisfactory alignment has been achieved ‘Note: On many applications, thermal growth of the driving or driven machinery may result in unacceptable shaft alignment in a running condition. It is always good practice to make a “hot alignment” check and re-shim if necessary Installation of Element and Drum (Narrow, Dual Narrow and Single Wide) Note the orientation of the drum flange with respect to the air connection(s) on the element and slide the drum into the element. Separate the shafts as far as the bearing learances will allow and hoist the ele- mentidrum into position. ‘Attach the drum to the drum hub with the appropriate fasteners. See Table 1 .Make sure the bore in the drum flange fully engages the pilot on the drum hub, ZXwaming: Use only the proper grade and num- ber of fasteners. Using commercial grade fasteners (Grade 2) in place of Grade 8 fasteners (where called for) may result in failure of the fasteners under load, causing personal injury or equipment damage, Install the air connection gaskets onto the air tubes. The metal backup washer is to be positioned toward the elbow (away from the spider), See Figure 10. Note: Some older elements use a flanged air connection tube and a thin gasket. See Table 3 for correct part numbers. Metal Washer. Fig. 10 {© Copyright Eaton Corp, 1989. All rights resewed.2.6.6 2.6.1 288 289 Rubber Sleeve Long ir Tube ‘Spacers Fig. 11 ‘Align the air connections and reassemble the ‘element halves, making sure the spacers are in place between the elements. See Figure 11 Reassemble the air connection tubes. If an elbow has been removed, use a good quality pipe sealant on the threads. See Figure 11. Note: The elbow assemblies on the outboard ‘element (farthest from the spider) use rubber compression slooves. Make sure the sleeves. are securely on the long er tubes. Install the air connection gaskets onto the air tubes. The metal backup washer is to be positioned toward the elbow (away from the spider). See Figure 10. ‘Align the element air connections with the coftesponding passages in the spider and altach the element to the spider with the appropriate festeners. See Table 1. Make sure the element fully engages the register in the Advani: Use only the proper grade and num- ber of fasteners. Using commercial grade fasteners (Grade 2) in place of Grade 8 fasteners may result in failure of the fasteners under load, causing personal injury or equipment damage. Air Control System A typical air control system is shown on Figure 12, Since the air contol system used will be dependent on the specific application, a detailed description cannot be made in this manual. Following are some general guidelines for instaling and adjusting air controls, The air receiver tank must be located as close. {o the rotorseal as possible (within five feet) for consistent clutch or brake response. Use full size piping and valves consistent with the rotorseal size. Keep the number of elbows to a minimum. Use poppettype solenoid valves. Spool valves are not recommended, ‘An air line lubricator is not required for the element; however, if one is used, it must be a norradjustable, mistype. Ifa flow control valve is used, it must have free ‘tow (indicated by an arrow on the valve body) directed away from the element The final connection to the rotorseal MUST be made with flexible hose and place no radial load upon the rotorseal. Aeaution: Do not use rigid pipe at the connec- tion to the rotorseal. Rigid piping will result in excessive loads on the rotorseal bearings, shortening life. Avautio Maximum applied air pressure is 125 ig (8.5. bar). Operation at pressures ‘exceeding 125 psig may result in damage to the element. Consult the factory if operation at pressures. greater than 125. psig is desired, Rotorseal Pressure Such now (ears (owmen” esr at (sti ue me Fig. 12 vo s0TABLE 5 442 FRICTION MATERIAL THICKNESSES NARROW SERIES Minimum ‘Oisial ning Element | Allowable Lining | Theses, Size | Thickness, n.(mm)_|_n. (rom) Fraveste tu) 8 (3,8) a) 20vce09. Tavesso tre 15 8) tay SVCD TaVeEsO tra 26 (70) Ba) anv C650 WIDE SERIES Tavcioeo wre] 18 (8) Ba 2ave1000, Taver0oD ew 1 a a (tay aver900 savci000 ewe wa any 42001200 ‘everat0 and 38 88) Ts) 5201200 3,60, and 66 30a) or ira, 61600 4.4.4.2 Contamination of Shoes or Drum - Oil or grease contamination will reduce the developed torque of the clutch or brake Disassembly will be cequired to clean any oil (or grease build-up. In extremely dusty environ- ments, dust may accumulate in the backing plate cavities to the point where the friction ‘shoes will not properly retract, Dust accumula tions may be vacuurned out of the cavities. Arcaution: Do not attempt to use a solvent to remove oil or grease without first removing the element. While squirting solvent into an installed clutch or brake may improve performance tem= porarily, a fire hazard exists from the hheat generated during slippage. Adcaution: Do not use compressed air to blow dust accumulations out of the backing plates. Although the friction material does not contain asbestos, the dust created as the friction material wears, ‘along with the dust from the operating ‘environment, may irritate the respiratory system, 4.4.4.3 Air Control Components - Check for proper yest adjustment of the air control components. Make sure the safety pressure switches, if used, are set correctly. Repair any air leaks as discovered. 2 eveot iy, 1905 OF koe) aint Partial or complete disassembly is required to inspect the following items: Drum Diameter Wear - Check the 0.0. of the drum and compare to the values shown on Table 6. Minor heal-checking may be removed by machining the drum O.D. Ifthe drum has, been subjected to excessive heat, the open end may flare out, giving the impression that the drum has not worn. It is therefore import- ant to check the diameter at several locations cross the face. ZS Caution: ‘Operation of the clutch or brake on a drum that has wom or has been ‘machined to less that minimum allow- able diameter will result in damage to ‘the element components. TABLE 6 DRUM WEAR LIMITS. NARROW SERIES Maximum Allowable Element Wear on Drum Diameter * she Inn) F.evesO0 thru tevCe0D 93 (2) [2ovesoo thru 24vees0 213) feevesse 210 (8) [sevosso thru «2vce50 is) WIDE SERIES fravet0eo thre 1evcI00e me faovci0e0 thre 24vcio00 3 zavcioes 185) 1 js2voio06 thru s8ve1700 B13) [savosz00 thru esvotz00 25-(6) s2vc1200 thru sevoxsoe 25-16) * Note: The number preceding the letters “VC" in the element size designates the original drum diameter in inches. Example: 16VC800 - Original Drum Diameter 16.00 inches (406mm), Minimum allowable drum diameter is: 16(406) - .09(2) = 15.91(404). Air Actuating Tube - Check that the tube has not been damaged by excessive heal. If any portion of the tube is hard or charred, the tube must be replaced. Check for any blisters, which would indicate ply separation. A tube in this condition must also be replaced. © Copyright Eaton Comp, 1885. Al its reserved432 433 434 435 438 437 44 444 ‘1.svcs00 zaveos0 savesoo seves00 2ovee0D veto Disconnect the dual element from the spider and allow it to rest on the drums. Remove the air connection tubes. Remove the fasteners and spacers attaching the element halves together. Attach an overhead support to the spider side ‘element and apply enough tension to support the weight of the element half and one of the drums. Remove the through bolts and nuts attaching the drums to the drum hub, DO NOT REMOVE THE SHORT SCREWS AND LOCKWASHERS: WHICH HOLD THE FEMALE DRUM ONTO ‘THE DRUM HUB, Carefully hoist the spider- side element and drum out from between the shafts. ‘Allach an overhead support to the remaining element and apply enough tension to support the weight of the element and drum. Remove the short screws and lockwashers holding the drum onto the crum hub and Carefully hoist the element and drum out from between the shafts, Zcaution: Use extreme care when disconnecting the drums from the drum hub, Shear points exist at the mounting holes. Removal of Spider and Drum Hub Puller holes are provided for removal. It will usually require heating along with the puller. When heating, heat unifomly to prevent hot spots. Snap ring and Counterbore Eliminated “aves ‘4vcion0 28v¢1000 Asvci000 savci00 poveroee 2evc1000 2BveSE0 savcss0 mvesso 45 454 482 453 484 455 ig. 13 Disassembly of the Element Lay the element flat on @ clean work surface. Remove the side plate and clean for reassemb- ly. I the torque bar holes are elongated more than one-half the diameter of the pin on the tend of the torque bar, the side plate must be replaced. Remove the fiction shoe assemblies, torque bars and release springs. If the forque bars ‘and springs come out of the element with the friction shoe assomblies, carefully tap them ‘out of the backing plate ‘cavities. Note wear and replace as necessary. Leaution: Whenever the element is removed and disassembled, itis always good practice to replace the release springs. Remove the air connection elbows. and spiral ‘snap Fings which secure the air actuating tube to the rim. Smaller size elements do not use snap rings. Carefully remove the air actuating tube from the rim and thoroughly inspect, Replace if necessary. Note: The snap rings may no longer be re- quired on cattain size elements. Also, rims manufactured before 1984 were counterbored al the tube valve hole to accept the snap ring ‘This counterbore hes been efminated, and a ‘second snap ring groove has boon added to the tube vale, See Figure 13. Remove the remaining side plate only if tis to be roplaced. Counterbore Eliminated end Second Snap Ring Groove Added sevci200 46vciz00 —sivcieo0 420C1200 52VCI200 —60VCIEOD ssevereao ‘© Copyright Eaton Corp, 1989. Al cghtsresorved.ve SPARE PARTS STORAGE Element Assemblies 61 61 Element assemblies rust always be stored flat. Storage in the standing position may ‘cause the rims to go outof-ound, Drums Drums must be stored open end down. Similar to element assemblies, storage of a rum in the standing positon ‘wil adversely affect roundness. Air Actuating Tubes ‘Ar actuating tubes are shipped from the Airex plant folded to conserve shipping space. Upon Feceipt, remove the tube from is crate and allow ito assume its natural shape. Store in a coo), dry atea, away from electrical equipment and ultraviolet ight. 6.0 ORDERING INFORMATION/ TECHNICAL ASSISTANCE Equipment Reference In any correspondence regarding Airex equip- iment, refer to the information on the product nameplate. if not available, note the drum diameter, alr connection configuraton, mount- ing arrangement or any other special features and call or write: Eaton Corporation Aliflex_ Division 9919 Clinton Road Cleveland, Ohio 44144 Tel: (216)281-2211 Fax: (216) 281-3890 THE PARTS LISTS ON THE FOLLOWING PAGES APPLY TO STANDARD ELEMENT ASSEMBLIES ONLY. ELEMENTS USED ON SLIP OR HIGH-TORQUE APPLICATIONS WILL HAVE DIFFERENT COMPONENT PARTS. CONSULT THE AIRFLEX FACTORY OR AN AUTHORIZED AIRFLEX DISTRIBUTOR PRIOR TO ORDERING REPLACEMENT PARTS FOR ANY ELEMENT NOT APPEARING ON THE FOLLOWING LISTS. 