HE-1359 (Revised May 1978 REPAIR AND MAINTENANCE INSTRUCTIONS FORRE-7 /3_ 2" SINGLE ROTOR HYDROMATIC BRAKE ASSEMBLY NO. -P196I6:X (TYPICAT: ASSEMBLY) THe Asy- D 6x593-X S 52443, as 06-41 Ip’ -04- O]=20¢. awe. 4 diadu,cturers of PARKERSBURG Products 2.) BOX 573 COFFEYVILLE, KANSAS 67337 AREA CODE (316) 251-5000 _ a Tw Soy. LITHO, US. Aconrents SECTIONS L = General... : . Replacement of Bearings and/or Seals: 2. - Disassembly “ 3 - Reassombly..... Hydromatic Brake Case: 4 = Disassembly ines ane boas - Reassembly.. 6 -- Lubrication. ILLUSTRATION DRAWINGS Bearing Adapter Installation for Bearing (26)........- Installation of Carrier Ring.. Bearing Adapter Installation for Bearing (17) Assombly of Rotor and Shaft, 6, 7, 8, 9, 10, 11, 12 13, 14 14, 15, 16, 17 a . PSK-905 ~ PSK-908 PSK-906 PSK-907 Checking Slope of Rotor Vane and Mating Pocket Section Vane, PSK-888 Grease and Relief Fitting Locations... Parts List of Typical Assembly P19626-X, HYDROMATIC, HYDROTARDER AND PARKERSBURG REGISTERED TRADEMARKS OF PARMAC, INC. MOUNTING SUPPORTS ‘Om nvoRoTaRGER REVISED MAY 1978 cevseees PSK-909 s+. HB 14-59@ MAINTENANCE AND REPAIR INSTRUCTIONS FOR 22" SINGLE ROTOR TYPE BC HYDROMATIC BRAKE TYPICAL ASSEMBLY P-19626-x General Part numbers given in these instructions are referred to as mark numbers and correspond to those used on the attached parts list and assembly drawing ‘These instructions apply to a number of similar 22" Hydromatic Brake assemblies, all of which are typified by the drawing of assembly P-19626-X. When ordering parts, always give the assembly number and serial number which are stamped on the Name Plate (37) of the Hydromatic Brake. Note: A - Principal differences between the typical assembly, P-19626-X, and similar assemblies are in shaft ex- tensions and direction of rotation "TO BRAKE” from extended shaft side. B - Most similar assemblies have the shaft extension on one _side only (1ike the typical assembly), although the of the shaft extension and its length may vary, A few Similar assemblies have the shaft ex- tended on both sides. © - Some similar assemblies with single shaft extension (like the typical assembly) have the shaft extended for clockwise rotation "TO BRAKE" from the extended shaft side instead of for counter-clockwise rotation "TO BRAKE” from the extended shaft side as is the case for the typical assembly. D - In Similar assemblies with the shaft extended for clock-wise rotation "TO BRAKE” from the extended Shaft side, the Shaft (1) extends from R. H. Side Cover (7) instead of L. H. Side Cover (8) as shown for the typical assembly. Likewise Bearing Adapter (25), Shim Set (27), and Cover Plate (28) for the large Bearing (26) are installed in &. H. Side Cover (7) for similar assemblies with the Shaft (1) extended for clockwise rotation "TO BRAKE” from the extended shaft side6 -10 =25 E = Some similar assemblies, typified by assembly P-19626-X, are equipped with special cover plates on one or both sides to meet specific requirenents. For any repair job, disassembly should proceed only to the point permitting replacement of damaged part or parts. ALL disassembly and assembly procedures aust be undertaken with the shaft of the Hydromatic Brake vertical. Bearings (17) and (26), Mating Rings (12), Carbon Rings (11), Inner O11 Seals (15) and Outer Oil Seals (29) are the only parts subject to mechanical wear, Normally these parts and the resilient rubber components of the water seals, O-Rings (13) and Gaskets (10), are the only ones requiring occasional replacement. Rotor (3) and Pocket Sections (5) and (6) are subject to erosion and cavitation from the action of the braking fluid and may, after Long periods of use, require replacement Tt will be noted that No. 1 Permatex (33) is used as a sealing com pound on many joints in this assembly. Whenever such a joint is broken in disassembly, both surfaces comprising the joint must be scraped free of hardened Permatex (33), washed with solvent, and thoroughly dried before being reassembled with new Permatex (33). In all cases where joints are to be made up using Permatex (33), the coating should be evenly applied and allowed to air dry about five minutes before being made up. Piiobond No. 20 (41) has been used on parts of this assembly for bonding the parts together. Whenever such a joint is broken it will be necessary to clean both surfaces by washing in a suitable solvent such as Methyl Ethyl Ketone. Parts must be thoroughly dry before being reassembled with Pliobond (41), In all cases where Pliobond (41) is used both surfaces should be coated with a Light coating of Pliobond (41) and allowed to air dry until tacky, (Approximately 3-5 minutes) before being made up. The mating faces of Carbon Ring (11) and Mating Ring (2) are highly lapped and polished. Successful performance of the water seals is dependent upon absolutely unnar faces of these parts. Too much enphasis cannot be placed on the care to be exercised in hand: Ling and protecting the lapped faces of these parts during disassemb- bly, Storage, and reassembly. Any small scratch, dust, dirt, burr, or other inperfection on either of these mating surfaces will result in immediate or early leakage As disassembly proceeds, the various parts removed should be thoroughly cleaned, wrapped and stored.~~ For the Replacement of Bearings and/or Seals (Refer to Paragraphs 1.3, 1.4, 1.8, 1.9 and 1.10) Instructions in this Section are given in sequence assuming that bearings and/or seals in both sides of the Hydromatic Brake are to be replaced or (hat the Hydroma(ic Brake is to be completely disassembled. Ti large bearing (26) and/or seals in side containing Large bearing (26) only are to be replaced, proceed as outlined in Paragraphs 2.2 to 2.11, then refer to Paragraphs 3.19 to 3.26 for reassembly instructions. If small bearing (17) and/or seals in side containing small bearing (7) only are to be replaced, start embly WIth Anstruetions in Paragraph 2.13, and refer to ssemble, (See Paragraph 1.3) disas: Paragraphs 3.10 to 3.17 to re Remove eight cap screws (30) and slide cover plate (28) with its pressed-in oi] seal (29) over end of shaft (1). Tf oil seal (29) is not replaced, take care that the Lip of seal (29) is not damaged in Ads operation, particularly by cuttimg on corners of keyway in shaft @). Remove shins (27) and store with removed cover plate (28). Remove tuo cap screws (31) Insert four hearing puller studs (fabricated per details on PSK-905) into the four puller holes in bearing adapter (25) on the 45° diagonals as shown on PSK-905 Pulling up evenly and progressively all around on the four bearing puller studs will jack the bearing adapter (29) out of bore of side cover (8) and pull bearing (26) off of its seat on shaft (1). Rapping end of shaft () with a soft hammer during this operation will aid in the removal of bearing (26) which is 2-1/2" long and installed with an average interference of .0019". After bearing (26) clears its seat on shaft () the bearing adapter (25) and bearing (26) can be Lifted over end of shart () Insert two cap screws (30), removed per Paragraph 2.2, into the two diametrically opposite tapped holes (see PSK-908 for location) appear- ing on the exposed face of carrier ring (4) and by pulling on these serews, withdraw carrier ring (14) from bore of side cover (8). Mating ring (2) is held on carrier ring (14) by the friction of O-ring (13) and will come out with the carrier ring (4). Note: A - This operation will expose the lapped sealing faces of nating ring (2) and carbon ring (11), Refer to Paragraph 1.92.9 2.14 2.15 ae B - Mating ving (2) and O-ring (13) can be easily pulled off carrier ring (14) IF NECESSARY but should remain undisturbed unless it is desired to ré the mating ring (12) and O-ring (13) © = Oi1 seal (15) is a press fit in carrier ring (14) and can be renoved for replacement without removing mating ring (12) and O-ring (13) if proper_precautions taken to protect the lapped Tace of mating ring ) Removal of carrier ring (14) per Paragraph 2.8 will expose the carbon ring (1), This seal component should not be disturbed in any way UNLESS it is to be replaced. Refer to Paragraph 1.9 if removal of carbon ring (1) is required, pour a small quantity of Methyl Ethyl Ketone into the groove of rotor (3) to soften the Pliobond (41) on both sides of gasket (10). Pour the solvent into the groove at both outside and inside diameters of carbon ring (11). Allow the solvent to remain undisturbed for about thirty minutes to soften the Pliobond, Then use a couple of thin picces of steel (thin hacksaw blades arc ideal), to lift carbon ring (11) and its gasket (10) out of groove of rotor (3). Clean all softened Pliobond (41) out of the groove inmediately. Instructions given in Paragraphs 2.2 through 2.10 wi11 completely disassemble that side of the Hydromatic Brake containing Large bearing (26) and permit replacement of the parts of that side normally subject to mechanical wear. If replacement of bearings and/or seals in both sides 1s the objective, the disassembled side should be