Industrial Gearbox Service Manual
Contents
1. 6 Industrial Gearbox Service Manual HOUSING gt CHALLENGE e Repair and rebuild worn bearing housing CAUSES IM Worn components lead to micro movement and additional wear M Load produces axial forces that are higher than original calculations M Spun bearing caused by seizure or inappropriate loads Industrial Gearbox Service Manual 7 SOLUTION e Rebuild worn housing surface with LOCTITE Fixmaster Superior Metal STEPS 1 Machine the housing by undercutting in the bore by 1 5 mm in the worn area leaving the surface rough Clean parts with LOCTITE ODC Free Cleaner and Degreaser Mix and apply a layer of LOCTITE Fixmaster Superior Metal and force it into the rough surface finish Build the surface above the final desired level Allow the adhesive to cure for 12 hours at room temperature 5 Machine the repair to the required dimensions typically a press fit using diamond cutting inserts 6 Clean the rebuilt surface and the outer bearing ring with LOCTITE ODC Free Cleaner amp Degreaser 7 Retain the joint between the housing and the outer bearing race with LOCTITE 2760 Threadlocker WY RESULTS M Assembly is restored unitized and ready for service without a major overhaul M Easy and fast repair method compared to alternative repair methods M Joint between housing and bearing outer race is strengthened by using Loctite adhesive 8 Industrial Gearbox Servi2. APPLICATION LOCTITE SOLUTION BENEFITS SIZE NO PAGE Prevent bearing spin Loctite 641 Retaining Compound Medium strength 50 ml 21458 16 Loctite 603 Retaining Compound High strength oil tolerant 50 mi 21441 16 Loctite 660 Retaining Compound High strength gap filling up to 0 020 50 ml 66040 16 Repair worn shafts Loctite Fixmaster Superior Metal Ferro silicone based epoxy with 1 Ib kit 97473 18 outstanding compressive strength Loctite 603 Retaining Compound High strength oil tolerant 50 ml 21441 18 Shaft Mounted Component Gear Sets Gear mounted on a shaft Loctite 620 Retaining Compound High temperature high strength 50 ml 62040 19 Secure keys and repair Loctite 243 Threadlocker Medium strength primerless 50 ml 1329467 20 al all 340057 Loctite 660 Retaining Compound High strength gap filling up to 0 020 50 ml 66040 20 Repair badly worn keyways Loctite Fixmaster Superior Metal Ferro silicone based epoxy with 1 Ib kit 97473 21 outstanding compressive strength Loctite 243 Threadlocker Medium strength oil tolerant 50 mi 1329467 21 Repair worn shafts Loctite 620 Retaining Compound High temperature high strength 50 ml 62040 22 Loctite Fixmaster Superior Metal Ferro silicone based epoxy with 1 Ib kit 97473 22 outstanding compressive strength Loctite 603 Retaining Compound High strength oil tolerant 50 ml 21441 22 Couplings Protecting the Loctite Moly Paste High lubricity heavy load ca
3. HALETI MOURN J COMPONENIS PU CHALLENGE e Repair worn shafts CAUSES M Incorrect reassembly during maintenance leading to micro movements M Overload conditions and elevated operating temperatures SOLUTION 1 e Bonding a sleeve on the worn shaft with LOCTITE 620 Retaining Compound STEPS Determine an appropriate size of sleeve and machine the shaft to match Clean parts with LOCTITE ODC Free Cleaner amp Degreaser Apply a bead of LOCTITE 620 to the circumference of the shaft Assemble sleeve onto the shaft Wipe off excess Apply the same product between the sleeve and the gear wheel DURUN Industrial Gearbox Service Manual 23 SOLUTION 2 e Rebuilding the worn shaft with LOCTITE Fixmaster Superior Metal and bonding the gear wheel onto the shaft with LOCTITE 603 Retaining Compound STEPS 1 Using a lathe undercut the shaft in the worn area 1 5 mm deep and leave a rough surface over the entire machined surface 2 Dovetail the ends of the worn area to lock the application into place Clean parts with LOCTITE ODC Free Cleaner amp Degreaser Apply a layer of LOCTITE Fixmaster Superior Metal building the surface above the final desired level Allow the adhesive to cure for 12 hours at room temperature Machine the repair with a diamond tipped tool to the original dimensions Apply LOCTITE 603 Retaining Compound to the components Assemble using normal procedu
