SERVICE MANUAL
Contents
1. 1 Remove retaining ring 8 as follows a With brake assembly oriented large end up as shown in exploded view on page 3 apply downward force on backing plate 4 to compress springs 5 Each spring exerts about 300 pounds of force b Press the plate as far as it will go about 1 16 inch of travel This can be done with a hydraulic press or a piece of at least 1 2 13 all thread washers and hex nuts through the middle of the brake c With backing plate 4 pressed away from the retaining ring 8 start the retaining ring out of the groove by pry ing the end of it with a screwdriver d Grab the end of the retaining ring with your hands and with a circular motion work the retaining ring the rest of the way out of the groove NOTE The retaining ring 8 is normally under very high spring load DO attempt to remove it without first re leasing spring load by depressing the backing plate 4 as de scribed above Personal injury and or damage to the brake will result if this step is not followed 2 Remove springs 5 3 Remove piston 3 as follows Apply low air pressure 20 30 psi to the brake release port while holding one hand on top of the piston 3 Itis a good idea to first place a shop rag over the piston The air will force the piston 3 out of the case 1 4 Remove the friction discs 6 separator plates 7 O rings 12 13 and back up rings 102. BacKUPRING BACKUPRNO NOTES 1 QTY OF SPRINGS MUST BE 2 4 5 6 8 OR 10 AS DETERMINED BY SPECIFIC BRAKE REQUIREMENTS 2 TOTAL QTY OF FRICTION DISCS ITEM 6 AND SEPARATORS ITEM 7 MUST EQUAL 8 FULL COMPLEMENT BRAKE INCLUDES 4 FRICTION DISCS ITEM 6 AND 4 SEPARATORS ITEM 7 OPTIONS 1 SEAL KIT P N 95 016 2541 INCLUDES 1 EACH ITEMS 10 11 12 13 2 FRICTION DISC KIT 95 016 2551 INCLUDES 4 EACH ITEM 6 3 SEPARATOR PLATE KIT 95 016 2561 INCLUDES 4 EACH ITEM 7 gt gt gt NOTE THAT BRAKE IS SHOWN INVERTED UPSIDE DOWN RELATIVE TO EXPLODED DRAWING OF PLANETARY GEARDRIVE LUBRICATION amp MAINTENANCE Using the chart below determine an appropriate lubricant viscosity Use only EP extreme pressure or API GL 5 designated lubricants Change the lubricant after the first 50 hours of operation and at 500 hour intervals thereafter The gear drive should be partially disas sembled to inspect gears and bearings at 1000 hour intervals Recommended ambient and operating temperatures for conventional and synthetic gear lubricants 50 25 0 25 50 100 125 150 175 200 225 250F 80W90 conventional 75W90 conventional 85W140 conventional Max mn temp Min Ambient operating temp Max Ambient temp 75W90 synthetic 80W140 synthetic 45 32 18 4 10 24 38 52 66 79 93 107 121C Note Ambient temperature is the air
3. 3 BEARNO PRP 011050500 01 105 0590 19 3 BEARNG P 01 106 0500 01 1050500 20 4 BEARINGCONE 1 102 0090 01 102 0090 P21 BEARING CUP 01 103 0080 22 1 BEARING CONE 07 102 0700 01 1020100 23 1 BEARING CUP OT 103 0090 07 10 0000 24 e HHS 38161 12GR8____ 0 160 1670 01 150 1670 25 s SHCS 12202126R8 01150 1480 07 10 1480 727 e LOCKWASHER smeo 017660010 01516550107 28 3 ROLLPIN SEC PL 011530210 0115302107 29 3 ROLL PIN PRI PL 76x78 011550180 101 153 0180 orn orazo 014020400 SHAFTSEAL 01 405 0380 32 1 PIPE PLUG 38 NPT MAGNETIC 01 207 0070 012207 0070 381 Pre rie mener 01 2070030 SEAL KIT P N 83 016 5011 INCLUDES 1 EACH OF ITEMS 30 amp 31 QUANTITY OF SHIMS DETERMINED BY PRELOAD DESIRED AND PART STACK UP GREASE ZERK 1 8 NPT 65 P N 01 215 0070 OPTIONAL X65EIBD2 AA 01 08 03 OUTPUT SHAFT Integral Brake Exploded Drawing ESKRIDGE EFFECTIVE FOR FROM S N 73000 10 01 02 TO CURRENT Model 10 Integral Brake 1 130049012 _ 13 04 9012 012880072 FRICTION DISC ROTOR 7 012880082 SEPARATOR PLATE STATOR 1 01460 0670 RETAININGRING e or t12 0230 THRUSTWASHER 10 4 014000220
