Torque-LOCK TM Static Input Brake Service Manual
Contents
1. DUE WORK CENTER COST CENTER CHARGE CODE NO REQ D OREWORK CLNO MATL 1 835 21820 20 2 88 _ 0005 A 1 170 250 4 030 X 45 1 450 1 ta 885 9 880 GF 2 00 ONE MLD STL HRDN GRD 1 STOCK SIZE OR PART NUMBER 8 FAIRFIELD MFG INC 8191015313159 DRIVE SOLUTIONS www falrfieldmfg com 9023109 DESCRIPTION PRESSING SUPPORT BASE PRESS SHAFT 101 TOLERANCE ON DIMENSIONS 005 005 015 030 UNLESS OTHERWISE SPECIFIED CHAMFERS 06 X 45 RADII 06 R DRAWN BY AJO 11 21 2013 21 0 Lbs ISSMILAR STAMP PART NO STAMP TOOL NO SHEET in REV DESCRIPTION APPROVED DATE 9023109 1225237 5 1 4 3 2 SOLIDWORKS SIZE DRAWING Last Saved aopell on Thursday November 21 2013 3 25 53 as C Foirfield Vault CAD_Mfg Tooling Assembly 1225237 1225237 slddrw 3195 LON 24 LEAK ROLL TEST FIXTURE DO NOT SCALE DRAWING2. DUE WORK CENTER COST CENTER CHARGE CODE NO REQ D ONEW OREWORK CLNO MATL D D B B 108 500 13 X 1 500 SHCS 107 106 105 104 103 102 1101 DET STOCK SIZE ERDE SOLUTIONS er DESCRIPTION A 7HBO ROLL CHECK 8 LEAK A TOLERAI IENSIONS UOS 00 X 1 015 X 030 UNLESS 01 CHAMFERS 4 15 RADII 06 R 1 DRAWN RAS 4 5 11 WEIGHT 114 51 s BBILAR UTTER WAS AJO 9 25 2014 STAMP PART NO STAMP TOOL NO SHEET A 21 WAS 63 RAS 1 30 15 DESCRIPTION ____ OVED DATE 7HBO 1220092 2 SOLIDWORKS B SIZE DRAWING Last Saved aopell on Thursday September 25 2014 12 36 38 PM as CAFairfield VoulINCAD_MfgNToolingNAssemblyNT220092NT220092 slddrw 21725 LON 25 125 TAP DRILL DEPTH SHOWN MUST INTERSECT 250 HOLE 1 HOLES LOC AS SHOWN 375 DIA MILL 25 DEEP 1 POCKET LOC AS SHOWN ONE CARB GRD 530 DIA THRU HOLES EQ SPACED AS SHOWN ON A 5 750 DIA B C 7HBO ROLL CHECK 8 LEAK TEST PLATE TOLERANCE ON DIMENSIONS 005 005 XX 015 X 030 UNLESS OTHERWISE SPECIFIED CHAMFERS 06 X 45 RADH 06 R 26 CWO WORK CENTER COST CENTER CHARGE CODE REQ D DRE
3. IN 47903 USA 765 772 4000 www oerlikon com fairfield
4. 1025 015 4 00 902493 9013374 5 00 ONE 4140 STL Q amp T DRAW TO 28 34 AMT MATL STOCK SIZE OR PART NUMBER DONERE DRIVE SOLUTIONS www oidieldmig com DESCRIPTION SEAL PRESS TOOL TOLERANCE ON DIMENSIONS UOS 005 2 015 X 030 UNLESS OTHERWISE SPECIFIED ALL CHAMFERS 06 X 45 RADII 06 R DRAWN BY AJO 10 16 13 WEIGHI 3 41bs SIMLAR REV DESCRIPTION APPROVED DATE STAMP PART NO STAMP TOOL NO SHEET EO3H006 T225020 4 3 2 SOLIDWORKS 8 SIZE DRAWING Last Saved aopell on Thursday November 21 2013 1 55 40 PM as C Fairfield Vault CAD_Mfg Tooling Assembly 1225020 T225020 slddrw 3155 LON 21 BEARING TOOL 3911434139 wen com 22 SHAFT TOOL RET SHAFT SUPPORT TOOL DO NOT SCALE DRAWING
5. H1333311W TLH1333309W TLH1333308W TLH1333307W TLH1333305W 17 Service Parts FRICTION DISC KIT AMTLH13WA SPRING KIT AMTLHO3B3 o SEAL KIT AMTLHO3C1 AMTLHO3D1 BEARING KIT Assembly Tools SUPPORT TOOL Z Bess Nez SEN IN LH Su lll a 3 ASS SS 35 8 A18W3SSY 1394 80 3715 4501 ON 131 3 4 90 57 X 434WYH2 93412345 980 910 9009 OffMNOISMEWNG 8 y2 USW o 05482 6 Da 0845 059 _nmoHssy S310H 2 51 005 9330 0011 dvL 3009 ON19 pz EG ng a 59K 000 910 90 SNOISMIWQ NO 20 SEAL TOOL DO NOT SCALE DRAWING DUE cwo WORK CENTER COST CENTER CHARGE CODE NO REQ D DNEW DREWORK CLNO 9013381 y BELL CENTER BOTH ENDS 2 81 50 1 840 1 835 030 X 45 1 555 T 1 545 125 38 R 10