4. LOCTITE 660 Retaining Compound into the keyway Assemble parts and wipe off excess Note If keyway wallow is severe shims can be used on both sides of the keyways in conjunction with the LOCTITE 660 Retaining Compound M A unitized assembly Industrial Gearbox Service Manual 21 CHALLENGE e Repair badly worn keyways CAUSES M Alternating loads and combined loading results in micro movement wear and loose parts M Over time wear can cause keys to loosen leading to damage of the keyway SOLUTION NEW KEYWAY IN EXISTING SHAFT AND GEAR e If parts are badly worn it may be necessary to cut new keyways in this case the old keyway should be filled with metal filled epoxy STEPS Clean parts with LOCTITE ODC Free Cleaner amp Degreaser Mix and apply LOCTITE Fixmaster Superior Metal into the keyway of both the shaft and gear Allow to cure Machine the cured adhesive to the original dimensions of the shaft and bore of the gear Machine a new keyway in the shaft and gear opposite the original keyway Clean again with LOCTITE ODC Free Cleaner amp Degreaser Apply several drops of LOCTITE 243 Threadlocker directly into new keyway and insert key Wipe off excess Assemble the components 10 Allow to cure OANA URWHN WY RESULTS M The assembly is restored and ready for service without a major overhaul M The key is secured into the keyway 22 Industrial Gearbox Service Manual
5. Strength Threadlocker to the mounting bolts 3 Assemble and tighten as usual Industrial Gearbox Service Manual 29 SOLUTION 2 e Apply LOCTITE 290 Wicking Grade Threadlocker to the mounting bolts after the gearbox has been leveled and aligned STEPS 1 Clean the parts with LOCTITE ODC Free Cleaner amp Degreaser 2 Align the gearbox 3 Tighten the nuts on the mounting studs A Apply several drops of LOCTITE 290 Wicking Grade Threadlocker to the mounting bolts A RESULTS M Mounting bolts and fasteners are secured in place M Eliminate vibration loosening M Eliminate bolt corrosion M Prevent misalignment 30 Industrial Gearbox Service Manual 40 O NDE ADO A DR N E mv kG B n Tr NN O N A D A ND PACKAGE PART APPLICATION LOCTITE SOLUTION BENEFITS SIZE NO PAGE Defects and porosities Loctite Fixmaster Steel Putty Steel filled repair epoxy 1 Ib kit 99913 4 Loctite 290 Threadlocker Wicking for post assembly 50 mi 29031 4 Prevent bearing spin Loctite 603 Retaining Compound High strength oil tolerant 50 ml 21441 5 Loctite 640 Retaining Compound High strength 50 mi 64031 5 Loctite 641 Retaining Compound Medium strength 50 mi 21458 5 Repair and rebuild worn Loctite Fixmaster Superior Metal Ferro silicone based epoxy with 1 Ib kit 97473 6 bearing housing outstanding compressive strength o gt Loctite 2760 Threadlocker High strength primerless 50 ml 32525 6 bh
6. or its affiliates in the U S and elsewhere registered in the U S Patent and Trademark Office 2013 Henkel Corporation All rights reserved 10773 LT 4872 10 13
7. LOCTITE Industrial Gearbox Service Manual i Industrial Gearbox Service Manual Introduction SSS This guide has been designed to provide guick and easy assistance to the professionals who service industrial gearboxes and look for reliability longevity and cost reduction With the help of this guide you can e Easily select the right LOCTITE products to help you service the wide variety of gearbox assemblies e Prevent wear proactively e Pinpoint the most suitable solution for servicing worn parts LOCTITE products are used in gearbox manufacturing worldwide to enhance quality and extend end product life The same high quality LOCTITE technologies and products are also available to the people who maintain repair and service gearboxes There is a comprehensive range of Loctite products to e Repair and prevent gearbox failures on site to minimize downtime e Reclaim worn or damaged assemblies to avoid scrap and replacement costs C e Assist in assembly installation and disassembly e Ensure reliability and smooth running by restoring performance to as new condition The Industrial Gearbox Service Manual Solves Real Problems The applications described in the Industrial Gearbox Service Manual are based on a bevel helical gearbox configuration They apply equally for helical gearboxes worm gear units and geared motors The Industrial Gearbox Service Manual is designed as a practical g