completely — bled per Paragraphs 3.19 through 3.26 using new parts as Fequired BEFORE turning the fiydronatic Brake over to disassemble the Side containing smait bearing (17), Refer to Paragraph 2.1 If the Hlydromatic Brake case is to be disassembled for replacement of the parts referred to in Paragraph 1.6 or other reason, do not, Feassemble the large bearing (26) side, Turn the partially dis Assembled Hlydronatie Brake over and proceed with the disassembly Instructions below. Roth sides of the Hydronatic Brake must conpletely disassembled per this Section BEFORE starting disassembly Of the case per Section 4 Remove eight cap screws (24) and cover plate (22). Remove shims (21) and store with removed cover plate (22). Cut and remove wire (20). Remove three cap screws (19) and keeper as) Remove two cap screws (23).7 19 oan Insert four bearing Puller Studs (labricated per details on PSK-905), into the four puller holes in bearing adapter (16) on the 450 diagonals as shown on PSK-906. Pulling up evenly and progressively all around on the four Bearing Puller Studs will jack the bearing adapter (16) out of bore of side cover (7) and pull bearing (17) off of its seat on shaft (1). Rapping end of shalt (1) with a soft hammer during this operation will aid in the removal of bearing Q7) whieh is 1-13/16" Long and installed with an average interference of .0017". Follow instructions contained in Paragraphs 2.8 through 2.10 to gain access Lo the seal components Tnstructions given in Paragraphs 2.13 through 2.19 will completely disassemble that side of the ydromatic Brake containing small bear— ing (17) and permit replacement of the parts of that side normally Subject to mechanical wear, Refer to Paragraphs 3.10 through 3.17 lor reassembly instructions, (See Paragraph 1.3, 2.1 snd 2.11) ALL disassembly procedures covered in this Section must have been performed BEFORE starting disassembly ol (he Hydromatic Brake Case per Section 4 _Roassemb1y For the Replacement of Bearings and/or Seats Assembly procedures outlined in Paragraphs 3.3 through 3.9 apply equally to either side of (he Hydromatie Brake. However, if the Hydromatic Brake has been completely disassembled per Sections 2 and 4 and the case has been reassembled per Section 5. assembly. operations should follow the sequence given from Paragraph 3.10 on. If replacement of Large bearing (26) and or seals in that side of the Hydromatic Brake containing large bearing (26) only ix the objective and disassembly per Paragraphs 2.2 Unrough 2-11 has been made to gain access to the part or parts requiring replacement (see Paragraph 1.3), start reassembly per instructions in Paragraph 3.19 If replacement of small bearing (17) and/or seals in that side of the Hydromatic Brake containing small bearing (17) only is the objective and disassembly per Paragraphs 2.13 through 2.19 has been made to wain access Lo the part or parts requiring re- Placenent (See Paragraph 1.3). start reassembly per instructions in Paragraph 3.10. Refer to Paragraphs 2.1, 2.11, and 2.203.6 Parts covered by instructions in Paragraph 3.4 must be joined under pressure for approximately 4 to 6 hours, to achieve a good bond between the joined surfaces. This can be done by completing the assembly of the seals and bearings, so that bearing Adapter (25) or (16) can be bolted into place. thereby giving the pressure needed for the bonding Press o11 seal (15) in recess in carrier ring (14), making sure that no part of the case of oil seal (15) projects above the surface of carrier ring (4). A-Vake care that the 3/16" diameter Locating pin projec from the surface of carrier ring (14) is not bent or burred during this or subsequent operat ions Not Place carrier ring (14) with pressed in oil seal (15) on a solid backing, 11 seal (15) down. (See Note A of Paragraph 3.6). Apply a Lhin coat of Light grease to the six inch diameter projection of carrier ring (14), including the chamfer, Lower mating ring (12) with O-ring (3) installed in groove, pin and spring side down, over the end of carrier ring (14), including the chamfer. Lower mating ring (12) with O-ring (13) installed in groove, pin and spring a side down, over the end of carrier ring (14), Carefully work O-ring (14). Do not use screw driver or other sharp tool on O-ring 3). Do not twist or pinch O-ring (13) in this operation. After O-ring (3) is well started up on chamfer of carrier ring (14) all around. the mating ring (2) can be pushed into position, the four pins projecting from the back side of mating ring (2) enter- ing