0 © Copyright Eaton Comp, 1969. All ghts reservedPonsou SU IW 6961 “diog UntES WsDUAdaD @ at (yeuu0s 4Gd) 9664 “Ainr :pesiney 0005 DA la fener cree | men [| na Pw ites e RE || aa EN om x | : sete 3 | 5 eee ae 4 I i Sas = = = cr 7 nin one == vex fe | oy Pence] eet et FE ome tes w TEE | Baan ET] |e “= & \ : = 2 al ; = (SE |S | ey ES : a | ; lee 2 BRE | oe PNET Ee a EE ome = g ; = 2 Wee t ic sors |e SO] ww [on [ooo] ee [v0 | ws [so amv] we || ame Oe eee ee eS“penseses SIU6i ity *686) "du0g UaTeS WYBUAdOD @ 0 (seus sae) $664 Aine :69s!42u 0008 0A a4 seyquiessy juewey apy eibuig EL7.4 Dual Wide Element Assemblies rem ‘Compete Dual Element With | _ Si 8 ° Four Side | Elements connections 46VC1000 vee eee ea 2ove1000 wee ‘ees [ae |e 2ave1000 wae ‘seen | ee | com 28VC1000 ee wage [ sowten | comet 32VC1000 wee ‘gee | towien | tome 38VC1200 ve gee [ewe [er 42vC1200 ad agar [rosea | some 46VC1200 = omen |g iear| ene 52VC1200 wai gana | sosema | toate | s1vc1600 —_ soe | gta eee eee “gene [em | All elements are dual drilled. ‘VC 5000 Revised: July, 1995 (POF Format) 22 * The second column under “ITEM lists the part numbers of the two single elements that make up the dual mounted element assembly. To find part numbers of the components, locate the element number in the pars list for single element application. Find the part numbers in the corresponding item column. (© Copyright Eaton Corp, 1089. Al Fights ocorved.Airflex® EATON PRODUCT WARRANTY Subject to the conditions stated herein, Eaton Corporation warrants to the Purchaser that each new Airflex Product manufactured by Eaton will be free from failures caused by defects in material and workmanship, and will deliver its rated capacity, for a period of twelve (12) months from the date of shipment to Purchaser, provided such Product is properly installed, properly maintained, operated under normal conditions and with competent supervision. Warranty claims shall be made in writing and the part or parts shall, if requested by Airflex Division, be returned prepaid to the Airflex Division for inspection. Upon a determination that a defect exists, Eaton shall thereupon correct any defect, at its option either by repairing any defective part or parts or by making available at Eaton's plant a repaired or replacement part. This warranty does not extend to normal wear parts or components of the Product, such as friction material and friction surfaces. Form ML-318 Revised September 3, 1997 PDF format LIMITATION OF WARRANTY THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN, ORAL OR IMPLIED. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE SPECIFICALLY EXCLUDED. In no event shall Eaton be liable for special, incidental or consequential damages. Eaton’s liability arising out of the supplying of such Product, or its use, whether in warranty, contract or otherwise, shall in no case exceed the cost of correcting defects in the Products as herein provided. Upon expiration of the twelve (12) month period, all such liability _ shall terminate. THE FOREGOING SHALL, CONSTITUTE THE SOLE REMEDY OF PURCHASER AND THE SOLE LIABILITY OF EATON. Eaton Corporation Airflex Division 9919 Clinton Road Cleveland, Ohio 44144 Printed in U.S.A,Equipment ManualCB 4000 Installation, Operation and Maintenance of Airflex® CB Element Assemblies /\ warning Forward this manual to the person responsible for Installation, Operation and Maintenance of the product described herein. Without access to this information, faulty Installation, Operation ‘oF Maintenance may result in personal injury or equipment damage. Caution: Use Only Genuine Airflex® Replacement Parts “Tha Airfex Division of Eaton Corporation recommends the use of genuine Alex replacement parts. The use of non-genuine Aix roplacsment paris could rest in substandard product performance, ‘and may void your Eaton wanany. For opémum performance, contact Aitox In the U.S.A. and Canada: 1-800-AIRFLEX (247-3539) Outside the U.S.A. and Canada: (216) 281-2211 Internet: wwwairflex.com June,1990 (Revised: June, 2001) 203674 © Copyright Eaton Corp., 2001. Al sights reservedFIG.1 - COMPONENT PARTS FOR, AIRFLEX TYPE CB ELEMENT — Tew DESCRIPTION 1_|_ Elbow Assembly TA] Optional - Quick Release Vaive Assembly | ‘Optional - Quick Release Valve Muffler ‘Compression Ring, ‘Air Connection Tube ‘Air Connection Gasket Friction Shoe Assembly ‘Ait Tube Group (Dual Mounled) ‘Spacer Group (Dual Mounted) ‘Shoe Pin Tockwire Friction Shoe Replacement Kit & lol! wloronlaleohoiay DUAL MOUNTED. POF Format 1 {@ Copytight Eston Corp, 2001, Al rights reservedFiguro 3 2.0 INSTALLATION POF Format i Only qualified personnel should in- stall, adjust or repair these units. Faulty workmanship will result in exposure to hazardous condi personal injury. having a drum in place. Inflation of the element without a drum in place will result in permanent damage to the element components. 24 244 242 Brake Bracket Figuro 4 Mounting Arrangements Figure 2 illustrates the gap-mounted arrange- ment. In this arrangement, the element is at- tached to a spider which is typically mounted on the driving shaft, The drum is altached to 2 drum hub which is typically mounted on the driven shaft. The gap between the two shafts allows the element and drum to be removed without disturbing either shat. Note: The text in the Installation, Alignment and Removal sections refer to this type of mounting arrangement. Close-mounted arrangements may be used when shaft-o-shaft clearance is limited, as ilustrated in Figure 3. Figure 4 ilustrates a typical CB brake applica- tion. The drum and drum hub are attached to {© Copyright Eaton Corp. 2001. Alights reserved2.2 Mounting Considerations 222 2.2.1 The element must be protected from contamination by oil, grease or excessive amounts of dust. L\caution: Oil or grease contaminati sult in a reduction of dev clutch or brake torque. Either of ‘these conditions will result in clutch or brake slippage and overheating. For clutch and brake applications, shaft align- ment must be within the lolerances indicated in the Alignment section of this manual. /\ caution: Operation with shaft misalignment exceeding the limits indicated in the Alignment section of this manual will result in accelerated wear of the ele- ‘ment components. Severe mislign- ‘ment will result in excessive bration and/or overheating when isengaged due to dragging of the friction shoes. /\ caution: 22.3 All mounting fasteners must be of the proper size and grade, and torqued tothe appropi- {it rotating equipment must be ate value. See Table 1. guarded to comply with applicable Safety standards, TABLE 1- FASTENER SIZE & ASE D = DRY TORQUE - FT-LB (Nm) LUBED TORQUE - FT-LB (Nm) (SAE 30 OIL OR ANTI-SEIZE COMPOUND) ALL FASTENERS GRADE 2 OR BETTER Size ELEMENT TO SPIDER TORQUE DRUM TO HUB TORQUE “408200 114-20NC D7 (10) — a t- 318-16NC 18 (20) ae 318-16NC 018 (20) 72CB350 1/243NC 3861) 14CB400__| — EEE *16CB500 “18CB500 [ae8s00 1I243NC D38(61) 2268800 2408500 3/4-10NC. 1.93 (126) [2608525 | [28ce525 s/8-11NC 77 (104) 3008525 [s2ces25 | EEaeHeecaaE | 36CB525 “40CBE25 314-10NG 193 (126) [“ascB525 deere [16s @2i) Dual assemblies use the same values as listed above. For element to element fasteners, use element to spider fastener sizes and torque value. POF Format 5 ‘© Copyright Eaton Corp, 2001. Al ihts reserve,2.42 243 244 245 2.48 25 254 Fabricate a rigil bracket for supporting adial 2.5.2 indicator and attach tothe spider. See Figure 8. Thoroughly clean the flange O.D. and the face 2.5.3 of the drum hub where alignment readings are to be taken Rotate the spider and take parallel alignment readings off the drum hub flange O.D. If both shafts can be rotated together, the alignmnet readings are less infiuenced by any surface irregularities. Avenue When recording parallel alignment readings, “Sag” of the indicator/indi ator bracket must be accounted for. 254 Angular alignment readings can be made by accurately measuring the gap between the spider and drum hub faces with an inside mi crometer. Ifa dual indicator Is used, make sure to monitor and correct for any axial movernent of the shaft. To reduce the influ- cence any surface irregularities may have on the angular alignment readings, index the spi der £0 degrees after taking the intial set of readings. Take an additional set of readings and index the spider another 90 degrees. Continue in this manner until four sets of read- ings have been taken. For misalignment cor- rection, use the average of the four readings, the four bottom readings, and each of the four side readings. 