8. SEALS e Fill the air spaces by applying LOCTITE 435 Instant Adhesive to the outside diameter of the oil seal e For longer positioning time and oil seal diameter larger than 60 mm use LOCTITE 480 Instant Adhesive e In the case of a cassette seal also bond the inside diameter to the shaft using LOCTITE 435 Instant Adhesive Industrial Gearbox Service Manual 15 SOLUTION 2 FOR METALLIC OIL SEALS e Fill the air spaces by applying LOCTITE 243 or 248 Medium Strength Threadlocker to the outside diameter of the oil seal STEPS 1 Clean the bonding surfaces of the oil seal and the gearbox with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply the adhesive recommended for the different kinds of oil seals to the outside diameter of the oil seal Note In the case of a cassette seal apply adhesive onto the cleaned shaft as well 3 Press the oil seal into position using normal techniques and wipe off any excess WY RESULTS M A sealed assembly eliminates leaks contamination and corrosion M Movement of oil seal during running is eliminated M The oil seal can still be easily removed with a screwdriver during the next overhaul 16 Industrial Gearbox Service Manual HA MUUN J COMPONENIS BEAKIRN CHALLENGE e Prevent bearing spin e Prevent downtime and scrap costs CAUSES M Bearings are prone to spinning on their shaft this results in damage M Load produces axial forces that are
9. Superior Metal See page 19 See page 18 Prevent keyway wear with LOCTITE 243 Threadlocker or repair keyway wear with LOCTITE 660 Retaining Compound See page 20 Increase the torque capacity of the flange coupling with LOCTITE 680 Retaining Compound See page 27 Prevent mounting bolts from loosening or corroding with LOCTITE 2760 High Strength Threadlocker See page 28 Prevent corrosion and seizure of dowel pins with LOCTITE Heavy Duty Anti Seize See page 10 4 Industrial Gearbox Service Manual L N CHALLENGE e Repair housing and cover defects e Seal oil leaks due to damaged housing CAUSES M Gearbox housings may be porous M Service or repair work may cause damage to gearbox housings and covers SOLUTION 1 SOLUTION 2 e Seal porosities up to 0 05 mm e Filling damaged areas with using LOCTITE 290 Threadlocker LOCTITE Fixmaster Steel medium strength wicking Putty metal filled epoxy STEPS STEPS 1 Thoroughly clean and dry the components 1 Thoroughly clean and dry the components with LOCTITE ODC Free Cleaner amp with LOCTITE ODC Free Cleaner amp Degreaser ensuring the porosity Is oil free Degreaser ensuring the repair area is 2 Brush LOCTITE 290 Threadlocker into oil free the porosities 3 Allow to cure typically for 3 hours Clean off excess product 2 Mix and apply LOCTITE Fixmaster Stee
10. apacity of existing flange drive couplings e Reuse worn flange couplings CAUSES M The transmittable torque of a flange drive coupling is limited by the friction of the surfaces M Overloading causes slippage and wear of the coupling surface v SOLUTION e Use LOCTITE 680 High Strength Retaining Compound on the flange face to increase the torque capacity e Increase torque capacity without any mechanical changes STEPS 1 Clean the surfaces with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply a thin film of LOCTITE 680 High Strength Retaining Compound on the entire surface of the coupling flange 3 Once you start to assemble torque bolts within 10 minutes 4 Allow to cure before applying full load WY RESULTS M Improved torque capacity without mechanical changes M Eliminates micro movement and loss of joint tension M Eliminates corrosion 28 Industrial Gearbox Service Manual VOUN TEN ARDUA 10 MOTLOR CHALLENGE e Secure motor and gearbox to the bedplate system e Prevent misalignment caused by loosening under high loads and vibration CAUSES M Vibration and shock load can loosen fasteners and mounting bolts M Loose bolts result in movement which in turn causes misalignment SOLUTION 1 e Apply LOCTITE 2760 High Strength Threadlocker to the mounting bolts STEPS 1 Clean threads with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply several drops of LOCTITE 2760 High