6. N DIMENSIONS UOS 005 015 X 030 UNLESS OTHERWISE SPECIFIED ALL CHAMFERS T X 45 RADII 06 MAX DRAWN BY RAS 4 5 11 WEIGHT 1 6 lbs SIMILAR ONE M STL CARB GRD STAMP PART STAMPTOOLNO 7HBO 1220092 8 7 I 5 1 4 3 2 SOLIDWORKS B SIZE DRAWING 27 28 CWO WORK CENTER COST CENTER CHARGE CODE REQD CLNO MATL 250 28 THRU 5 1 HOLE LOC AS SHOWN 250 04125 4 875 REF REF 1 500 Ly H NE M STL 4 875 O D 375 W 1 F x 0 ONE MISIL 4 875 O D 375 WALL DOM TUBING FAIRFIELD MFG INC DERD DANI SOLUTIONS DESCRIPTION 7 ROLL CHECK amp LEAK TEST PLATE TOLERANCE ON DIMENSIONS UOS 005 015 09 UNLESS OTHERWISE SPECIFIED ALL CHAMFERS 06 X 45 06 DRAWN BY RAS 4 5 11 WEIGHT 0 7 lbs SIMILAR TO STAMP PART NO STAMP TOOL NO 7HBO 1220092 8 7 6 5 1 4 3 2 SOLIDWORKS SIZE DRAWING 5 4 5 Mailing Address Physical Address Shipping Address Fax E mail Fax Contact Information Since 1919 Fairfield has been at the forefront of gear and drive design Fairfield has the people knowledge and resources to provide solutions for a wide range of application needs With manufacturing capabilities in t
7. WORK CLNO EXTERNAL INVOLUTE SPLINE DATA PER ANSI 892 1 1970 APPROVED BY HOLLINGSWOX 02 14 11 1 390 1 395 1 395 875 FILLET ROOT SIDE 1385 91390 21390 870 TOLERANCE CLASS 26 5 TURN TURN TURN TURN 1200 3200 D 003 A 1575 213780 A esas 21575 4 1 378 FORMDA 0740 _JROLLANGIE 20187 1 373 FOR LENGTH 213780 MINOR DIAMETER O O O 06720 11 0002 A SHOWN ADDENDUM 7 0002 WHOLE 0105 88 PIN DIAMETER 0 12000 FULL SPLINE MIN MEAS OVER PINS 0 9843 MEAS OVER PINS 09867 MAX EFF CIRC TKS a 640 E MIN EFF CIRC TOOTH REF 0 0965 17 BELL CENTER BOTH ENDS MN ACT CIRC TOOTH TKS 00945 500 DIA BALL 15224 CIRC REF 0 0962 2189 DIA DRILL 1 250 MIN DEEP 2375 16 I 8 224398 MILLING CUTTER 1 HOLE LOC AS SHOWN N A T 114474 GO SPLINE GAGE WIN A MILL TO LOW LIMIT _ 4 23 209 45 290 290 030 45 030 x 45 285 285 MAX 188 LLI02 A 125 197 192 TURN 190 pe 2 19 je GRIND an MFG INC sara er L 4 765 MILL DESCRIPTION 4 755 7 ROLL CHECK amp LEAK TEST PLATE 4 750 TOLERANCE O
8. cerlikon fairfield Torque LOCK Static Input Brake Service Manual Models TLH13 Revised 8 18 2014 While every precaution has been taken in the preparation of this document Fairfield Manufacturing Co Inc assumes no liability with respect to the use of the documentation described herein or for any act or omission of Fairfield Manufacturing Co Inc concerning this documentation Torque Hub is a registered trademark of Fairfield Manufacturing Co Inc Features and specifications are subject to change without notice TORQUE LOCK Service Manual Table of Contents di a 4 BLAKE TOS lc 5 Tightening and Torquing Bolts dd 7 Lubrication INTOFMALIOMN 8 DISASSEMBLY i 10 11116 a oi 14 Assembly o 16 17 PANTS E 18 Assembly u utc ee AE rates ed 19 Contact RAAR 29 Introduction This manual is a step by step guide to the disassembly and assembly of the specific Torque Hub family of units shown the cover It is designed for the customer or mechanic who is repairing this particular Torque Loc
9. g inner race Be sure to support the inner race of the bearing Turn the Spring Housing over and install the Retaining Ring 11A onto the Brake Shaft 1 Install Retaining Ring 11 into the bearing counter bore Turn the Spring Housing 8 over and install Dowel Pins 19 into the Spring Housing Install the correct number and combination of springs 23 and 24 into the counter bores of Spring Housing 8 If Spring 23 is required note the position in the diagram Install Pressure Plate 4 onto the springs Insure that the slots on the pressure plate are aligned with the dowel pins Install the Brake Rotors 3 and Brake