255 26 é 26.4 Shim and shifl the base of the movable shaft to correct the misalignment. After tightening the base, recheck the alignment and correct If necessary. Make sure to check for a “soft foot" conditton. Dowel or chock into position after satisfactory alignment has been achieved, 26.1.4 Note: On many applications, thermal growth of the driving or driven machinery may result in unacceptable shaft alignment in a running condition. It is always good practice to make a *hot alignment” check and re-shim if neces- sary. 26.4.2 26.1.3 Installation of Element and Drum (Single and Dual) 2.6.1.4 Note the orientation of the drum flange with 26.45 respect to the air connection(s) on the ele- ment and slide the drum into the element. POF Format 7 Separate the shafis as far as the bearing clearances will allow and hoist the ele- ment/drum into position ‘Attach the drum to the drum hub with the ap- propriate fasteners. See Table 1. Make sure the bore in the drum flange fully engages the pilot on the drum hub. Apply @ small amount of gasket cement to the air connection gaskets to hold them in posit during installation. install the air connection gaskets onto the air tubes. See Figure 9. Elbow AlrTubo Air Connection Assembly Gasket Le Figure 9 ‘Align the element air connections with the pas- ‘sages in the spider and altach the element to the spider with the appropriate fasteners, See Table 1. Make sure the element fully engages the register in the spider. Air Control System Atypical air control system is shown in Figure 10. Since the air control system used will be dependent on the specific application, a de- tailed description cannot be made in this man- ual, Following are some general guidelines for Installing and adjusting air controls. The air receiver tank must be located as close to the rotorseal as possible (within five feet) for consistent clutch or brake response. Use full size piping and valves consistent with the rotorseal size. Keep the number of elbows to a minimum, Use poppettype solenoid valves. Spoo! valves are not recommended. An airline lubricator is not required for the ele- ment; however, if one is used, il must be @ non-adjustable, mist-type, ‘© Copyright Eaton Cop, 2001. Al rights reserved,4.0 44 44a 4444 4AA2 4443 MAINTENANCE Warning: Only qualified personnel should maintain and repair these units. Faulty workmanship may result personal injury or equipment dam- age. A\eaution: When replacing components, use only genuine Airflex replacement parts. Use of other materials may severely effect performance. Periodic Inspection ‘The following items may be inspected without disassembly of the element: Air Control Components - Check for proper adjustment of the air control components. Make sure the safety pressure switches, if used, are set correctly. Repair any air leaks, Friction Shoe Assembly Lining Wear - If the linings have worn to the minimum allow- able thickness of 1/46" (1.6mm), they must be replaced as a complete set, with the excep- tion of element size 4CB200, where repiace- ‘ment of the entire element is required when worn to the minimum lining thichness of 1/32" (0.8mm). friction material worn imum allowable thick- damage to the Contamination of Shoes or Drum - Oil or grease contamination wil reduct the developed torque of the clutch o brake. Disassembly will be required to clean any oil or grease build-up. Any dust accumulation may be vacuumed from between the friction shoe assemblies, L\caution: Do not attempt to use a solvent to remove oil or grease without first removing the element. While squirt inga solvent into an installed clutch POF Fomat 4a AAA 4122 L\caution: Do not use compressed air to blow dust accumulations out from be- tween the friction shoes. Although the friction material does not contain asbestos, the dust created as the fric- tion material wears, along with the dust from the operating environment, may irritate the respiratory system. Partial or compiete disassembly is required to inspect the following items: Drum Diameter Wear - Check the O.D. of the ‘drum and compare to the values shown on Table 4. Minor heat-checking may be re- moved by machining the drum O.D. If the drum has been subjected to excessive heat, the open end may flare out, giving the impros- sion that the drum has not wom. Its therefore important to check the diameter at several lo- cations across the face. L\eautio Operation of the clutch or brake on a drum that has worn, or has been machined, to less that minimum al- Jowable diameter will result in dam- age to the element components. TABLE 4- DRUM WEAR LIMITS ‘Maximum Allowable! Weer on Orum meter *, in. (mm) 082) 20) ©) 8) Element Size "708200 ru 1408400 5J6CBS00 wu 248500, “Note: The number preceding the letters “CB in the element size designates the original drum diameter in inches. Example: For 1008300 - Original Drum Diameter = 10.00 inches (254mm) Minimum allowable drum diameter is: 10.00 - 09 = 9.91 (254 - 2 = 252mm). Air Actuating Tube - Check that the rubber tube has not been damaged by excessive hheat. If any portion of the tube is hard or charred, the entire element must be replaced, Check for any biisters, which would indicate ply separtion. A tube in this condition also re- quires replacement of the entire element. {© Copyright Eaton Corp, 2001, Al rights reserved.4.4 Removal of Spider and Drum Hub 4.4.4 Puller holes are provided for removal. It will usually require heating along with the puller. ‘When heating, heat uniformly to prevent hot ‘spots. 4,5 — Friction Shoe Replacement ZX caution: Use only genuine Airflex replacement parts. Use of other materials may adversely effect performance. 454 ‘Withdraw the shoe pins from the element. element. 483 tion. Insert the shoe pins with the heads located on the mounting flange and/or air con- ction side of the element, as in Figure 12. Flange counterbored__ for air connection ‘Figure 12 45a pins making sure that the scallop or bend in the wire points away from the friction material Each lockwire should go through two shoe pins, securing one friction shoe. See Figure 13. 455 POF Format Remove the shoe pin lockwires and discard. Remove the friction shoe assemblies from the Place the new friction shoe assemblies in posi- Slide lockwires through the holes of the shoe Center the lockwire so that equal lenghts ex- fend from each shoe pin. Bend each end of wire inward toward the friction material and around the shoe pin, as in Figure 13, " 5.0 54 51.4 5.2 624 6.0 64 ett 6244 62.4.2 621.3 6214 SPARE PARTS STORAGE Element Assemblies Element assemblies must always be stored flat, Storage in the standing position may ccause the rims to go out-of-round. Drums, Drums must be stored open end down, in a dry environment. Similar to element assern- bles, storage of a drum in the standing position will adverely affect roundness. ORDERING INFORMATION Product Nameplate In any correspondence regarding Airflex equip- ment, refer to the information on the product nameplate. Element Description/Identification In the event the product nameplate is not avail- able oF Is illegible, note the following element characteristics: Mounting Arrangement - See section 2.1 of this manual for descriptions of various mount- ing arrangements, Drum Diameter - Measure the 0.0. of the «drum, fo the nearest inch. Rim Style - Referring to Figure 14, note any special rim features, ‘Air Connection Configuration - Note the number of valves, and methad of connection to the air supply. See Figure 15. Technical Assistance Technical assistance and/or information re- garding Airflex equipment can be obtained by calling or writing: Eaton Corporation Airflex Division 9919 Clinton Road Cleveland, Ohio 44144 Tel. (216) 281-2211 Toll Free: (800) AIRFLEX or (800) 824-1586 ‘© Copyright Eaton Corp. 2001. Al rights resorved.‘ponsosos uBu RY “Looe "dog ueres WYBUKdeD © eL ewes $0 SRT eer TET wre | rare oe svxze os =z on ot + aor ose na fo [ihr —2 Me | ope ae setae nee ee eee ee orn | =}=}=4= eae} ay : Sa ; 7 wren | + | Seo a ves i SSpsmcsops ts anes 10016 any | oaave a ——— ee gseooz | 862/06 3g wean ey | 20% couse ees orssozh | + | wopant eae | oo eT a ae tee meen to Saar = SS eee ae See | oe roves een soj woes eeiboace | 2o% ee pe] “tao “sped “ame ates | eo | ayaa | ao Pana tig 904 yaHSED “WUOD ANY | aqM] “WED JN mee oemyoon| sores | vou | rsa N00 sau wonaocog woes : : een eH soliquessy juewelg a6ulg 1-2 SLSITSLYVd OL “SLSI'1 SLUVd AS3HL NI ONINVAddV LON LNSW31S ANV YOd SLUVd ANSINZOV1d34 ONINACHO OL HO!d HOLNEINLSIG XT TINY GAZIYOHLAV, NV MO ANOLOVS X314UIV FHL LINSNOD ‘'SLUVd SLNANOdWOD INAY34dI0 SAVH TIM SNOLLWOIIdd¥ SNDYOL-HOIH YO dIIS NO G3SN SLN3W374 “AINO SANSWASSV LNAIN313 GUVONVLS OL Aldd¥ TWANVW SIHJ NI SLSIT SLUvd SHLonveses siyBu ay ‘L002 "hea woIea WEAKdeS a weaves soc sosorst 5 oe ob |b ye | abe 21 soeszziy| oie | Our POUR a pew bb | pb zz soeezztr | 6116 aoe, exes [Cau pee ob |p cz | wees oF eosazety| 9116. | sete FA em dee lat} tft ~ iste} = felset al 1 tf] = | = fatsiiotey tt fale] = dsfel = [=| abl 1 | = fale = Fetal) Ef fH] = | = bststestal a) 1 filed = fle feted ' ia Lil} = Jetel = lelsdedt file = | = felpste tiie} = fated = fe] BEY Cia) veleteni U Ei dt a ea_| SH Per] ON | S| is BB I~ el] ~ eye] Fels efe] = beled = | besetlogeted = bale) = [af] fof i 8) 8 fl § ‘de ‘SeMB0T [a PONS] — VEE é ’ B § * 4"poruasor aybu ny 400% “diog vores WSUAdoo a yeuos sad z z 7 + somin = $ : : + i axa |e 08 2 x10 | = 2 : ; ; = eae nna o, | noms ae | rin cpeeziy} css Sune t r + con ian ; ; - + . ; ; t 1 sen |= : : ‘ = ee awe Fe = nyo, | wimg oe | wie Bae at | Me : + Sh : 7 ; ; . ; F ; amen -= i i oan att =tS+ eg er nina 11 | wom | noe 2 : ; Sou Bed | ant | aa \ ; ={ =] "ON Wed_| ON ved | ONT Lm Na) NO; ON ea | KO | ON WOT Sen ae Ve fees a ee Saypanies Y6U ly L00 "4109 HOI 4EAEOD 6 ewuod sod fe quowoje oj6us puodse1ico ou) ul siaquinu Led 3p pu “W 20)381 sued 94} ul sequinu juBwale 24) 2}229} ‘suauoduic: ‘YBno1y ssed saqm) se Buoy pue BOYS eu yJOq YoI\y 12m oe Teno rs = i oa zen sesa00 i ea sizer an ce ot SESE | ORL og aneazzeh ‘susszzrt yo GOA apis omy | SESBOBE ee oe oe waco of oe ee ae — eee et a as aoe oe OSESDL Saaz | ize ‘DOREDPE a eee ; 8 “youngiong | ewe cm pu nee Wau soljquiessy juewoyy (eng ZLAirflex EATON PRODUCT WARRANTY Subject to the conditions stated herein, Eaton Corporation warrants to the Pur- chaser that each new Airflex Product manu- factured by Eaton will be free from failures caused by defects in material and workman- ship, and will deliver its rated capacity, for a period of twelve (12) months from the date ‘of shipment to Purchaser, provided such Product is properly installed, properly main- tained, operated under normal conditions and with competent supervision. Warranty claims shall, be made in writing and the part or parts shall, if requested by Airflex Divi- sion, be retuned repaid to the Airflex Divi- sion for inspection. Upon a determination that a defect exists, Eaton shall thereupon correct any defect, at its option either by re- pairing any defective part or parts or by mak- ing avaitable at Eaton's plant a repaired or replacement part. This warranty does not ex- tend to normal wear parts or components of the Product, such as friction material and friction surfaces. E:T-N PDF Format Form ML-318 Revised September 3, 1997 LIMITATION OF WARRANTY THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRAN- TIES WHETHER WRITTEN, ORAL OR IMPLIED. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE ‘SPECIFICALLY EXCLUDED. In no event shall Eaton be liable for special, incidental or consequential damages. Ea- ton’s liability arising out of the supplying of such Product, or its use, whether in war- ranty, contract or otherwise, shall in no case exceed the cost of correcting defects in the Products as herein provided. Upon expira- tion of the twelve (12) month period, all such liability shall terminate. THE FOREGOING ‘SHALL CONSTITUTE THE SOLE REM- EDY OF PURCHASER AND THE SOLE LIABILITY OF EATON. Eaton Corporation Airfiex Division 9919 Clinton Road Cleveland, Ohio 44144 Printed in U.S.A.Equipment ManualWC 11050 /\wani Forward this manual to the person responsible for Installation, Operation and Maintenance of the product described herein. Without access to this information, faulty Installation, Operation ‘or Maintenance may result in personal injury or ‘equipment damage. Installation, Operation and Maintenance of Airflex® WCB Water Cooled Tensioners Ref.: Parts List #’s 146246A thru 146298J E-T-N /\caution: Use Only Genuine Airflex® Replacement Parts “Tho Alfie Divison of Eaton Corporation recommends the use of genuine Alex replacement pari. Tho uoo of non-genuine Ail rplacement pats oould osu in substandard product pertormance, and may void your Eten waranty. For optimum pefomance, contact Alfio In the U.S.A. and Canade:: 800-233-5926 Outside the U.S.A. and Canada: (216) 281-2211 August, 1995 PDF Format 204054 © Copyright Eaton Corp. 1995 All rights reserved40 a4 coos an A sep 207A eco. oun st Jere 14. WCB. 7 Loca we BATS SA Pb We, Figure 2 space NOTE: The coolant outlets should be positioned at the 12 o-clock position. Porroraat 2 (©Copyright Eaton Corp., 1995, Al eights reserved18, 24 & 36 WCB Single Disc ose oe qh ; ot : g 2, < eu iz NJ —3 JI \\18, 24 & 36 WCB Triple Disc ay Figure 6 or rortant 6 copyright Eaton Corp., 199. All ights reserved.item Description tor 18, 24 & 36 WCB items for Figures , 4, §, 6,7 & 8 tor 18, 24 & 36 WCBs with screwed on linings and stop tubes Hem Desciption tem Description 4___|Mounting Flange Sub-assembi [24 [Warning Decal [_ Mounting Flange a 25 [Name Plate 3__|Wear Plate 26 [Drive Sorew 4 [Hox Head Screw 28 |Gear San 8 |Locknut 29 |Wear Spacer 6 __|Stud 30 |Reaction Plate Sub-assembly ‘8 [Friction Dise ~_| 31 [Reaction Plate ‘9 [Friction Disc Core 32 [Decal Pate 12 |Giamp Tube 33 [Piston 13, [Pressure Plate Sub-assembi = 34 [Release Spring 14 [Pressure Plate ‘50 [Inner Support Ring 47 [Flat Washor ‘51 [Outer Support Ring, 48 [Locknut ge ‘57 [Flet Head Screw 19 [Cylinder '58__|Wear Fing SE 21__[Polypak Seal a 59 [Stop Tube 23 [Polypak Seal ‘80 [Stop Tube Fo par number listing 29 cocion 5.0 Tensioner Mounting Register Diameters - in. (mm Female Register | Male Register 8375/0378 12126112122 12. 712%2.8) (998.0/307.9) y4.a76/16.378 | 18.750/18.747 (965.1/565.2) (476.9/476.2) ve.250/1e.259 | 23.250/29.247 ($90,5/580.8) 24.076/24.978 | 29.998/20.905 (619.1/619.2) (764,9/761.8) Ya.a7s/10.078 | $4.498/44.405 466.7466.8)_] _(1130.2/1130.1) jeter to bo 125". 188" out ome. OAD yore Re Rie ie von BE Bae Be 24 WCB Figure 8 36 WCB NOTE: The coolant outlets should be positioned at the 12 o-clock position. porreraur 8 ‘@copyight Eaton Corp., 1995. All rights reserve124 125 126 127 13 134 144 114 WCB Models with *H" (146XXXH) designator have a special friction disc core for mating with a 112.8 WC gear. The triction ise core (9) PIN is 416126 and the friction disc sub-assembly (7) PIN is 416125, all other paris are the same as the "B" model WCB. WCB models with "J* (146XXXJ) designator have Corrosion Resistant Pistons and Standard screwed on friction linings. Contact Aitflex for piston (33) PIN's. WCB models with *K" (146XXXK) designator have Corrosion Resistant Pistons and High Costficient screw ed on friction tinings(8). Call Aiidlex for piston (33) PIN's. WCB models with part list numbers, not just alphanumeric designator, other than listed on ‘cover use WC 11040. Upgrades 418, 24 and 36 WCB elements ending with a "B" (146XXXB) alphanumeric designators have been discontinued, however, existing models may be upgraded to new standards ‘To upgrade the element you must change the friction disc subassembly with cores having ‘screwed on linings. See table X, all disc's must be changed. Also stop tubes (59) & (80), wear rings (58) must be installed. See the part list in section 9.0 for part numbers and quantities for the individual elements. Note; if these changes have been made stamp ‘out the “B" letter designator and stamp the *B designator. How It Works eter to Figure 1. Airis introduced to the unit causing the pressure plate assembly (13) to ‘move and make contact with the friction discos {8). Torque is transmitted through the studs (6) to the mounting flange (2). The release springs (34) assist in disengagement and retraction of the piston and pressure plate. High heet dissipation is accomplished by passing water through a special cavity behind copper wear plates (3). rorrorwur 10 2.0 24 INSTALLATION AXwersing Only qualified maintenance personnel ‘should install, adjust or repair these units. Faulty workmanship will result in unreasonable exposure to hazardous conditions or persoral injury. /\caution: Read these instructions thoroughly and review until you fully understand the Installation sequence before proceeding ‘with the wrk described in this section. Failure to follow these instructions will result in unreasonablo exposure to hazardous conditions or personal injury. eda Do not paint the clamp tubes (12) or the springs (34), as this may hinder the ‘engagement or disengagement of the tensioner. i ‘Maximum ambient temperature is 110°F (43°C ), Minimum ambient temperature for closed loop systems using ethylene ‘glycol antifreeze is 0°F (-18°C). For open oop systems using water, the minimum temperature is 45°F (7°C). Note: Some three and four disc units may require support on the cylinder end of the tensioner in certain high torque applications. Contact the factory for specific application information. Preparation “Tablo 2 shows the relationship between the tensioner mounting surface and the end of the ‘gear (dimension “A” on Figure 1, 3-6). The ‘gear is bored and keyed for a resulting Class FN2S interference fit for inch shafting and ISO System S7h6 for metric shatting. ©Copyright Eaton Corp, 1995. Al rights reserve./Npanger: 232 To facilitate the tensioner mounting process, the friction disc assemblies should be aligned Use only the proper number and grade to the gear and centered in the tensioner, With fasteners shown in Table 4. Use of the tensioner laying on the floor, ower the gear ‘commercial grace (Grade 2) fasteners (28) stowly and very carefully into the splined whore Grade 8 fasteners are specified bore of the friction d'se assemblies (7). Adjust ‘may resuft in falure of the fasteners and the discs so that they are centered in the a suxiden and castle reduction in brake tensioner and fit the gear. Apply and maintain torque. ‘an air pressure of 2 PSIG (1.7 bar) to the cylinder. This will engage and hold the discs in position to facilitate tensioner installation, /\ caution: Remove the gear ‘Make sure that the water inlets and 283 Ensure that the shalt is free of nicks or burts Cutlets are at the 6 o'clock and 12 and the key fits properly in the shaft and gear. o'clock positions, respectively. See Fi- tures 2 & 8. This will ensure that there 284 Apply allight coat of anti-seizing compound to will be no air pockets in the water cavity the shaft and key. Tap the key into the shaft during operation, which would allow the keyway. tensioner to overheat. 238 Press the gear onto the shaft, making sure that the dimension between the gear and the tensioner mounting surface ("A") is maintained. See Figure 1 and Table 1. Heating the gear uniformly to 250°F (121°C) will expand the bore and ease assembly. 102-14 NET ___24 wee 1214 NPT 36 WCB 3/4-14 NET. TABLE 6 Coolant Supply D: ‘Min. Fig | Min. Flow | Min, Flow Min. Flow Rate Rate” Rate” ‘Thermal ‘Water Inlet Rate” GPM GPM GPM Sizo Rating’ | and Outlet GPM (een3imin) | (dmd/min) | (am3/min) HP (kW) Pipe Size | (dm3/min) | 70% Water, | 60% Wate, | 50% Water, 100% Water | 30% Ethylene | 40% Ethylene | 50% Ethylene Glycol by Vol. | Glycol by Vol. | Glycol by Vol. 108 302.4) | tesanpr | 3cia) | 35c3.4) [ 3.9047) [4.5 (17.0) 208. 