11. b 51007 Loctite Silver Grade Anti Seize General purpose for use up to 1600 F 20 g stick 37230 1 Ib 76764 Loctite Heavy Duty Anti Seize Metal free anti seize for use up 20 g stick 41205 reer 1 2 Ibs 51606 Maintenance Cleaners General cleaning of Loctite Natural Blue Biodegradable Large parts cleaner water based 24 fl oz 82249 external surfaces Cleaner amp Degreaser Cleaning and degreasing of Loctite Pro Strength Degreaser Solvent cleaner 15 oz 1578099 machined parts aerosol Cleaning and degreasing of Loctite ODC Free Cleaner amp General parts cleaner prior to 15 02 22355 surfaces prior to bonding Degreaser bonding solvent based aerosol 16 fl oz 20162 pump spray 1 gallon 20260 Surface Protection Rust treatment Loctite Extend Rust Treatment Rust treatment coating 10 25 oz 30539 aerosol Corrosion protection Loctite Maxi Coat Long term corrosion protection 12 02 51211 aerosol Industrial Gearbox Service Manual 33 LOCTITE U S A Canada Henkel Corporation Henkel Canada Corporation Engineering Adhesives Engineering Adhesives One Henkel Way 2515 Meadowpine Blvd Rocky Hill Connecticut 06067 Mississauga Ontario L5N 6C3 Tel 1 800 LOCTITE 562 8483 Tel 1 800 263 5043 within Canada Tel 1 860 571 5100 Tel 1 905 814 6511 Fax 1 860 571 5465 Fax 1 905 814 5391 www henkelna com mro Except as otherwise noted all marks are trademarks and or registered trademarks of Henkel and
12. ce Manual el NG AND CC KA VIE CHALLENGE e Prevent gasket failure between the upper and lower housing of a split gearbox e Prevent leaks between the inspection cover bearing cover input output flange and housing e Ensure close tolerance control of the assembly e Sealing of damaged surfaces CAUSE M The use of cut gaskets is associated with several inherent problems such as gasket relaxation shrinkage extrusion and breakage that can lead to leaks SOLUTION 1 e Use LOCTITE 518 Flange Sealant e Use LOCTITE Instant Gasket for flexible flanges such as inspection covers STEPS 1 Remove old gasketing material and other heavy contaminants with LOCTITE Chisel Paint Stripper 2 Clean both flange surfaces with LOCTITE ODC Free Cleaner amp Degreaser 3 Apply a continuous bead of LOCTITE 518 Flange Sealant or LOCTITE Instant Gasket Circle bolt holes with sealant if appropriate 4 Assemble parts and tighten as required 5 Allow to cure a gt Industrial Gearbox Service Manual 9 fe P 14 SOLUTION 2 e When the existing gasket needs to be used as a shim use LOCTITE 534 Hi Tack Gasket Dressing Stick STEPS 1 Remove old gasket material with LOCTITE Chisel Paint Stripper 2 Clean both flanges with LOCTITE ODC Free Cleaner amp Degreaser 3 Coat flange face on both sides cover and housing with LOCTITE 534 Hi Tack Gasket Dressing Stick 4 P
13. d Housing and Cover Assembly Prevent gasket failure Loctite 518 Flange Sealant General purpose up to 0 25 mm 300 ml kit 22424 8 between upper and lower gap fill evens KEP eoi Loctite 534 Hi Tack Gasket Increase the reliability of cut 19 g stick 39156 8 prevent leaks Dressing Stick gasket seals Removal of cured Loctite Chisel Paint Stripper Aggressive gasket remover 18 oz 79040 9 chemical gasket Housing and cover Loctite 243 Threadlocker Medium strength oil tolerant 50 mi 1329467 10 jastene rs palaniaient pine Loctite 248 Medium Strength Semisolid stick medium strength 19 g stick 37087 10 Threadlocker Stick Loctite 2760 Threadlocker High strength 50 mi 32525 10 Loctite Heavy Duty Anti Seize Metal free high lubricity 1 2 Ib 51606 10 Lubrication and Cooling System Threaded fittings for Loctite 567 Thread Sealant General purpose 50 mi 56747 12 Je Loctite 561 Thread Sealant Stick Semisolid stick controlled strength 19g stick 37127 12 cooling system Prevent leaks between oil Loctite 248 Medium Strength Semisolid stick medium strength 19 g stick 3 7087 14 seal and housing Threadlocker Stick Loctite 435 Instant Adhesive Transparent toughened fast cure 20g 40994 14 Loctite 480 Instant Adhesive Black toughened 20g 48040 14 E Loctite 243 Medium Strength Medium strength oil tolerant 50 mi 1329467 14 A J Threadlocker lt Industrial Gearbox Service Manual 31 PACKAGE PART