Stators 6 in accordance to the above exploded view The rotors and stators must alternate as shown above 14 15 Grease and install O ring 17 and Back up ring 18 into the inner groove of the Piston 9 Insure the back up ring 1 in the correct location Grease and install O ring 15 and Back up ring 16 into the outer groove of the Piston 9 Insure the back up ring 1 in the correct location ASSEMBLE WITH CAST SLOTS _ ALIGNED AS SHOWN y Install the Piston 9 with the O rings into the Piston Housing 2 being sure to orient the piston relative to the brake stators The cast slots must be in line with the Dowel Pins 19 Be sure not to cut the O rings during installation of the piston Install Gasket 7 into Spring Housing 8 Install Piston Housing subassembly onto Spring Ho
10. he United States India and China Fairfield offers custom gears with spur helical or bevel forms from 20mm through 2M to AGMA Class 14 standards We also design and build custom drives for mobile equipment and stationary industrial machinery with torque outputs from 800 Nm to over 4 000 000 Nm We provide Torque Hub planetary drives drop boxes right angle drives transfer cases specialty transmissions differentials and differential carrier assemblies housing and custom drive assemblies We can provide integrated solutions for mechanical hydraulic or electrically driven systems Fairfield is part of Oerlikon AG a global technology company with over 16 000 employees in 36 countries Together with our sister firm Graziano Trasmissioni Fairfield forms Oerlikon Drive Systems Our combined technologies enable us to provide fully integrated drive systems from transmissions to final drives for both on and off highway vehicles For more information contact Oerlikon Fairfield today Oerlikon Fairfield U S 52 South P O Box 7940 Lafayette IN 47903 7940 2400 Sagamore Parkway South Lafayette IN 47905 2309 Concord Rd Lafayette IN 47909 Main 765 772 4001 Applications Engineering 765 772 4011 Sales and Service 765 772 4010 Applications Engineering apps fairfieldmfg com Sales sales fairfieldmfg com www oerlikon com fairfield 29 cerlikon fairfield Oerlikon Fairfield U S 52 South P O Box 7940 Lafayette
11. in seal and where the O rings or gaskets meet on the exterior of the unit and then checking for air bubbles If a leak is detected in a seal O ring or gasket the part must be replaced and the unit rechecked Leak test at 10 psi for 20 minutes Model Code Leak Test Tool ALL T220092 Tightening and Torquing Bolts If an air impact wrench 1 used to tighten bolts extreme care should be taken to ensure the bolts are not tightened beyond their specified torque The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle BOLTA BOLTB 1 Tighten but do not torque bolt A until snug 2 Goto opposite side of the bolt circle and tighten B until equally snug 3 Crisscross around the bolt circle and tighten the remaining bolts 4 Use a torque wrench to apply the specified torque to bolt 5 Using the same sequence crisscross around the bolt circle and apply an equal torque to the remaining bolts General Properties Maintenance Oil Fill Level Lubrication Information The lubricant used in Torque Lock TM brakes should be ISO VG 32 hydraulic fluid Some applications require special considerations consult the machine manufacturer and Oerlikon Fairfield for more additional information An initial oil change should be made after the first 50 hours of operation Subsequent oil changes should be made at 1 000 hour intervals or a