6044.7) | 12-14npr_| 622.7) 7 (26.8) 7.8(29.4) | 93.9) 114 60 (44.7) | 12-14ner | 6 (22.7) 726.8) | 7.8(29.4) | 983.9) 214 120 (89.4) |_We1aner_| 1245.4) | 1463.6) | 15.6 68.8) | 18 (67.9) 148, 120 (89.4) [ s2-tanpr [12 (45.4) | 14 (63.6) | 15.6 (68.8) | 18 (67.9) 218 240179) | vet4ner_| 24 (1) 2eio6) | 31017) | 36.1136) 318 360 (268) | w2t4npr | 36 (136) | 42 (161 47176) | 54 204) 124 270201) | 3/ataner_| 27 (102) | 32121) | 35(132) | 40151) 228 540 (402) | 9/414.NeT_[ 54@04) | 64 @42) ‘80-(303) 324 810 (603) | 9/4-14 er | 81(308)_| 96 (363) 120 (453) 42a 1080 (804) | 9/414 NPT | 108 408) | 128 484) | 140 (528) | 160 (604) 136, 650 (485) [41/411 NPT | 65 (246) | 76@88) | 64,318) 98 (871) 236 | 1300 (970) | 14/4-11NPT| 130492) | 152,676) | 168 (636) _| 196 (742) 336 1950 (1454) | 11/6-11 NeT | 195.738) | 228 863) | 253985) | 204 (1113) 436. 2600 (1940) | 114-11 NPT] 260,84) | goa (1152) | 936 (1272) | 392 (1484) T Thermal rating based on a 70°F (212C) water inlet temperature rise belween inlet and outlet, ? Fiow rate is based on requirement of 1 US. GPM per 10 HP thermal dissipation. ore 12 ‘©Copyright Exton Corp, 1995, Al aghie reseedTABLE7 Maximum Mixture Outlet Coolant Temperature Water/Ethylene Maximum Outlet Glycol Mixture | Coolant Temperature % byVolume | PF °C) 100/0 150 (66) 70/30 165 (74) 6040 "165 (74) 50/50 470.77), 262 25.3 254 Figure 10 shows the flow control valve settings for each type of element depending on the ‘number of friction surtaces to be cooled. i Improper or low coolant temperature can ‘cause condensation to occur on the friction surfaces which will affect torque ‘and wear performances. Coolant should be shut off when element is not in use. /\ caution: Make sure that the water inlets and outlets are at the 6 o'clock and 12 o'clock postions, respectively. This will ‘ensure that there will be no air pockets in the water cavity during operation, which ‘would allow the tensioner to overheat, 255 ‘The coolant supply and discharge pipe sizes, along with minimum flow rates for the tensioner rated horsepower, are given in Table 6. Each coolant cavity of each WOB tensioner has been statically tested at the factory before shipment. if leakage is suspected, a static or dynamic test may be made as follows: Static Pressure Test: First, bleed ail air from within the coolant cavity. Air bleeding must be accomplished by running coolant through the cavity with the tensioner secured in its operating position. Af- ter the air has been removed, install a pipe plug in the outlet and apply 45 PSIG (3.1 bar) cool ant pressure measured at the inlet to the water cavity, Maintain this pressure for 30 minutes. Chock for leakage at C.D. and ILD. seal areas, 257 rorrcreur 14 JX caution: Do not apply air pressure to the cylinder of the tensioner during static ‘coolant pressure testing. Surge pressures exceeding 45 PSIG (3.1 bar) could be developed within the cootant cavities which wil cause damage to the seals. Dynamic Flow Test: Dynamic flow testing of the tensioner should be conducted at the required flow rate for the fated HP dissipation and coolant quality, as given in Table 6. Inlet pressure is not to exceed 45 PSIG (3.1 bar) “There should be no restrictions on the outlet side of the brake to cause any back pressure to the unit, Coolant inlet and hose size should be as given in Table 6. Check for leakage at the (QD. and LD. seat areas ‘The coolant supply temperature at the inlet should be 100°F (38°C) of lower. The coolant outlet temperature should not exceed the values given in Table 6. However, in no event should there be more than a 50° (28°C) tomporature rise between inlet and outlet. See ‘able 7 for maximum allowable outlat coolant temperature with a water/ethylene glycol mix, ‘Open Loop Systems, For efficient operation of the WCB an adequate supply of filtered fresh water is required. (See 2.5.1-2.5.2). Excessive water hardness promotes the formation of scale deposits, which, in time, will affect the service fifo of the WCB unit. Water of high acidity may cause electrolytic corrosion between the dissimilar metats used in the WCB Water treatment should be considered ifthe proper- ties of the water exceed the following: Equivalent calcium carbonate content hardness): Maximum 100 ppm. pH valus: 7.0 to 9.0. Closed Loop Systems For effiotont operation of the WCB in a closed loop system, ethylene glycol cootant contor- ing to SAE Standard J1034 should be used. For preparation of the proper concentration of a water/ethylene glycol mixture, use makeup water which is low in corrosive ions such as chlorides and sulfates. ‘©Coryight Eston Corp, 1995. Al ight reserved.4.0 PERIODIC MAINTENANCE warning: Before doing any maintenance work on ‘the WCB unit, make sure that the ‘machinery will remain in a safe position. Failure to do so could recuit is sorious injury or possibly death, /\Warning: Only qualified maintenance personnel should instal, adjust or repair these WCB. units. Faulty workmanship will resutt in Unreasonable exposure to hazardous cconeitions or personal injury. L\gaution: ead these instructions thoroughly and review until you fully understand the parts replacement steps before proceed- ing with the work described in this soction, Failure to follow these instruc- tions can result in unreasonable ‘exposure to hazardous conditions or personal injury. 4.1 Wear Adjustments (WCBs w/Stop Tubes) 434 Single disc WCBS Note: Item numbers (#) are shown on Figure 3. ‘There is no adjustment for single disc elements. When the pressure plate (13) bottoms against the stop tubes (59) , replace friction material and inspect wear plates for ‘wear. See section 6.0. Note: Stop tubes may be added to 18, 24 & 36 WOB single oloments that did not originally ‘come equipped with stop tubes. Order tem (68), (59) and (80) from parts list for WCB elements including stop tubes.(Part lists’ alpha-numeric number ends with *E.) ‘See section 9.0. Forres 16 4a2 4a24 413 4134 41.82 41.93 Dual, Tiple & Quad disc WCB's Note: Items (f) referenced in Figures 4,5 and 6. Dual cise elements have one adjustment, triple disc elements have two adjustments and quad disc elements have three adjustments. Folow the wear spacer adjust ment procedures in section 4.1.3 for each adjustment made. Note: Stop tubes may be added to 18, 24 & 36 WCB multi disc elements that did not originally come equipped with stop tubes. Or- dor Items (58), (59) & (80) from parts lst for WCB olemonts including stop tubes. Part lists’ alpha-numeric number ends with "*. See seo- tion 9.0. Wear adjustment procedures (Multi disc) ‘Noto: Item numbers (#) are shown on Figures 4, 5 and 6, Note: On all units, the friction material must be replaced when worn to the bottom of the groove on the friction lining. See Figure 11. See Table 17 in Section 7.0 for new weat (groove depth. Disconnect air and water supply lines from the tensioner. While supporting the cylinder (19), loosen the locknuts (18) ONE TURN AT TIME and in an altemating (crosswise) pattern until the spring force is completely relieved. Remove the focknuts and washers (17). Mark all of the ‘water outlet ports for identification. Deop well sockets are required. See table 9 for size and depth of socket required, Using lifting equipment, carefully remove the cylinder (19) and piston (83) as an assembly. Sot aside in a clean area. (Piston side up.) Note: If a stud (6) should happen to come loos remove ft competes clean the treads on the stud andthe threads in the mounting flange Apply Locquic® Pimer Grade "T" to the stud threads Alte the threads have dtd, assemble to the mounting flange using Loctite? #262. The end of the stud must not extend past the mounting surface of the mounting flange (Copyrint Eaton Corn, 1995, Al Hghts reserved,41.89 441.8.10 443.41 41.9.12 424 424 orton For multi-ise units, repeat steps 4.1.3.7 and 4.1.3.8 for each additional friction dise and reaction plate ** 422 Slide the pressure plate and the oylinder/piston assembly onto the studs. Lubricate the threads (on the end of the studs with 30 wt. oll or anti- seizing compound and install the washers (17),\ear spacers (29) and the looknuts (18) removed in 4.1.3.6. The wear spacers are “stored” under the Jocknuts and washers for use after replacing the friction discs. See Figure 12. Discard ur-used wear rings. New wear rings ‘are included in friction disc replacement kits. 428 While supporting the weight of the cylinder/piston assembly, tighten the locknuts, ONETURN AT A TIME and in an alternating (crosswise) pattern until the cylinder is seated firmly against the clamp tubes. Torque the ocknuts to the appropriate value See Table 4. /\eation The locknuts (18) must be tightened gradually to prevent damage to the sioner components ‘Check that clearance exists between friction discs and wear plates. Reinstall air and coolant ines per 2.0. Wear Adjustments (WCB's without stop tubes) ‘Measuring Lining Wear A\wiasiog Periodically examine the tensioner for ‘Wear of linings and wear plates. Failte to perform this examination will result in excessive wear, a significant reduction in torque, and may result in personal injury ‘and/or damage to the machinery. Wear limits for the WCB components are shown in Section 7.0. If any wear limit has been reached or exceeded, that Component must be repaitod or replaced. 