the four holes in flange of carrier ring (14) Note: A - Make sure pins do not bind in the holes and that the springs can be compressed to solid height B - Every precaution must de taken to prevent _marring the lapped face of mating ring G2). Refer to Para- praph 1.9 Apply an even coat of Permacex (33) to the shoulder of side cover (7) or (8) against which carrier ring (14) seats. Make this a fairly heavy application with the Permatex (33) worked well into the corner and forming a sort of cove that will completely fill the 1/16" chamfer of the carrier ring (4) when it is seated against the shoulder of side cover (7) or (8). The Permatex (33) applied per this Paragraph should be confined to the shoulder of the side cover (7) or (8). Note: A - Excess Permatex (33) should be wiped out of the eight inch diameter bore of side cover (7) or (8) before proceedingBelore any reassembly procedures are begun, all parts lo be use either (hose removed in disassembly per Section 2 or new part should be thoroughly cleaned; i.e., all Permatex (33) and Pliobond (41) removed, washed with solvent, and dried thoroughly. ALL parts should be inspected and any nicks and’or burrs filed smooth, Refer to Paragraphs 1.7, 1.8 and 1.10 For optimum results and easier assembly, carbon rings (11) should be cemented to gaskets (0) with Pliobend (41). Use every precaution to protect the lapped face of the carbon rings (11) and proceed as Follows: 1 - Place carton ring (11), lapped face down, on a clean piece of heavy paper or cardboard, The paper oF cardboard must rest on a flat, solid surface. 2 ~ Apply a Light, even coat of Pliobond (41) to the upper or back side of carbon ring (11). and Lo one side of Rubber Gasket (10), air dry until tacky 3 ~ Place Pliobond covered side of Rubber Gasket (0) in position on the Pliobond covered surface of the Carbon Ring G1). It will be noted that the Rubber Gasket (10) is narrower than the Carbon Ring (11). Properly positioned, the Rubber Gasket (10) and the Carbon Ring (11) will be centered, i.e., the edges of Gasket (0) will not at any point, touch or extend beyond the edges of Carbon Ring (1). 4 - Let air dry while completing Step No. 5 & 6. = Apply a Light, even coat of Pliebond (41) to the exposed surface of Rubber Gasket (10) cemented to Carbon Ring (11) and to the clean and thoroughly dry groove in Rotor (3) Air dry until tacky 6 - Lower Carbon Ring (11) with Rubber Gasket (10) carerutty into groove of Rotor (3). Use Light pressure, evenly applied with the fingers, to seat fipmly against bottom Of groove, CAUTION: Do not scrateh or mar the lapped face of Carbon Ring (11), and clean off any dust or dirt particles before proceeding with assembly Note: A= Rotor (3) must be centered with the bore of Side Cover (7) or (8) to permit Carbon Ring (11) to enter groove of Rotor (3). The 0.D. of the Rotor (3) groove and the bore of Side Cover (7) or (8) are both eight inches and must therefore coincide to permit entry of the Carbon Ring (11).Thoroughly cover the surface of shaft (1) on which oil seal (5) ms with a Light coat of thin grease (See Note A) and insert two cap screws (30) into the two tapped holes in the face of carrier ring (14), Handling with the cap screws (30) and remembering that the mating ring (2) is held on the projection of carrier ring (14) only by the friction of O-ring (13). lower the carrier ring sub- assembly per Paragraph 3.7 into bore of side cover (7) or (8) prepared per Paragraph 3.8. See sketch PSK-908 for proper position of the 3/16" diameter locating pin projecting from the face of carrier ring (4). Tt is imperative that the carrier ring (14) be installed with the 3/16” diameter Locating pin aligned with the tapped hole in side cover (7) or (8) exactty as shown on PSK-808. Tap ng (14) carefully into place with a wooden block or hammer handle. Do net strike the carrier ring (4) too sharply or the mating ring 2) and O-ring (13) will be jarred off the end of carrier ring G4). The fit of earvier ring (4) in the bore side cover (7) or (8) is 002" ~ 003" loose, therefore very Light tapping, evenly distributed around the face of carrier ring (4), will suffice. Remove the two cap serews (30), Note: A - Great care mist be exe reised in this operation to prevent damaging the lip of oi! seal (15) on the corner of shaft shoulder, Use of tapered 0, D. sleeves is Strongly recomended. C1 such sleeves are not avail- able, 2 piece of fairly heavy shim stock can be wrapped several times around the shatt () to form an installa- tion sleeve. Lacking