14. ginal diameter and bond the bearing onto the rebuilt shaft with LOCTITE 603 Retaining Compound STEPS Using a lathe undercut the shaft in the worn area 1 5 mm deep Dovetail the ends of the worn area to lock the application into place and leave a rough surface Clean parts with LOCTITE ODC Free Cleaner amp Degreaser Apply a layer of LOCTITE Fixmaster Superior Metal and build the surface above the final desired level Allow the adhesive to cure for 6 hours at room temperature Machine the repair with a diamond tipped tool to the required dimensions Apply LOCTITE 7649 Primer to the rebuilt area of the shaft Apply LOCTITE 603 to the inner bearing race BWN gt o NOD wu YW RESULTS M Cylindrical joint is strengthened by using a LOCTITE Retaining Compound M Shaft is repaired to provide full surface contact M Quick return to service M Extended shaft life M Reduce component consumption Industrial Gearbox Service Manual 19 SHAFT MOUNTED OMPONENTS GEAR SET CHALLENGE e Increase reliability and strength of a gear mounted on a shaft CAUSES M Incorrect reassembly during maintenance leading to micro movements M Overload conditions and elevated operating temperatures SOLUTION e Bond gear wheels directly onto the shaft with LOCTITE 620 High Strength Retaining Compound STEPS 1 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply a bead of LOCTITE 620 t
15. higher than original calculations SOLUTION FOR GAPS UP TO 0 005 0 1 mm e Retain joint using LOCTITE 603 oil tolerant high strength or LOCTITE 641 medium strength easy to dismantle Retaining Compound STEPS 1 Clean parts with LOCTITE ODC Free Cleaner 8 Degreaser 2 Apply a bead of LOCTITE 603 or LOCTITE 641 to the circumference of the shaft 3 Mount the bearing onto the shaft using normal techniques 4 Wipe off excess material Industrial Gearbox Service Manual 17 SOLUTION FOR GAPS UP TO 0 020 0 5 mm e Bond using LOCTITE 660 Retaining Compound and LOCTITE 7649 Primer STEPS Clean parts with LOCTITE ODC Free Cleaner amp Degreaser Apply LOCTITE 7649 Primer to the inner bearing race Apply a bead of LOCTITE 660 to the circumference of the shaft Assemble the components Wipe off excess UR WN gt WY RESULTS M Cylindrical joint is strengthened by using a Loctite Retaining Compound M Shaft is repaired to provide full surface contact M Quick return to service M Extended shaft life M Reduce component consumption 18 Industrial Gearbox Service Manual SHAFT MOUNTED OMPONENTS BEARIN CHALLENGE e Repair worn cylindrical shafts or gaps exceeding 0 020 0 5 mm CAUSE M Spun bearing caused by insufficient interference or inappropriate loads SOLUTION e Rebuild with LOCTITE Fixmaster Superior Metal to the ori
16. l Putty onto the area to be repaired 3 Allow to cure typically for 12 hours to achieve functional strength 4 Machine to original size if required V RESULTS M Ouick return to service M Reduce scrap by salvaging and extending the life of gearbox housing and cover Industrial Gearbox Service Manual 5 CHALLENGE e Prevent bearing spin corrosion and housing damage CAUSES M Bearing outer races are prone to spinning within their housings resulting in dam age to the housing regardless of whether or not they have been pressed or shrink fitted in place M The air space between a bearing and housing is an area susceptible to rust and fretting corrosion thus causing damage to the parts SOLUTION e LOCTITE 641 Retaining Compound is medium strength allowing for easy disassembly during future overhauls e Alternatively use LOCTITE 603 Retaining Compound for a high strength joint STEPS 1 Clean the mating surfaces with LOCTITE ODC Free Cleaner amp Degreaser NOTE LOCTITE 603 is oil tolerant and cleaning is less critical 2 Apply a film of LOCTITE Retaining Compound to the outside diameter of the bearing 3 Assemble using normal techniques Functional cure in 6 hours at room temperature WY RESULTS M Bearing movement is eliminated M Bearing can be easily removed with standard tools M Corrosion is eliminated because the air space between the bearing and the housing is sealed