424 425 18 Note: Item numbers (i) are shown on Figure 1. Single Dise Units Apply approximately 25 PSIG (1.7 bar) air pressure to the cylinder to engage the tensioner, Measure the gap "X" between the cylinder (19) and the pressure plate (13) or the gap "Y" between the pressure plate (13) and the mounting flange (2) as shown in Figure 1. If the gap exceeds the limits shown in Ta- ble 9, the friction dises andor wear plates must be inspected to ensure that the weat limits listed in section 9.0, Table 10 have not been exceeded, Mut-dise Units Apply approximately 25 PSIG (1.7 bet) air pressure to the cylinder to engage the tensioner. Measure the gap "X" between the cylinder (19) and the pressure plate (13) or the gap "Y" or"Z" between the pressure plate (13) and the reaction plates (81) and the gap "Y" between the reaction plate (31) and the mounting flanga (2) as shown in Figure 14, 15 and 16. If the gap exceeds the limits shown in Table 10, the friction discs and/or wear plates must be inspected to ensure that the wear limits listed in section 7.0. A\warning: If wear adjustment is not made, the piston may pop out of the cylinder result- ing in loss of torque and/or seal damage. ‘Wear Adjustment ce Premature wear adjustment may result in improper disc clearances. A\warning Ita wear adjustment is not made, the piston may be allowed to travel past the ‘end of the cylinder resulting in a suciden logs of air pressure and a complete loss in torque, Disconnect air and water supply lines from the tensioner. ‘©copyright Eton Corp, 1995, Al fights reserved.426 427 428 429 42.10 42m ‘While supporting the cylinder, loosen the locknuts (18) ONE TURN AT TIME and in an altemating (crosswise) pattern until the spring force is completely relieved. Remove the locknuts and washers (17). Mark all of the water outlet ports for identification. Deep well sockets are required. See table 9 for size and depth of socket required. Using lifting equipment, carefully remove the cylinder (19) and piston (83) as an assembly. Set aside in a clean area. Note: if a stud (6) should happen to come loosa remove it completely, clean the threads (on the stud and the threads in the mounting fianga. Apply Locquic®Primer Grade "T" to the stud threads. After the threads have dried, assemble to the mounting flange using Loctite® #262. The end of the stud must not extend past the mounting surface of the mounting flange. JX caution: Loctite ©4262 must be shaken prior to application. A\eawson Loctite®#262 may initate sensitive skin. Reter to the product label for proper safety precautions. Using lifting equipment, remove the pressure plate assembly (13) and carefully place it on a suitable work surface with the wear plate (3) facing up Do not damage the wear plate. Remove the friction disc assembly, the reaction plate assembly (30) and the release springs (34) and set aside ‘Siide the clamp tubes (12) off of the studs. Remove one wear spacer from each stud. Feinstall the clamp tubes and set aside the removed wear spacers. Place a release spring over every other clamp tube and slide the reaction plate assembly ‘onto the clamp tubes. 20 Slide the friction disc assembly onto the geat. For multi-disc units, repeal steps 4.2.5.7 and 4.2.5.8 for each additional friction dise and reaction plate Place a release spring on every other clamp tube and slide the pressure plate and the cylinder/piston assembly onto the studs. Lubricate the threads on the end of the studs with 30 wt. oil or anti-seizing compound and install the locknuts (18) washers (17) and the wear spacers removed in 4.2.5.6. ‘The wear spacers are "stored" under the locknuts for use after replacing the friction discs. See Figure 12. ‘While supporting the weight of the cylinder/piston assembly, tighten the locknuts, ONE TURN AT A TIMEand in an altemating (crosswise) pattem until the cylinder is seated firmly against the clamp tubes. Torque the locknuts to the appropriate value. See Table 4. /\cautio ‘The locknuts (18) must be tightened gradually to prevent damage to the tensioner components. Reinstall the air and coolant lines per 2.0, DISASSEMBLY, INSPECTION & ASSEMBLY hen Before doing any maintenance work on the WCB unit, make sure that the machinery will remain in a safe position. Failure to do so could result is serious. injury oF possibly death. /\Warning: ‘Only qualified maintenance personnel should! install, adjust or repair these WCB units. Faulty workmanship will result in unreasonable exposure to hazardous conditions or personal injury. ©copyright Eaton Corp, 1995, All aghtsresoved623 524 625 626 827 628 829 6210 A\eaion Loctte™#262 may inate sensitive skin. Rafer tothe product label for proper ‘safety precautions. Using lifting equipment, remove the pressure plate assembly (13) and carefully place it on a ‘ultable work surface with the wear plate (3) facing up. Do not damage the wear plate. Remove the friction disc assembly, the reac- tion plate assembly (30), release springs (34), stop tubes (69) or (80) and wear rings (68) (if present) and set aside. For mult dise units repeat step 5.2.4 for each reaction plate and friction disc set until all are removed. Slide the clamp tubes (12) and wear spacers (29) off each of the studs. Pace the cylinder and piston assembly with the piston facing down on blocks approxi- mately 6" (150 mm) high, The blocks must only contact the cylinder (19) so that the piston (33) will be free to move out of the cylinder bore 11 a regulated airline is avaiable, the piston can be partially ejected trom the cylinder by applying no more than 15 PSIG (1.0 bar) to the oylinder, /\caution: ‘Application of a higher pressure may cause damage to the components. ‘To complete the removal of the piston from the cylinder, open all air inlets Altemately in- sert 0.50" (12 mrn) diameter by 6* (150 mm) long wood dowel into each air inlet and gently tap the piston with a mallet so that it moves evenly out of the cylinder. Be careful not to damage the sealing surfaces of the pis- ton of cylinder by cocking the piston in the cylinder. Inspect the cylinder sealing surtace condition for nicks or scratches or any other defect which may prevent the seals {rom being effective Refer to the Wear Limit tables in section 7.0. Replace the cylinder, if necessary. 52.11 52.12 62.13 5.4 bat BAR 848 Bad 545 646 SAT 648 5.5 56 22. Noting how the lips of the seals are oriented in the piston grooves, remove the seals. Thoroughly clean the seal grooves in the piston and apply a thin, even coat of Parker “O* Lube® to the seal grooves, the seals, the sealing surfaces of the cylinder and to the chamfer on the piston. ‘See section 6.4 for inspection and section 5.5 for assombly. Ingpection of WCB components ‘Note: Wear limit tables for the following paragraphs are in section 7.0. Inspect the friction disc assemblies (8) for wear (or contamination. On single and multi-dise units, the friction material must be replaced when wom to the bottom of the groove on the friction lining, See Figure 11. For friction disc repair see section 6.5 for ‘elements with riveted linings or section 6.4 for elements with screw ed-on lining. Inspect the wear plate (3) for weer. Wear plates must be replaced if they exceed the wear limits. See section 6.6 for repair procedures, Inspect the cylinder (19) seal area. inspect the cylinder sealing surface condition for nicks or scratches or any other defect which may prevent the seals from being effective. Refer to section 6.1 for repair procedures. Inspect the reaction hole diameters in the reaction plate (21) and pressure plate (14), Inspect the clamp tubes (12) for wear on the reaction area. Inspect the friction dise core (9) and the gear for excessive backlash, Inspect the release springs (34) for free height, Assembly of WCB 18, 24 & 36 WCB’s (with Stop Tubes) ‘Note: Item numbers (#) are shown on Figures 4, 5, 6 and 7. Position mounting flange (1) with studs (6) installed, on a level working surface, mounting face down. ©copyright Eaton Corp, 1986. Alright reserved.6.0 61 oi4 COMPONENT MAINTENANCE Warning: Before doing any maintenance work on the WCB unit, make sure that the machinery will remain in a safe position, Failure to do so could result Is serious injury or possibly death, A\warning: (Only qualified maintenance personne! ‘should install, adjust or repair these WCB units, Faulty workmanship will result in unreasonable exposure to hazardous ‘conditions or personal injury. /\gaution: ‘Read these instructions thoroughly and review until you fully understand the parts replacement steps before [proceeding with the work described in this section, Failure to follow these instructions can result in unreasonable ‘exposure to hazardous conditions or personal injury. Cylinder Seal Replacement Note: item numbers (# ) are shown on Figures 1, 3, 4, 5, 6 and 7. 615 ‘Soe the Section 11.6 for the appropriate seals for each WCB tensioner. Disconnect the air connections. Bir ‘While supporting the cylinder, loosen the focknuts (18) ONE TURN AT TIME and in an alternating (crosswise) pattem until the spring force is completely relieved. Remove the locknuts and washers (17). Remove any wear spacers stored under locknuts. Mark all of the ‘water outlet ports for identification. Deep well sockets are required. Soe table 9 for size and depth of socket required. 18 Using lifting equipment, carefully remove the cylinder (19) and piston (33) as an assembly. Set aside in a clean area. 619 orromaxr 24 Note: I astud (6) should happen to come loose, remove it completely, clean the threads on the stud end the threads in the mounting flange Apply Locquic® Primer Grade'T" tothe stud threads. Alter the threads have dried, assemble tothe mounting flange using Loctite? #262. The end of the stud must not extend past tne mounting sure of the mounting flange /Xcautio Loctite #262 must be shaken prior to application. LX caution: Loctite®#262 may initate sonsitive skin. Rafer to the product label for proper safety precautions. Place the cylinder and piston assembly with the piston facing down on blocks approximately 6° (150 mm) high. The blocks ‘must only contact the cylinder (19) so that the piston (33) will be free to move out of the cylinder bore, Ifa regulated airline is availabi the piston ‘can be partially ejected from the cylinder by. applying no more than 15 PSIG (1.0 bat) to the cylinder ZX caution: Application of a higher pressure may ‘cause damage to the components. ‘To complete the removal of the piston from the cylinder, open all air inlets. Alternately insert a 0.50" (12 mm) diameter by 6" (150 mm) long wood dowel into each air inlet and gently tap the piston with a mallet so that it moves ‘eveniy out of the cylinder. Be careful nat to ‘damage the sealing surfaces of the piston or cylinder by cocking the piston in the eylinder. Inspect the cylinder sealing surtace condition for nicks or scratches or any other defect which may prevent the seals from being effective Replace the cylinder, if necessary Noting how the lips of the seals are oriented in the piston grooves, remove the seals: €Copyioht Eaton Corp, 1995. A ght reserved,1_ NOTCH 2 PUES 180" aeAeT (ox 1a ua IDENTIFICATION) STANDARD Figure 18 LINING Loctite®#262 must be shaken prior to application. /\caution: Loctite?