even this, the smooth, well-rounded end of a small dowel, preferably hard wood, or rod can be used to work the lip of oi1 seal (5) over the well~ greased corner of shalt (1), Patience is required for (has and screw-drivers or other sharp tools are not, under any circumstances, to be used B - The pressure exerted by the four springs of mating ring (2) will not permit the carrier ring (4) to seat and remain seated solidly against the shoulder of side cover (7) or (8), However, these springs will be compressed to working height and the carrier ring (4) drawn gown solidly against the shoulder of side cover (7) or (8) when bearing adapter (6) or (25) is installed © - Tf mating ring (2) and O-ring (3) are inadvertantly jarred off the end of carrier ring (4) during this operation, remove these parts from the bore of side cover (7) or (8) and resume operations starting with Paragraph 3.73.10 3.11 3.12 3.13, 3.15 3.16 Bu7' “Gs Assemble parts in side cover (7) per instructions contained in Paragraph 3.3 through 3.9. Install gasket (44) on locating pin projecting from face of carrier ring (14), Visually inspect installation to see that gasket does not block any weep hole passages in carrier ring. Align hole on inside face of bearing adapter (16) with the locating in projecting from the surface of carrier ring (14) and bolt holes in bearing adapter (16) with tapped holes in side cover (7). Start bearing adapter (16) in bore of side cover (7) by tapping uniformly all around with a soft hammer and continue tapping until bearing adapter (16) seats solidly against carrier ring (14) which will then be against shoulder of side cover (7). Secure with two screws (23) evenly drawn up through the two counterbored holes, on the horizontal center line, in bearing adapter (16). See PSK-906. Note: A - The use of two pins, 5/16" diameter by about 4"! long and threaded 5/16" ~ 18 N.C, on one end, inserted into two of the tapped holes in side cover (7) will facilitate lining up the bolt holes of bearing adapter (16) for this operation. B - Take care that the 3/16" diameter locating pin projecting from the face of bearing adapter (16) is not bent or burred in this operation. Pack bearing (17) with a small quantity of grease (32) and press or drive bearing (17) into place on shaft (1), supporting shaft (1) from the opposite end. The pressing or driving force should be applied to the inner race of bearing (17). Install keeper (18) with three cap screws (19), locking with wire (20). Install shims (21) on face of bearing adapter (16), making sure grease hole and weep holes (See PSK-906) are not covered by shims. Line up hole in cover plate (22) with locating pin projecting from face of bearing adapter (16) and tap cover plate (22) into place. Secure with eight cap screws (2/4) drawn up evenly and firmly all around, Procedures given in Paragraphs 3.10 through 3.16 will completely assemble the small bearing (17) side of the Hydromatic Brake. Turn the partially assembled Hydromatic Brake over and proceed per fol lou- \g instructions.3.18 3.20 3.21 3.22 3.23 3.24 = 10- Note: A - If only the side containing small bearing (17) has been disassembled for repairs and reassembly has been completed per above, proceed to check end play of the shaft according to instructions in Paragraph 3.26. After turning the partially assembled Hydromatic Brake over as directed in Paragraph 3.17, check the assembly of the small bearing (17) side by rotating the shaft (1). If the shaft (1) cannot be turned or if there is any noise occasioned by its turning, it indicates that some part or parts of the just assembled side of the Hydromatic Brake have not been properly installed or that rotor (3) is not properly centered on its seat on shaft (1). In this check turning, keep the shaft (1) centered in the bore of side cover (8). If shaft (1) turns freely, proceed with assembly of large bearing (26) side of Hydromatic Brake. Assemble parts in stde cover (8) per instructions contained in Paragraph 3.3 through 3.9. Install gasket (Mt) on locating pin projecting from face of carrier ring (14). Visually inspect installation to see that gasket does not block any weep hole passages in carrier ring. In hole on inside face of bearing adapter (25) with the locating pin projecting from the surface of carrier ring (Il) and bolt holes in bearing adapter (25) with tapped holes in side cover (8). (Two pins, as described in Note A of Paragraph 3.12 will be helpful.) Start bearing adapter (25) in bore of side cover (8) by tapping uniformly