4. tested at the factory for function leaks and static breakaway torque and are tested to be within 20 of rated torque Because the brake is integral with the gear drive it is designed to run wet Brake holding torque will be affected by the actual lubricant used but it is intended for operation with EP 80 90 gear oil Orientation of the gearbox also affects the performance of the brake With the gearbox mounted horizontally or vertically pinion up the clutch plates will be bathed in oil and the holding torque will be in the 20 range Withe the gearbox mounted in the vertical output down ori entation the brake plates will not run in oil and the holding torque should be in the 20 range Brake Specifications Table MAXIMUM 3000 PSI 3000 PSI PRESSURE INTERMITTENT CONTINUOUS MAXIMUM 3000 RPM 2000 RPM SPEED INTERMITTENT NO LOAD CONTINUOUS 200 F LOAD OPERATING INTERMITTENT 170 F CONTINUOUS PRESSURE OIL VOLUME REQUIRED TO RELEASE 0 62 CUBIC BRAKE INCHES SEAL FLUID COMPATIBILITY MINERAL BASED HYDRAULIC OIL NORMAL OPERATING POSITION OF BACKING PLATE Detent G shoulder TSN a MAXIMUM BACKING PLATE DEPRESSED FOR INSTALLATION OR REMOVAL OF RETAINING RING Spiral Wound Retaining Ring 8
5. 11 and thrust washer 9 from case 1 Brake Inspection 1 Clean all parts prior to inspection 2 Case 1 Grooves for O rings and retaining ring should be clean and free of nicks and dings 3 Shaft 2 Should be free of heavy wear Gear teeth should show no signs of pitting or surface spalling Spline on inside and outside of shaft should not show any fretting wear be yond surface discoloration 4 Piston 3 Should be free of all scratches nicks and dings the two diameters that seal against the O rings in the case Only very minor scratches may be dressed with 600 grit and finer paper to at least a 32 micro inch finish 5 Backing plate 4 Shoulder that bears against retaining ring 8 should be square and free of nicks and dings 6 Springs 5 May be reused if no signs of cracks or rust Springs do eventually fatigue and fail after many cycles so it is always recommended that they be replaced during non routine servicing 7 Friction amp separator plates 6 amp 7 May be reused if not ex cessively worn There should be 8 parts total in the friction pack 1 to 4 friction discs and 4 to 7 separator plates The full stack measures 0 800 inches new Replace friction discs if the full stack measures less than 0 775 inches height This height represents a 10 reduction in holding torque versus new 8 Retaining ring 8 Should lay relatively flat and round in the free state Replace if height measures m
6. shaft item 12 from gearbox exploded drawing Using a mallet or light force press the piston into the case 1 until it drops below the retaining ring groove Install springs 5 into the piston 3 They must be evenly spaced such that the spring force is always balanced side to side Set backing plate 4 with stepped side up on top of springs 5 in case 1 Set the retaining ring 8 on stepped lip of the backing plate 4 Using hydraulic press or suitable ap paratus mentioned above press and hold the backing plate 4 as far as it will go below retaining ring groove Refer to detailed view in disassembly instructions page 6 Using your hands install the retaining ring 8 in its groove in the case 1 Start one end into the groove and work the rest of it into the groove with a circular motion A flat blade screwdriver or awl may help in the installation but no other tools should be needed If the retaining ring doesn t go freely then the backing plate is not pressed in far enough into the case 1 When installed release the load against the backing plate 4 Check that the ring is properly seated in the groove and below the detent shoulder in the backing plate 4 Refer to detail view in disassembly instructions page 6 Reinstall shaft 12 gear drive drawing or 2 brake draw ing and verify that it will insert through the brake to the thrust washer 9 If not apply pressure to the release ports to disengage t