#262 may initate sensitive skin. Rafer to the product label for proper ‘safety precautions. Friction Lining Replacement for 8 & 14 WCB’s (Riveted Lining) Friction disc cores may be relined with now friction material per the following instructions. Refer to Section 11.0 for the appropriate friction disc replacement kit part number. /\ caution: Use only genuine, Alrflex friction ‘material. Use of material not of Airflex origin may result in unpredictable brake performance andior excessive wear of the brake components. 63 eat res orwar 26 2. NOTCHES Pewee’ seo wast (ee Lane wart, HDeNTCATON) HIGH COEFFICIENT Figure 19 LINING 63.2 Drill out the old rivets and discard the old friction discs, 63.3 Refer to Figure 20 and carefully examine the counterbored holes in the friction iso segments (512308). One set of counterbored holes is tapered and designed to accept the rivet head, while the other set of counterbored holes is flat-bottomed and designed to accept the clinched end of the rivet. 63.4 Position the friction discs on both sides of the disc core and align the rivet holes. Driver —>{~“]_ Ret [ aie Friction Tasca Disc Friction Disc Core J —~ ™ Washer Anvil Pin Fig. 21 Punch ae Rivet Washer — > Friction oe a‘ a Disco S J I Friction Disc Core Anvil Fig. 22 ‘©copyright Eaton Coen, 1098. Al ight reserved.Loctite Supertiex®#596 Silicon Sealant will begin to set up and skin over in ap- proximately 10 minutes. The wear plate ‘must be fastened to the mating compo- ‘nent within 10 minutes of applying the sealant. 647 Install the new sorews and locknuts provided with the wear plate replacement kit and secure finger tight /\ caution: ‘Toprevent excessive warpage and to err sure a good sea, the following hardware tightening procedure must be followed, For each wear plate being replaced, follow the tightening sequence shown in Figure 23 for the first 16 screws, The remaining screws ‘may be tightened in any reasonable crosswise pattern. Soe Table 12 for tightening torques, A \emtion Allow the Loctite Supertiex®4596 Silicon Sealant 24 hours to completely ‘cure before performing the following leak test procedure. 24 hours after completion of assembly, each ‘water cavity should be checked for leaks. 48 649 /\ caution: Premature pressurization may cause leaks 64.9.1. Using lifting straps, suspend each assembly with the water outlet port at the 12 o'clock position. Connect awater supply line to the in- let port (at 6 o'clock postion). See Table 13 for water port size 64.9.2 Slowly fill with water to purge all air from water cavities, 64.9.3 Install apipe plugin the outlet port and apply 45 PSIG (3.1 bar) water pressure measured at the inlet. Maintain this pressure for 30 minutes, ‘Check for leakage at QD. and |.0. seal areas, NO leakage is allow ed. e404 64.95 If the assembly leaks, check the torque on each screw and retest. If leaks still occur, the wear plate(s) may be damaged. Repeat procedure from 6.4, 64.96 Follow steps in section 5.5 or 5.6 to reassemble the tensioner, 64.97 Reinstall the tensioner por 2.0, ORDERING INFORMATION’ TECHNICAL ASSISTANCE Equipment Reference {n any correspondence regarding Airflex equipment, refer to the information on the product nameplate and call or write: Eaton Corporation Airflex Division 9919 Clinton Pa Cleveland, Ohio 44144 Inside the USA and Canada: 800-233-5926 ‘Outside the USA and Canada: (216)-281-2211 Fax: (216) 261-3890 Loctite Locquig, Pormaflex and Supetox are rogisterad trademarks of Woette Corporation. Patypak and Parker O-Lubo ave resiered trademarks of Parker Hanna Corporation (Gi Gara is a registered trademark of ‘The Guden Company Motb-Alloy O°. is aregisteed trademark of ‘mnponial Mata Lubricate Co. 28 ‘©Copyright Eaton Corp, 1995. 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Spz0rs|_t SPLOTS| ‘aiog 810 oH] Te g a 22803] 9 s2z803|_v sele0s 2 $2805 esi wonspa| Te. g ZE_| ea0oxseoo0] 2b | 1eooxsrzo00} et | tZ00xSPe000]_zt_| _6900KSPe009] pas) 9 S| 0s¥_|_evsoxesro00] € | _ar90xest000| oze | er90xeSt000| O8t | eraoxesto00] TOAST ¥ Osy | Se9OXEStOOO] Ose | Se9OxEStOOO| oe | Se9OxEStOOO| ost | se9oxeSTOOO ~~ ‘malog PeeH XEH| spe ‘esva03] © oarae| —P eave03| BerR0e Sid EH z zeeers] zeeeis| + Zeeers]_t Zeer ‘SBE BuTUROH t ro-areers} to-ereers| 1 Toereers]_ 1 TO BPEL TS|NGURSSEGS SBE BUENO wor [MO] saved | NO| enwed | MO enwed | MO | wn ved wonduaseg wrived | Wembupazscort | Gembuya rseerr |W amnbia) aeecopr (Canby) 380694 sn Sued TePOW, gOm ber BOM bzE aOm bez, gom vel, POW SISPOW BOM Fe PlEpUEIG| a610.0 SUB-ASSEMBLIES 10.1 [Sub assembly breakdown for 8 WCB’s Sub-essembly | Item | Qty. _ Description | ____Part Number Mounting Flange |___2 +____|Mounting Fiange 512406 Sub-assembly 3 1 |Woar Prato 1512507 PIN 512508-01 [~~ 42 |Socket Head Screw loo0030% |_ Hom #1, Fig 4 5 42 |Locknut [000153x: Friction Dise é 2__[Friction Diso 1512509, ae Sub-assembly 9 + [Fiction Disc Gore 512510 PIN 512512 10 20 [Rivet (000130x0086 Rem #7, Fig. 1 im 20 [Washer (000153x0055, Pressure Plate 14 | 1 [Pressure Plate 1512502 i Sub-assembly 3 + [Wear Pate [512507 + | PIN 612500-09 4 42 | Sookst Hoad Serew '000030x5407, tem #13, Fig. + 5 42 |Locknut [0001 10x0024 7 31 + [Reaction Plate 512504 Seance, 3 2 [Wear Plate [512507 pins12508-02 |__49 42 [Socket Head Screw [000030x5408 Hom #30, Fig. 1 |__5 42 [Locknut [000153x1049 15 42 Washer [000670036 10.2 [Sub assembly breakdown for 14 WCB's i Sub-assembly | item | Qty. Description Pari Number Mounting Flange | 2 "1 [Mounting Flange 512875 Sub-assembly 3 + Wear Pate la18212 PIN 513900-01 4 60 |Hex Head Sorew (oo015ax1017 tem #1, Fig. 4 5 Locknut (000153x1061 Fiction Dise 8 Fiction Diss 415227 ‘Sub-assembly_ 9 Friction Disc Core 415207, PIN 416208, 10 Fivet _ (000130x0085 banal hl eal 11_| 30 |Washer (000153x1064 Pressure Plate 14 1 [Pressure Piate [512377 Sub-assombly 3 [1 Wear Pate iai5212 zi Pin 612200 6 4 60__|Hex Head Screw [o00153x1017 Hem #18, Fig. 1 5 60 [Looknut [000153%1061 3 |__| Reaction Plate 512380 Sisson) 3 2 [Wear Pate la15212 PIN 513300-02 |__49 60 |Hox Head Screw fo00183x1018 ftom #30, Fig. 1 5160 ILocknut [o00159x1061 15 | 60 [Washer [o0067x0001 or romuar 34 ©copyright Eaton Corp., 1995. All ight reserved10.5 ‘Sub assembly breakdown for standard 36 WCB's with screwed on linings. Sub-assombly | item | Qty. | ___Deseript E art Number 2 Mounting Range Mounting Flange 3 Wear Plate Sutrassembly [Socket Head Screw 5 lLooknut Eee roeae acto: linner Support Ring 81 [Outer Support Bing | 14 [Pressure Plate | 3 Later (Wear Plato Information not available at this 7" iescker Hea Scie ime. Contact Airtlex for details. 5 lLocknut er ates a eae (eaeiso inner Support Ring | 51 [Outer Support Ring | at [Reaction Plate Reaction Plate 3 lWear Pate Subrassembly 4 lHex Head Screw | 5 lLocknut eee a esciso linner Support Ring 51 [Outer Support Ring Friction Dise 8 1 Friction Disc Core [513667 a Sub-assembly 9 16 Friction Blocks [Contact Airflex PYN 613966-01_ 57 144 [Flat head scrows [0002940407 10.6 [Sub assembly breakdown for high coefficient friction discs. Friction Disc Sub-ascombly | item ay. Description Part Numbor Standard lining 8 1 [Friction Dise Core 513666 = panes as 9 2 [Friction Disc 513680 37 48 |Flat hoad screws (0001531147 8 1 [Friction Dise Core. 510745 24weB 613964-02 9 2 [Friction Dise 512825 Baseedie (ee 48 [Fiat head screws (000294x0407 8 1 [Friction Disc Core: 513667 a ee ee eS Eee a7 144 [Flat head screws [0002940407 Dr roruar 36 [©Copyright Eaton Corp, 1995. Al rights reserved11.3 Friction Lining Kits for 24WCB models with screwed on friction lining Each friction lining kit includes the following: a Model___[Kit Part Number [Quantity Each [Description [Part Number | szawes | 1078218 LOCO 224WCB 107821BA LO-CO- Contact Airflex for details 324WCB 10782188 LO-CO 424WCB 107821BC 11.4 Friction Lining Kits for 36 WCB models with screwed on friction lining [Each friction lining kit includes the following: everett Mode! kit Part Number [Quantity Each [Description Part Number 136weB 1078228 L0-CO 236woB 107822BA LO-CO ContactAirtlex for details aa6weB, 10782288 L0-00 | 436WCB yo7ez280. | 2eroruaT 38 {©copyright Ealon Com, 1095. All its resarved.