all around with @ soft hanmer (See Note B of Paragraph 3.12 regarding locating pin) and continue tapping until bearing adapter (25) seats solidly against carrier ring (14) which will then be against shoulder of side cover (8). Secure with two cap screws (31) evenly drawn up through the two counterbored holes, on the horizontal center line, in bearing adapter (25). See PSK-905. Pack bearing (26) with small quantity of grease (32) and press or drive bearing (26) into place on shaft (1). Apply pressure or driving force to inner race of bearing (26). Install shims (27) on face of bearing adapter (25). Line up hole in cover plate (28) with locating pin projecting from face of bearing adapter (25) and tap cover plate (28) into place. Secure with eight cap screws (30) drawn up evenly and firmly all around.3.25 3.26 3.27 eae Procedures given in Paragraphs 3.19 through 3.24 will completely assenble the large bearing (26) side of the Hydromatic Brake Check the assembly by rotating the shaft (1). It should turn freely with no noise except normal roller bearing noise. If the assembly of the small bearing (17) side of the Hydromatic Brake was checked per instructions in Paragraph 3.18 and the shaft (1) cannot now be turned or extraneous noise is evident, sone part or parts of the just assenbled side have not been properly installed or the rotor (3) is not properly centered on shaft (1) Measure the shaft end play with 2 dial indicator as follows: I - Having the Indicator base securely fastened to side cover (8), zero the indicator dial and lift shaft (1) until the complete Hydromatic Brake assembly is raised from its support and is suspended by the shaft (1) The dial indicator will register the movement of shaft Q) relative to the case 2 - Lower assembly and slack off on hoist. If indicator does not return to zero repeat procedure in Step 1 and continue until actual shaft end play has been de- termined 3 - If more than .012" end play is present, remove the y amount of shims from shim sets (21) and (27), dividing the deduction between the sets to obtain .010" = .012" end play. 4 - If less than .010" ond play is present, shims must be added to shim sets (21) and (27) to produce the re~ quired .010" ~ ,012" end play = Recheck end play per Steps 1 and 2 Install grease fittings (34) and relief fittings (35) in cover plate (22) and bearing adapter (25) in exact locations shown on PSK-909. Only by installing the fittings (34) (35) exactly 2s shown will the Lubri- ting systems for the bearings (17) and (26) function properly. Also, there will be no danger of plugging any of the 1/8" N.P.T, weep holes in bearing adapter (25) and cover plate (22). Lubricate the bearings (26) and (17) as per lubrication instructions Section 6.- 4. Disassembly Hydromatic Brake Case (Refer (o Paragraphs 1.3. 1.6, 1.7, and 2.21) 4.1 Procedures under this Seetion should not be undertaken unless ri placement of rotor (3) and pocket sections (5) and (6) are required, 1.6, 1.7, and 2.21. Relor to Paragraphs 1.3 4.2 Procedures under this sides of the Hydromatic Br per Section 2 ction must not be undertaken UNTIL both ke have been completely disassenbled 4.3 Starting on cither side of the Hydromatie Brake case, remove the twenty-four cap screws (9) on the outside edge of side cover (7) or (8). Do not remove the twelve cap sereus (@) Located on the inner bolt circle of the side cover (7) or (8) 4.4 111 the side cover (7) or (8). along with its attached pocket section (3) or (6) from casing (4) Noter A = Use a soft hammer and rap casing (4) smartly to break the join B- After joint has becn broken, wedges may be used at several places between the flange of side cover (7) or (8) and casing (4) to facilitate disassembly Great care should be exercised, however, that such practice docs not produce appreciable indentations ineither part. Deep marks or burrs on the flange of side cover (7) or (8) and/or race of casing (4) are detrimental to properly reassembled water-tight joints © = Note that the locating pin is pressed in the [ange of side cover (7) or (8). Take care that this pin is not bent or burred in any way 4.5 After operation in Paragraph 4.4, the sub-assembly of shaft (), keys (2), and rotor (3) can be lifted out of casing (4). 