17. ng housing seat with a LOCTITE Fixmaster A Ea Superior Metal rd i 707 o See page 6 LOCTITE ae Remove baked on gaskets with LOCTITE Chisel Paint Stripper Clean and degrease surfaces with LOCTITE ODC Free Cleaner amp Degreaser See page 8 Prevent bearing spin and fretting with LOCTITE 603 or LOCTITE 641 Retaining Compound See page 5 and 16 Secure and prevent leakage between oil seal and housing with LOCTITE 248 Threadlocker Stick LOCTITE 480 or LOCTITE 435 Instant Adhesive See page 14 Prevent corrosion seizure and bolt loosening with LOCTITE 243 or LOCTITE 248 Medium Strength Threadlockers See page 10 Seal rigid parts without gasket shimming using LOCTITE 518 Flange Sealant Seal and lock fittings at any angle with LOCTITE 567 or LOCTITE 561 Thread Sealants See page 12 See page 8 Industrial Gearbox Service Manual 3 Make any size or shape gasket for flexible covers and covers with large bolt spacing use LOCTITE Instant Gasket for rigid assemblies use LOCTITE 518 Flange Sealant See page 8 Repair housing cracks porosities and defects with LOCTITE Fixmaster Steel Putty Metal Filled Epoxy sO Sie See page 4 Prevent pinion and all other gear movement with LOCTITE 620 Retaining Compound Rebuild a worn shaft using LOCTITE Fixmaster
18. o the circumference of the shaft 3 Press the gear onto the shaft using normal techniques 4 Wipe off excess material VW RESULTS M Assembly is strengthened by using a Loctite Retaining Compound 20 Industrial Gearbox Service Manual Pi MOUN CHALLENGE e Secure the key in the keyway on new equipment e Prevent micro movements that lead to wear e Repair worn keyways CAUSES M Alternating loads and combined loading result in micro movement wear and loose parts JMPUONEN Po M Over time wear can cause keys to loosen leading to damage of the keyway SOLUTION 1 NEW COMPONENTS e Proactively apply a LOCTITE Medium Strength Threadlocker to eliminate any future wear of the key or keyway STEPS 1 Clean the keyway and key stock with LOCTITE ODC Free Cleaner amp Degreaser Apply several drops of LOCTITE 243 Medium Strength Threadlocker directly into the keyway Insert the key stock into the keyway Note Cover the shaft with a rag to prevent splatter when Inserting the key stock Wipe off any excess threadlocker YW RESULTS M Eliminate mirco movement which leads to fretting M Prevent keyway wallow SOLUTION 2 SLIGHTLY WORN KEYWAYS e LOCTITE 660 Retaining Compound Compound is a very thick product allows it to fill large gaps STEPS 1 M Prevent corrosion Clean the keyway and key stock with LOCTITE ODC Free Cleaner amp Degreaser Apply
19. osition the pre cut gasket 5 Assemble and tighten as required Note Accurate repositioning component assembly and tightening should be handled in a continuous workflow without interruptions WY RESULTS M Elimination of common cut gasket failures such as compression set shrinkage relaxation and breaks M Constant clamp load is ensured M Elimination of oil leaks between the bearing frame and frame adapter along with associated cleanup costs and hazards M Reduced oil consumption and risk of running low on oil M Eliminate corrosion on the flange surface M Ensures all potential leak paths are filled and sealed 10 Industrial Gearbox Service Manual m KO N ANL 2 PU TS p b gt UU im CHALLENGE e Prevent loosening and corrosion of the housing and cover fasteners to ensure gasket reliability e Prevent corrosion and seizure of split gearbox alignment pins CAUSES M Cover fasteners that are rusted and seized make gearbox maintenance difficult and create additional labor associated with drilling and tapping the fastener hole M Fasteners can work loose when subjected to torque vibration thermal expansion and shock loads CG M Once the fasteners become loose the preload for the gasket will be lost and the gasket will fail M Dowel pins can rust and seize into component making disassembly very difficult Industrial Gearbox Service Manual 11 SOLUTION e Apply LOCTITE 243 or 248 Medi
20. pacity 1 Ib 51049 24 spline assembly moly paste brush top Repair spline Loctite 660 Retaining Compound High strength gap filling up to 0 020 50 ml 66040 25 Loctite Fixmaster Superior Metal Ferro silicone based epoxy with 1 Ib kit 97473 25 outstanding compressive strength Prevent coupling Loctite 243 Threadlocker Medium strength oil tolerant 50 ml 1329467 26 MSIE SD E Loctite 248 Medium Strength Semisolid stick medium strength 19 g stick 3 7087 26 Threadlocker Stick Upgrade load Loctite 680 Retaining Compound High strength 50 ml 1835201 27 Capacity reuse worn flange couplings Mounting Gearbox to Motor Mounting fasteners Loctite 290 Threadlocker Wicking for post assembly 50 ml 29031 28 Loctite 2760 Threadlocker High strength primerless 50 mi 32525 28 32 Industrial Gearbox Service Manual PACKAGE PART APPLICATION LOCTITE SOLUTION BENEFITS SIZE NO Maintenance Lubrication To free rusted corroded Loctite Freeze amp Release Freezing action plus penetrating oil 13 52 fl oz 996456 and seized parts during aerosol dismantling Assembly aid for all Loctite ViperLube High High performance grease 14 oz 36782 assembly works Performance Synthetic Grease cartridge Loctite Moly Paste High lubricity heavy load capacity 1 Ib 51049 moly paste brush top Protection for fasteners and Loctite C5 A Copper Anti Seize Copper based general purpose use 20 g stick 37229 alignment pins up to 1800 F 1 1