[Wear Plate Kit é Ilocknut 001 ro 153 24wcB LLoctite® Suneriex [000153x Reaction Plate Kit peteee instruction Sheet —[poa' limer Ring fi3107 ring lara Wear Plate 4 —{Screw __ )153x08 Locknut looo1sax0844 107662 Seopa ae jon Sheet 204063 Wear Pi 2 414032 inner Fin i [Ou 414033 Fin Ser "159x084; z 107662E oct 15 3x sews ion Sheol Reaction Plate Kit fear Plat 14021 inner Fin l414032-01 la [Outer Bin 14033-04, 11.6 [Cylinder Seal Kits : He Ha Each Kit Includes the follow ing: - ant ‘Size Part Number Large seal ‘Small seal cues vorerio. oeooba pani xcoot tawoe torerec [0094020004 peoasaxo00s tawee ~sorracc __[Q09fgax0022loonanaxtuet mawea arvere___[onsaaxooae ooosoaxo028 sewes ro7asz0 _[ongtaexooes peosoaxo00s Al Rite include Teach Instruction Sheet (PINDO40G7) and 402 tube of Parker O-Lube (P/NO00153x088 1). rota 40 ‘©Copyright Eaton Corp., 1995, Al ghts reservedEquipment ManualAirflexe WCB2 & WCBD Brakes Designed for continuous slip service, these units can absorb and dissipate the thermal loads found in severe applications.WCB2 & WCBD Component Parts ‘Wear Pate Hex Head Serow Locknut Stud, 8 Friction Dise Su 10 Friction Diso 1 Friction Dise Core 2 Fat Head Soren, 13, ‘amp Tube 4 Pressure Plate SubAssembly 15, Pressure Plate 16 Fiat Washer TE SA TA SR P © 7 dda Dual Piston Cylinder Nem Description Note: 7 Lock Nut @ Duals wo shown. Other mutase units se sib ams 28 and 26 ae net veqited ‘or single des uns, 24 RexctionPlate 25 iston 26 Release Spring 20 Dual Piston Cylinder 28 Dual Piston 29 Dual Piston inner Seal 30 Dual Piston Outer SealWCB2 & WCBD Elements— Dimensional Data ase 4 40) at 6 75 was £ oe s8 1900 5 © 4 ea eon ss ee ge a = Twine Tuer RIC 2 co 7 62 Tene a ‘ea ove = ss = are 26 23 os ieee ‘usnce wa 6, erie ‘outs 2 a6 sie sid ewer ‘Monts 20 “0 ca ie aa i i Ce A o 83 Air inlet Ports Equally Spaced Notes: ‘nly wo pots, £80" apart furnished on sis Band 141103 Tolnsur pope cotng, int pot ust be loci ate sicock position, “olranee Stes @W/08 tru 26608 +0000 (4000-008) ‘v8 4.000005 (+0,00-019) ‘ves ¥.000/0.08 (+0,00/-0,13) ‘Ararcan National Standard for Unitas ‘Secow Treads Tolerance 40.0080 000i. ‘6,000.00 mm) -Avetican National Pipe Thread 1.00 25 om) for 108008 1.38 1 (5 rm) for 208008. 018 n (48 ram) for S0BWCB. 1.08 in (27 me) for 1aWoB & staves 4.8n (48 min fo 21408 ‘rimum ore sie are basa on at kos, allowable ear hub esses and torque anys a1 80s (5 ban Mavirwm dameter of 28 cast" surfaces 1.86 (50 im) for Y4BWCB 1.75 (44 me) for 24808 175i (48 me) for SeBCB 1.75in (44 mm) for 2408 ‘Some high torque appations of thee or four isc elamenis rau addtional torsnial support ‘onthe cyinder en ofthe unit. Contact your local Artx representative for more detaWCB2 & WCBD Elements— Technical Data a a ae (ET a z Sas ai ra arp ggg Se SE i a a ee a it i ¢-ASSSSG AES ESE EE it 38a se = 2a Pg a gee ET a 38 as sa = a a ess 5 a 0 ea i Ts esc PSE Eiger eRe OE Baits is eT ance 78 a — a a ‘entet ie a9 tetas etm sa ‘once es S80 gas eg i nicl a5 ea in asieh 4s ae a TT — soe See a nies risen an ss Sees hss ss st ot a canal = ee ee a eee ‘spa ‘Soaet ‘wast Gente ray 2 a reece eee OTERICE ee tt 210) a — Zoe PI TI a a a a oe i a a a tH ee a ts = ee a ee oe ippeceecea gree ‘aaa ee tie a oe sha i 3 — ma geese eee aT] 8 ie age = a i ara ass a ie Bite a ae a a rm ae Bist ema i esp Se ET ng TEASE SCTE ts ener sp et py SE ECE ITSTEET 7 ie eye ses ut is gE ters ETT ST EETCT MOTE is 7 eat a Notes: © Absolute volume of cylinder at contact with new © Besed upon a continuous slip velocity of 4500 and worn fiction discs. tome me) © Prue ctp coc aid on maar (©. Mosmum festa ety 75004 G84 mp), MSO ase © Located irom mourting tango suc. Re RT ETREEquipment ManualRS 9010 Installation, Operation and Maintenance of Airflex® Model AA2, B2, B3 and C2 Rotorseals /'\ warming Forward this manual fo the person responsible for Installation, Operation and Maintenance of the product described herein. Without access to this information, faulty installation, Operation ‘or Maintenance may result in personal injury or ‘equipment damage. AX caution: Use Only Genuine Airflex Replacement Parts ‘ho Allox Oision of Eston Corporation recommends tho uso of genuine Altox rplacamert parte. The use of ron genuine Alex roplacomont ports could reultin substandard product perioamance, and may void your Eaton waranty. For optimum gevtorrance, contact Aix In the U.S.A. and Canada: (800) 233-5903 Outside the U.S.A. and Canada: (800) 233-5890 June, 1994 (Revised: September 1998) PDF Format 204082 Copyright Eaton Corp. 1998. Al sights reserved.1.0 1 4a INTRODUCTION “Throughout this manual there area number of HAZARD WARNINGS that must be read and adhered to in order to prevent possible ‘exsonal injury andor damage tothe equipment. ‘Three signal words “DANGER’, “WARNING', fend" CAUTION’ are used to indicate the severity ofthe hazard, and are preceded by the safety alot symbol AN, /\pancen Denotes the most serious injury hazard, and is used when serious injury or death WILL result from misuse or failure to fo low specific instructions. A\WARNING Used when serious injury or death MAY result from misuse or failure to follow specific instructions. Z\caution Used when injury or producVequipment damage may result from misuse or fare to follow specific instructions. {It is the responsibility and the duty of all person ivaved nthe instalation, operation rdmantenence ofthe exupment on which this dovice Is used to uly understand the Axoovaen. A\wanna, ang AAoasmon procedures by which hazards are to be vole Description The Airflex single passage rotorseal is a positive seal rotary union (rotary joint). The Totorseal pormits the transfer of gases or liquids, under pressure into or out of the exposed end of a rotating shaft. The rotorseat operates continuously or ntermittently up to rated speeds in elther rection, /\caution: ‘The factory must be consulted when contemplating the use of Airtlex rotorseals with mediums other than air, Pv Soa 99) 142 Bal bearings are used between the stationary and rotating parts, The rotorseals are lubricated for lfe at the factory to give fong, maintenance-free service ‘The rotorseal housing (1) features an inlet port with the American National pipe thread size shown on Table 2. ‘TABLE? otorseal Si inet Port Pipe Top Bz 18 NPT 5 7 SB NET, @ U2NeT 1.2 424 2.0 24 2a2 22 224 * B39 rotorseal is furnished with an adapter, having 1/4 NPT intemal threads and is @ di- rect replacement for the discontinued 82 rotorseal How It Works The sealing between the stationary housing (1) of the rotorseal and the carbon seal ring a, Occurs at the lapped seal face of the rotating shaft (3). A light col spring (4) keeps the carbon seal ring in place assuring a positive seal between the components. Seo Figure 1 INSTALLATION Preparation ‘The Airflex rotorseals have threaded shafts for direct and easy mounting to the shaft or assembly. Inspect the internal thread form in the mounting shaft to insure that there is no damage to the threads, Insure that the proper diameter and depth conform with Tablo 3 specifications, ‘A good pipe thread sealant should be applied to the outside thread on the rotorseal shaft before mounting, Air connection ‘The rotorseal housing has an American National Pipe Thread air ilet as show in “Table 2. This connection to the rotorseal should always be through a flexible hose. Fefer to Figure 2 for examples of mounting assemblies. ‘Copyright Eaton Corn, 1888. Ad ight rossrve.4.0 44 4.2 424 422 423 424 428 AX caution: ‘The operation of Airflex rotorseals at maximum air pressure combined with maximum speed should be avoided. Consuit the factory for details of specific application data. MAINTENANCE Z\waanine Prior to performing any maintenance on the rotorseal, make sure the equipment isin, and will remain in, a safe concition. Wear Limits ‘The Airllex rotorseals are lubricated for life and require no maintenance: If a rotorseal has. become ineffective after prolonged service, it can be restored to good operating condition by rebuilding it. Rebuilding A replacement kit is available to allow the rebuilding of these rotorseals in the field. Aliflex rotorseals are manufactured of quality ‘materials which are held to precision toler- ances, NOTE: Only genuine Airflex rotorseat parts should be used. The rotorseal should be removed from its mounting and repairs should be made in a clean, dust-free environment Disassembly Remove the snap ring (11). This can be done with the aid of snap ring pliers. Insert the pins of the pliers into the holes in the snap ring, Compress the ting enough to insure that the _gf00ve in the housing (1) will not be damaged, and remove the snap ring. Refer to Figure 1 for bearing arrangement. Remove shaft (3) and bearing (9) and/or (9A) from the housing (1) by hoiding the hex portion of the shaft in a vise while striking the housing gently with alight mallet. Rotate the housing while striking to reduce the tendency of binding the bearing in the housing, Remove the spring (4), spring stop (6), "O" ring (6), and seal (7) from the housing (1) with the aid of a small wire hook. (FosesSgtenne 100) 43 434 432 4324 433 434 44 44a 4aaa CLEANING AND INSPECTION lean all the parts thoroughly efter disassembly with a grease cutting solvent. ZA\paNceR ‘The manufacturer of any grease cutting solvent publishes a Material Safety Data Shoot. Ths shoot must be read and Understood before using the product. Inspect the lapped sealing end of the shatt (3) This sealing surface should be free of scoring and excessive wear Inspect the bearings (9)(9A) for roughness, end play and contamination. They should be in good condition, free of rust, and should re- volve smoothly without any tendency to bind. If the shaft (3) or the bearings (9)@A) are in poor condition, they must be replaced. If these two parts require disassembly, remove the shaft extemal snap ring (8) and press the bearings from the shaft, Inspect the housing (1) for damage from the ‘outer race of the bearings (9)(9A) rotating Replace the housing if necessary. JX caution: ‘Only genuine Airflex rotorseal parts ‘should be used (Bearings or shaft can be ‘obtained from the factory separately), ASSEMBLY Assemble the spring (4), spring stop (6), ting (6), and seal (7) as show n in Figure 1, ‘making sure the "O" ring seats properly on the chamfered surface of the seal. e-pack grease cavity in the housing (1) of rotorseais with Alvania #2 Oil grease or ‘equivalent. All unsealed bearings must be packed (refer to parts list). LXcaution: Failure to follow this lubrication procedure may result in rotorseal damage or failure. (©copyright Eaton Corp, 1998. Al ights reserve7.0 REVISIONS Original Publication Date June 1994 Revision Date ‘September 1998 ‘Add Revision Section, This Page Update Warranty to Sept. 97 version Change (Povet Sion 208) ©copyright Eaton Corp, 1998. Al sights reserve,