4.6 Repeat procedure in Paragraph 4.4 to remove other side cover (7) or (8) and pocket section (5) or (6) from casing (4)To disassemble side cover (7) or (8) trom pocket section ) or (6) remove the twelve attaching eap screws (9) from the inside bolt cirele of side cover (7) or (8) and separate the parts. Note: A= Use a soft haumer lo rap the Mange of side cover (7) or (8), B - Several wedges may be used around the periphery of pocket section (5) or (6) after the joint has been broken. Take care that the edges do not sear the mating faces of either part. Refer to Notes Band C of Paregraph 4.4 The rotor (3) may be pressed from shaft (1), using a press of 20 tons capacity, and the keys (2) removed Note: A= This operation should not be performed unless replacem of rotor (3) is required B = Before this operation is perfurmed, note should be made of the direction of rotation "TO BRAKE”. (refer to Paragraph 1.2) Compare the SLOPE of the rotor vanes. looking at the assembled shalt (1) and rotor (3) trom the extended end of shart (1), vith the SLOPE of the olor vanes as shown on PSK-907, Sce Paragraph 5.4 warding reassembly of shaft (1) and rotor (3) 5. Reassembly Hydromatic Brake Case Before any reassembly work is started, whether the Hydromatic Brake Case has been completely or partially disassembled per Section 4 all parts must be thoroughly cleaned and readied for reassembly. Refer to Paragraphs 1.7 and 1.9 Assuming (he Hydronat iv Brake Case has been completely disaasenbled per Scetion 4, procedures in this Section will reassemble 11. ALL Work outlined in this Section mist be completed BEFORE attempting to assemble either side of the liydvonatic Brake per Sect ion 3 Fit two keys (2) into keyways of shaft (1) making sure they are seated solidly, Using 6” outside micrometers, mike across both ends of keys. If mike measurement is more than 6.202", the keys are not properly seated and must be removed and refitted PSK-907 Coat rotor seat and keys Lightly with white lead and, with shaft (1) vertical, lower rotor (3) over end of shaft (1) te rotor seat5.5 5.6 5.7 5.8 5.9 + the NOTE: A - Note that it is possible to assemble rotor (3) on shaft (1) backwards if the Hydromatic Brake Assembly has a single shaft extension. Refer to Paragraph 1.2. B - For Hydromatic Brake Assemblies having symmetrical extensions on both sides, rotor (3) cannot be assembled on shaft (1) backwards. € - Note that rotation "TO BRAKE" is counter-clockwise from extended shaft side for the typical assembly. See PSK-907 for SLOPE of rotor vanes for such assemblies. For assemblies with a single shaft ex- tension for clockwise rotation "TO BRAKE" from extended shaft side, rotor (3) must be assembled on shaft (1) with SLOPE of vanes reversed from that shown on PSK-907. Refer to Note B of Paragraph 4.8. Rap rotor (3) evenly all around with a soft hammer to start on shaft (1). Check carefully to see that rotor (3) is square with shaft (1) and that keyways in rotor (3) are properly aligned with keys (2). See PSK-907. Press rotor (3) completely onto shaft (1) seat. A press of 20 tons capacity will be required. NOTE: A - Check to make sure that ends of rotor (3) hub are e: actly flush with shoulders of shaft (1). These shoulders are only .005" high and considerable care must be exer- cised in checking to see that ends of rotor (3) hub coincide with the shoulders. On clean mating surfaces of side covers (7) and (8), and on mating surfaces of pocket sections (5) and (6), install "o" rings (43) in Eroove on 0.D. of pocket sections (5) and (6), and install "o" ring (42) in groove on side of pocket sections (5) and (6). Assemble pocket section (5) with side cover (7) and pocket section (6) with side cover (8), using twelve cap screws (9) for each sub-assembly, evenly drawn up all around. NOTE: A ~ The locating pin in the two side covers (7) and (8) and the matching holes in pocket sections (5) and (6) are so posi- tioned that it is impossible to assemble L.H. pocket section (6) with R.H, side cover (7) and vice-versa. Apply @ thin even coat of Permatex (33) to surface around inlet cavity guly on casing (4). Allow the applied Permatex to air dry five minutes. Assenble side cover (7) or (8) prepared as per Paragraph 5.6 with casing (4), securing with twenty-four cap screws (9) evenly drawn up all around.MB-13-59 15 5.9 Continued: NOTE: A - Check the position of the locating pin in this side cover (7) or (8) against the position of the matching hole in casing (4) to determine proper side of casing (4) for this step. B - In all assemblies with single shaft extensions (like typical assembly), the side cover (7) or (8) through which the shaft (1) extends should be secured to cas- ing (4) first, e.g., in the typical assembly, secure L.H. side cover (8) with casing (4) in this step. 5.10 Turn assembly per Paragraph 5.9 over and with the side cover (7) or (8) testing on suitable supports, lower shaft (1) and rotor (3) sub-assembly per Paragraph 5.5 into casing (4). NOTE: A - Check slope of rotor (3) vanes against slope of pocket section (5) or (6) vanes for proper relationship. See Sketch PSK-888 for illustration. Vanes of adjoining elements must check as shown. B - In assemblies with single shaft extension (like typical assembly), long end of shaft (1) will project downwards through assembled side cover (7) or (8) if instructions in Note B of Paragraph 5.9 have been followed. 