21. res Kw o N ou w RESULTS M Assembly is strengthened by using a Loctite Retaining Compound M Assembly is restored and ready for service without a major overhaul 24 Industrial Gearbox Service Manual CHALLENGE e Protecting the spline assembly to prevent unnecessary fretting CAUSE M Wear will occur where there is friction and movement in the spline SOLUTION e Use LOCTITE Moly Paste proactively to reduce friction and wear STEPS 1 Clean mating surface with LOCTITE ODC Free Cleaner amp Degreaser 2 Coat mating surface with LOCTITE Moly Paste 3 Assemble parts WY RESULTS M Prevention of wear caused by friction M Prevention of corrosion M LOCTITE Moly Paste provides very high lubricity and heavy load capacity Industrial Gearbox Service Manual 25 3 A rat vi A E _ i i E CHALLENGE e Protecting the spline assembly to prevent unnecessary fretting CAUSE M Wear will occur where there is friction and movement in the spline SOLUTION e For repair of a non sliding spline with backlash STEPS 1 If possible abrasive blast the surface of the spline shaft and socket 2 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 3 Check the spline area for uniformity A Apply LOCTITE Fixmaster Superior Metal to the spline shaft and disperse the product uniformly over the spline circumference Note For wear between socke
22. stem leads to stress on the pipe work Industrial Gearbox Service Manual 13 SOLUTION e Seal threaded assemblies with LOCTITE 567 or 561 Thread Sealants STEPS 1 Clean parts with LOCTITE ODC Free Cleaner amp Degreaser 2 Apply a bead of LOCTITE Thread Sealant to the leading threads of the male fitting 3 Assemble parts and allow to cure WY RESULTS M Less oil consumption thereby reducing the risk of the gearbox running low on lubricant M When cured LOCTITE Thread Sealants are resistant to oil and water glycol and ensure zero leakage M Thread sealants prevent fittings from loosening yet allow easy disassembly with normal hand tools M Elimination of the potential hazards and cleanup associated with oil leaks M Elimination of seized fittings because moisture and air have been sealed out M Elimination of rust and corrosion within the thread space M Contaminants prevented from getting into the oil through the gaps in the threads M Reduced coolant consumption 14 Industrial Gearbox Service Manual SHAFT SEALS gt CHALLENGE e Prevent leaks between the gearbox housing and oil seal e Prevent movement of oil seal in housing CAUSES M As with any press fit there are small air spaces between the housing and the oil seal and this air space can create a leak path M Inthe case of a split gearbox housing T joints are potential leakage points SOLUTION 1 FOR ELASTOMER OIL
23. t and shaft below 0 25 mm use LOCTITE 660 Retaining Compound in combination with LOCTITE 7649 Primer 5 Immediately push the spline shaft into the socket and remove excess adhesive Allow the adhesive to cure before putting the equipment back into service WY RESULTS M Assembly is restored and ready for service without a major overhaul 26 Industrial Gearbox Service Manual COUPLINGS gt CHALLENGE e Prevent couplings from moving due to loose setscrews e Ensure optimum assembly life in on site conditions CAUSES M Couplings are commonly held in place by a key and a setscrew M Coupling assemblies are subjected to vibration and high loads which can cause threaded fasteners to loosen M Typically couplings are assembled on site for this reason it is difficult to ensure that tightening specifications are followed SOLUTION e Secure all threaded fasteners on couplings using LOCTITE 243 or 248 Medium Strength Threadlocker STEPS 1 Clean the components with LOCTITE ODC Free Cleaner 8 Degreaser 2 Apply LOCTITE 243 or 248 Medium Strength Threadlocker to all threaded fasteners 3 Align the coupling and assemble 4 Tighten each fastener within 5 minutes of assembly WY RESULTS M All fasteners are secured in place M Prevention of misalignment and O coupling failure Industrial Gearbox Service Manual 27 ry XT CHALLENGE e Upgrade the load c