7. temperature measured the immediate vicintiy of the gearbox Gearbox exposed to the direct rays of the sun or other radiant heat sources will operate at higher temperatures and therefore must be given special consideration The max operating temp must not be exceeded under any circumstances regardless of ambient temperature If your unit was specified shaft up or with Z option a grease zerk was provided the base housing For shaft up operation the output bearing will not run in oil and must be grease lubricated Use a lithium based or general purpose bearing grease sparingly every 50 operating hours or at regular maintenance intervals Over greasing the output bearing should be avoided as it tends to fill the housing with grease and thicken the oil ESKRIDGE MODEL 65E OIL CAPACITIES Operating Position Oil Capacity Oil Level Single stage Double stage T Horizontal Shaft 2 25 pints 1 1 liters 2 25 pints 1 1 liters To horizontal centerline of gear drive Vertical Shaft Pinion Up 2 5 pints 1 2 liters 2 5 pints 1 2 liters To side port on gear drive base me Vertical Shaft Pinion Down 2 5 pints 1 2 liters 2 5 pints 1 2 liters To midway on upper primary gear set ESKRIDGE PART NUMBER INTERPRETATION Note All non custom Eskridge Geardrives are issued a descriptive part number which includes information regard ing the Model means of shaft retention base style shaft style input mounting input shaf
8. 19 22 amp 28 1 Disassembly procedure is the same as previous section on primary planet carrier subassembly steps 1 4 except sub stitute these parts secondary carrier 2 secondary planet gears 9 planet bearings 19 secondary planet shafts 7 and roll pins 28 Reassembly 1 Place carrier 2 with hub down as shown above Place bear ing retainer plate 5 in bottom of carrier Insert secondary planet gears 9 2 Turn carrier 2 over while using the planet gears 9 to hold retainer plate 5 in place 3 Remove one planet gear 9 and insert a bearing 19 In stall two washers 15 one on either side of the planet gear Place in carrier and install planet shaft 7 and roll pin 26 Repeat for two remaining gears NOTE Press bearing onto hub by pressing on inner race only DON T press on roller cage or it may damage bearing 4 If tapered inner bearing cone 22 on hub of secondary carrier 2 must be replaced it may be removed using a gear puller Then press a new bearing cone onto hub making sure bear ing shoulder is tight against hub shoulder Case Subassembly 1 Inspect inner and outer bearing cups 21 amp 23 and replace if necessary 2 Clean all foreign material from magnetic drain and fill plug 32 Brake Disassembly Procedure The 10 inch integral brake is spring loaded normally applied and requires hydraulic pressure to release All brakes are individually
9. 65 PLANETARY GEAR DRIVE WITH INTEGRAL BRAKE SERVICE AND REPAIR MANUAL lt A WARNING While working on this equipment use safe lifting procedures wear adequate clothing and wear hearing eye and respiratory protection THIS SERVICE MANUAL IS EFFECTIVE FROM S N 55013 JUNE 2002 CURRENT RER C SM65EIBD2 AB 65E Single Stage Exploded View Drawing MODEL 65E WITH INTEGRAL BRAKE EFFECTIVE FOR TO CURRENT DOUBLE PLANETARY RATIO ITEM DESCRIPTION PART NO PART NO 1 CASE E60 STD 83 004 3012 83 004 3012 BRAKE ASSEMBLY REFER TO BRAKE EXPLODED DRAWING 1 CARRIER SEC 83 004 1262 83 004 1232 1 CARRIER 13 04 1032 13 004 1032 2 THRUST WASHER SECONDARY 81 004 2711 81 004 2711 PLATE BEARING RETAINER 86 004 1002 86 004 1002 5 1 e 1 INTEGRALBRAKE SEE BRAKE BP ODED DRAWING 7 3 PLANET SHAFT SEG 83 004 1031 83 004 1031_ 3 PLANETSHAFT PR 13 004 021 13 004 021_ Pe 3 PLANETGEAR SEC 1 004 10 s PLANET GEAR PR jiao 13000 1112 004 INPUT SHAFT SAE 1 6B 2 DIA 3 8 KEY 83 004 4023 83 04 4023 2 DIA 23T 12 24 DP SPL 83 004 4043 13 1 2 1 4 DIA 1 2 KEY 84 004 4073 3 DIA 3 4 KEY 83 04 4233 2 DIA 1 2 KEY 83 04 4393 1 CUSTOM 1 ae Sis o o aOR TOT 75 12 THRUST WASHER PLANET 810041561 81 0041567 78
10. et carrier assembly 2 5 7 9 15 19 22 amp 28 may now be lifted out of case Output Shaft Subassembly Items 13 20 31 1 Outer tapered bearing cone 20 may be removed using a gear puller If reusing old bearing cone do not damage roller cage by pulling on it 2 To replace shaft seal 31 lubricate inner lip of new seal and turn so that open side is facing upward Slide seal down out put shaft 13 all the way to gear teeth or until it fits snug over seal diameter Primary Planet Carrier Subassembly Items 3 8 10 11 15 18 amp 29 45 1 Rotate the planet gears 10 to check for abnormal noise or roughness in bearings 18 or planet shafts 8 If further inspection or replacement is required proceed as follows 2 Drive roll pins 29 into planet shafts 8 3 Press or drive planet shafts out of carrier 3 4 Slide planet gears 10 along with planet washers 15 out of primary carrier 3 5 If planet bearings 18 must be replaced they may now be removed from primary planet gears 10 6 Use 1 8 inch pin punch to remove roll pins 27 from planet shafts 7 Rebuild primary planet carrier assembly in reverse order us ing any needed new parts Planet shafts 8 should be in stalled with chamfered end of 1 8 inch hole toward outside diameter of carrier This will aid in alignment of holes while inserting roll pins Secondary Planet Carrier Subassembly Items 2 5 7 9 14 15