5.11 Assemble side cover (7) or (8) prepared per Paragraph 5.6 with casing (4), securing with twenty-four cap screws (9) evenly drawn up all around as per Paragraph 5.9. 5.12 Operations to this point completes assembly of the Hydromatic Brake Case. Procedures in Section 3 may now be undertaken, starting with Paragraph 3.10, to assemble each side of the Hydromatic Brake. 6. Lubrication Instructions 6.1 If bearings of the disassembled Rydromatic Brake are to be reused, wash bearings in a suitable solvent, such as Kerosene, until all of the old grease has been removed. 6.2 Lubricate the bearings (17) and (26) of reassembled Hydromatic Brake with about twelve strokes from a 9 oz. hydraulic gun using No. 2 water resistant (Calcium Base) grease (32) (Texaco Novatex 2 or equivalent).Note: 16 - A ~ In some cases where the Hydromatic Brake uses oi1 as a braking mediwi in place of water, 4t will be nec to use a high meting point Lithium base grease of No. 2 consistency with a reconmended operating temperatu range of OF (0 300°F in place of the Calcium base grease The type of grease required for cach individual Hydromatic Brake will be indicated on the parts List furnished with each Hydvomatie Brake When in use, bearings (17) and (26) are to be Lubricated daily: Three or four strokes of a hand type grease gun for cach bearing is usually sufficient, “DO NOT OVER-LVBRICATE’ Note: A - Bearing cavities should never be more than 13 to 1.2 full, Over-Lubrication will cause excessive heating and Iead to early bearing Iailure. A check can be made periodically for loss o! grease through outer shaft seal (29) and relief titting (35) and Limit ly plenishment accordinTOP OR OUTLET SIDE LOCATING PIN POSITION OF WEEP HOLE / a FOR CAP SCREWS (30) @ POSITION OF GREASE HOLE (/ / “LOCATING PIN HOLE / ON FAR SIDE- TO ENGAGE / LOCATING PIN IN CARRIER RING, (14) HORIZONTAL 4 el OF BRaKee | VERTICAL TT \ Z —~" £4 HOLES ON 45° Se eo eae DIAGONALS TAPPED 1/2"-13 NC “ / FOR BEARING PULLER STUDS. POSITION OF WEEP HOLE BOTTOM OR INLET SIDE. BEARING ADAPTER (25) AS INSTALLED IN SIDE COVER (8) (BEARING (26) AND SHAFT (1) NOT SHOWN) pe" HEX NUT BRAZE OR STAINLESS STEEL WELD ALL AROUND. TTT 42 PA oy THREAD W213 He 5" fs THREAD a IEN. erca END yee, J SMOOTH BEARING PULLER STUD, THE PARKERSBURG RIG & REEL CO. FOR 22" HYDROMATIC BRAKES PARKERSBURG, W.VA. PES. 6/18/54 PSK-9O5TOP OR QUTLET SIDE LOCATING PIN HOLE ON FAR SIDE TO ENGAGE LOCATING PIN IN CARRIER LOCATING PIN Ine 14) 8 HOLES FOR CAP SCREWS \ 4° —*d (24), 4 4 WEEP HOLE GREASE HOLE HORIZONTAL OF BRAKE | tt OF BRAKE “SWEEP HOLE / “4 HOLES ON 45° “ 2 GOUNTERBORED HOLES DIAGONALS TAPPED 2-13 NC FOR CAP SCREWS (23). FOR BEARING PULLER STUDS. BOTTOM OR INLET SIDE BEARING ADAPTER (16) AS INSTALLED IN SIDE COVER (7). (BEARING (17) AND SHAFT (1) NOT SHOWN) FOR 22" HYDROMATIC BRAKES THE PARKERSBURG RIG & REEL CO. PARKERSBURG, W.VA. RES. 6/18/54 P. SK- - 906NOTE ROTATION— E_ IMPORTANT NOTE BELOW. IMPORTANT NOTE~ FOR ASSEMBLIES WITH SHAFT (1) WITH SLOPE OF VANES REVERSED FROM THAT SHOWN ROTOR MUST BE KEPT- SQUARE WITH SHAFT \ @ \Z, wos VANES RELATIVE 2D SHAFT THIS. FACE - TOWARD EX- TENDED END OF SHAFT (1). EXTENDED END OF SHAFT (1) ROTOR (3) JUST PRIOR TO STARTING ON SEAT | “mage MUST NOT EXCEED 6208%< | SS ton a" KEY (2) — aR HYDROMATIC_ BRAKES WHEN PROPERLY POSITIONED ROTOR HUB WILL’ COINCIDE WITH THIS SHOUL ‘KEY (2) THE PARKERSBURG RIG 8 REEL CO. PARKERSBURG, W VA PES 6/18/54 PSK- 907THE PARKERSBURG F168 REEL CO 22” HYDROMATIC BRAKES CARRIER RING (14) MUST BE INSTALLED MN SIDE COVER WITH LOGATING PIN POSITIONED Wh NOTE- SHAFT (1) 1S NOT SHOWN IN ABOVE ‘SKETCH, INSTALLATION OF CARRIER RING ees_sverse PSK-GOS.VANE OF POCKET SECTION (5 OR 6) STRAIGHT EDGE VANES OF ROTOR & ADJOINING POCKET SECTION MUST CHECK AS SHOWN. ‘ oan “ G@ ROTOR (3) C CHECKING SLOPE QF ROTOR VANE & MATING POCKET SECTION VANE. THE PARKERSBURG RIG & REEL CO. 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