24. tings for the lubrication and cooling system 12 Shaft Seals Prevent leaks between the gearbox housing and oilseal 14 Shaft Mounted Components Bearings Prevent DeariN SDIN sesaess sate ennast o seen seed rOn EE ceded vaen wai esos eee 16 Repair worn cylindrical Shaft 0 0 0 cc eee eee eee eee tenn eens 18 Shaft Mounted Components Gear Sets Increase reliability and strength of a gear wheel mounted on a shaft 05 19 Prevent and repair keyway wear eeee e ee a een 20 Repair badly worn keywayS 00 cues eee eee neern ANA 21 Repair worn Shafts 0 0 0 0 ccc eee ne s a ANA 22 Couplings Protect the spline assembly to prevent unnecessary fretting 24 Repair spline backlash 4 M AN OA VA KAA 25 Prevent couplings moving due to loose setscrews ene 26 Increase the load capacity for flange couplings 4 ea 27 Mounting Gearbox to Motor Prevent loosening of gearbox and motor mounting bolts 0 0 ccc cee eee 2 SINN Gearbox Application Product Table To speak with someone in our tecanisa ose A ce or to contact yous local sales represe call 1 800 LOCTITE TEG6e aan or 1 8 800 2 26 2 Industrial Gearbox Service Manual Gearbox Application Diagram Rebuild and repair the beari
25. uide to provide information covering key gearbox assembly groups Feasibility Confirmed The recommendations given in this Industrial Gearbox Service Manual are based on collaboration with customers institutes and universities to establish their validity and confirm that these methods are operable practical and indeed the best solutions for servicing and repairing gearbox assemblies Profit from Reliability Henkel provides products for cost efficient easy and effective gearbox maintenance and repair When gearboxes and ancillary equipment fails the greatest concern is getting it running again but spare parts may not always be readily available LOCTITE products not only provide reliable on site repair capability but emergency repair and service solutions that last or even extend the lifetime of equipment Industrial Gearbox Service Manual 1 SC Contents Introduction Gearbox Application Diagram 2 Housing Repair housings and covers Damaged surfaces and porosities 4 Prevent bearing spin corrosion and housing damage ccc eee teens 5 Repair and rebuild worn bearing housing cc cece cence eens 6 Housing and Cover Assembly Prevent gasket failure between the upper and lower housing of a split gearbox 8 Prevent loosening and corrosion of the cover fasteners 0 0 cece eee eens 10 Lubrication and Cooling System Prevent leaks from threaded fit
26. um Strength Threadlocker to the housing fasteners e Use LOCTITE 2760 Threadlocker for high strength or on stainless steel and plated fasteners e If locking of the fasteners is not required use LOCTITE Heavy Duty Anti Seize STEPS 1 Clean the threads and pins with LOCTITE ODC Free Cleaner and Degreaser 2 Apply LOCTITE 243 or 248 Medium Strength Threadlocker to the housing fasteners Apply LOCTITE 2760 High Strength Threadlocker if stainless steel or plated fasteners are in use 3 Apply LOCTITE Heavy Duty Anti Seize onto the dowel pin Note If a liquid gasket is in use ensure only a very thin layer of LOCTITE Heavy Duty Anti Seize is applied 4 Assemble and tighten WY RESULTS M Correct clamp load is maintained M Elimination of rust and seizure M Easy disassembly with normal hand tools 12 Industrial Gearbox Service Manual p ON AND COOLIN AYA UU PU 7 CHALLENGE e Prevent leaks from threaded fittings of lubrication and cooling systems Lubrication System e Prevent oil leaks on oil drain plug oil inlet housing ventilation oil pump oil filter and gauge Cooling System e Prevent leakage on the coolant pump pressure and temperature control unit and all pipe work CAUSES M Traditional thread sealants are susceptible to leaks M Pressure and temperature changes within a gearbox system can aggravate any leak M Vibration between the gearbox and lubrication cooling sy
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