11. he brake Shaft must insert all the way through to the thrust washer 9 in order for the brake unit to install properly on the geardrive Unit Reassembly Bearing Pre Load Measurement and Setting DIM ao RA LO P 7 A oe 2 Em im 4 2 E A Fal 1 Install the secondary carrier assembly with the bearing 22 installed into the base 1 with cups 21 amp 23 installed Turn this assembly upside down outer bearing pointing up Sup port the retainer plate 5 on a suitable support so the entire assembly is free to rotate on the inner bearing on the support See the illustration above Place the outer cone 20 into the outer cup 21 and carefully spin this assembly 1 3 revolu tions to allow the bearings to seat Using a depth micrometer measure down from the outer bearing cone mounting surface to the bottom surface of the retainer plate 5 Record this measurement as A Next measure from the inner end of the shaft 13 where the three threaded holes a
12. n centered between planet gears A certain amount of tool clearance will be necessary in order to install and torque the capscrews 25 8 Install secondary carrier assembly 2 into case 1 as fol lows Rotate secondary carrier assembly back and forth until planet gear teeth 9 mesh with gear teeth in case 1 Let carrier assembly down until carrier spline touches output shaft 13 spline Rotate carrier by hand until you are cer tain carrier spline has started cleanly and squarely onto shaft spline View down through top of secondary carrier assembly through counter bored holes in retainer plate 5 If needed align holes in retainer plate directly over holes in the shaft and shim s 14 9 Counter bored holes should be centered between planet gears 9 Slowly press secondary carrier assembly down tightly against output shaft 13 NOTE 1 Rolling torque at proper bearing preload will vary ac cording to the application At output speeds of greater than 25 RPM preload torque including seal drag should be in the range of 50 to 150 in lbs At less than 25 RPM rolling torque should be 150 to 250 in lbs 10 Tighten the socket head capscrews 25 to a torque of 90 ft lb Spin the gearbox case 1 on the shaft 2 to 3 revolutions Now re tighten the capscrews 25 to a torque of 90 ft lb This step allows the bearings to seat into their running position and ensures the correct torque on the fasteners 11 Place secondary th
13. ore than 25 when checked on a flat surface of the 2 spiral coils do not lay one on top of the other Back up and O rings 10 11 12 amp 13 It is recommended that they be replaced during non routine servicing They may be reused if replacements are not available only if they are free of cuts and wear Be sure to check all surfaces Install thrust washer 9 case 1 Friction discs 6 may be installed dry or they may be pre wetted with gear oil A friction disc 6 should be placed in the case 1 followed by a separator plate 7 Alternate with friction discs 6 and separator plates 7 in exactly the same order as they were removed There must always be a sepa rator plate 7 on the exposed piston end of the stack and a friction disc 6 on bottom end of the stack NOTE If a friction disc 6 is placed next to the piston 3 the 3 unit will overheat and fail With the friction pack in place align the splines of the friction discs 6 using the shaft item 12 from gearbox exploded drawing The shaft must be able to slip all the way through the friction pack to the thrust washer 9 Install O rings 12 amp 13 such that they are nearest each other with the back up rings 10 amp 11 to the outside Lubricate the O rings 12 amp 13 and piston 3 with gear or hydraulic oil Gently slide piston 3 into case 1 using heel of both hands as far as it will go Recheck spline alignment of friction discs with
14. re located to the bearing seat Record this measurement as B Subtract A B This number is the un preloaded gap in the bearing stack The correct amount of pre load is generally between 0 005 inch and 0 020 inch compression of the bearings Add or re move shims to achieve the desired gap which will compress or pre load the bearings Each shim is 0 005 inch thick The lower gap will produce rolling torque of 50 150 in lb the high er gap will produce rolling torques of 150 250 in lb Fewer shims tighter bearing pre load more shims looser bearing pre load Place the shaft seal 31 onto the seal diameter of the shaft 13 Press the outer bearing cone 20 onto the shaft press only on the race not on the cage Turn case pinion side up Apply a layer of lithium grease to outer bearing cup 21 Place the shaft 13 into case 1 so that the shaft s outer tapered bearing cone 20 is seated in case s outer bearing cup 21 Tap shaft seal 31 into place CAUTION Shaft is not retained at this time 4 Turn case pinion side down 5 Apply a layer of lithium grease to inner bearing cup 23 6 Install the correct number of shims 14 determined in step 1 onto the end of the shaft 13 with the holes lined up cor rectly 7 Rotate bearing retainer plate 5 inside secondary carrier as sembly so that counter bored holes are centered between planet gears 9 NOTE It is important that the holes in the retainer plate re mai
15. rust washer 4 onto center of secondary planet carrier assembly 12 Install sun gear 11 into center of secondary planet carrier 13 To install primary planet carrier assembly hold inside diame ter of carrier 3 and rotate until planet gears line up with case gear teeth and sun gear Assembly will drop into place NOTE A simple planetary such as this does not require a gear timing procedure 14 Insert input gear 12 into unit so that teeth mesh with primary planet gears 10 15 Place carrier thrust washer 4 over input gear 16 Place a new O ring 30 on bottom of brake 6 17 Set brake 6 on top of unit and refer to scribed line for proper orientation Install and torque eight cover bolts 24 with lock washers 27 to 32 ft lbs 17 Check to be sure magnetic plug 32 is securely installed into side of case 1 18 Add gear oil as specified on page 2 Correct oil level will measure to middle of primary planet gears 10 when in the vertical operating position 19 Install plug 15 from brake drawing and install into oil fill hole in brake 6 20 Insert a shaft such as an output shaft from a hydraulic motor into input gear 12 release brake and rotate by hand to be sure unit turns smoothly and easily THE GEARBOX IS NOW READY FOR USE
16. t size overall ratio and various available options For a detailed breakdown of this information please refer to Eskridge product specifica tion sheets found at http www eskridgeinc com geardrives gearprodspecs html Unit Disassembly Procedure 1 Scribe a diagonal line across the outside of the unit from cover brake 6 to case 1 before disassembly to assure proper positioning of pieces during reassembly 2 Remove magnetic pipe plug 32 and drain oil from unit Maxi mum drainage occurs when oil is warm 3 Remove eight cover brake bolts 24 and lockwashers 27 4 Lift off cover brake 6 The input shaft 12 and carrier thrust washer 4 may be lifted out of carrier assembly 5 Lift primary planet carrier assembly 3 8 10 15 18 amp 29 out of case 6 The output shaft 13 and secondary planet carrier assembly may now be removed as follows a The secondary planet carrier 2 spline is a press fit onto output shaft 13 spline Case 1 should be set on a plate or table with output shaft protruding downward through hole in table b Loosen but do not remove shaft retaining cap screws 25 NOTE Care should be taken not to damage output shaft or injure your feet when shaft falls out of case c Press output shaft out bottom of case by applying press load to top end of capscrews 25 Remove capscrews to allow shaft to pass through case d Remove shim s 14 from top end of shaft 13 7 Secondary plan
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