12. k model Users of this manual should note that each part mentioned 1 followed by an identification number enclosed in parentheses These part numbers may be referred to in the Parts List and Assembly Drawing sections of this manual Specialized tools used to assemble this unit are noted in the assembly procedures and diagrammed in the Assembly Tools section Users should familiarize themselves with the procedures for brake test roll and leak test as well as bolt tightening and torquing found on the following nine pages before starting any repairs Standard safety practices should be followed during the disassembly and assembly procedures described Safety glasses and safety shoes should be worn and heavy heat resistant gloves should be used when handling heated components Be especially alert when you see the word CAUTION This indicates that a particular operation could cause personal injury if not performed properly or if certain safety procedures are not followed The word NOTE s used to bring attention to certain procedures or helpful hints that will aid in the disassembly and assembly process The Brake Test Brake Test 1 an appropriate pressure supply to the brake port and slowly increase the pressure to the prescribed pressure in the brake chart to check for correct release pressure by rotating the brake input with a 13 tooth 16 32 spline shaft with 25 in Ibs of torque Continue increasing the p
13. nnually whichever comes first Oil temperatures should be not higher than 160 to 180 for continuous operation and no higher than 2009 for intermittent operation For special applications high horsepower high speeds or wide temperature changes please consult Oerlikon Fairfield When the Torque Lock unit is mounted horizontally unless otherwise specified the gearbox should be filled half full of oil or 2 4 1 02 4 9 cu in 80cc Release volume is 7 cu in 11 5cc Vertically mounted Torque Hub units may require special lubrication procedures Please contact Oerlikon Fairfield for vertically mounted applications DISASSEMBLY Disassembly Remove the Plugs 21 and the oil Place the brake on the bench with the shaft down supported on a fixture that does not allow the output shaft to contact the bench Remove Socket Head Cap Screws 13 and Lock Washers 14 Remove the cap screws as evenly as possible and note that there is spring pressure pushing on the Piston Housing 2 Remove the O ring plugs 20 Remove the Piston Housing 2 which will contain the Piston 9 and associated O rings To remove the Piston 9 replace one of the O ring Plugs 20 Use air pressure in the other brake port and push the Piston 9 out of the Piston Housing 2 Remove the O rings and Back up Rings 15 16 17 and 18 Remove the Gasket 7 from the Spring Housing 8 Remove the Brake Stator
14. ressure to 3000 psi 200bar and check that the brake rotates freely by rotating the brake shaft Note Release pressure during bench testing should be limited to 2000 psi 138bar unless fully installed to a gearbox The brake should hold 3000 psi 200bar without leakage NO OF INITIAL FULL pigits SPRINGS RELEASE RELEASE 24 23 PRESSURE psi PRESSURE psi 16W 12 154 188 188 206 15W 10 2 140 176 172 190 13W 10 129 158 156 172 12W 8 2 115 145 140 156 11W 8 104 127 125 138 09W 6 2 89 114 108 122 08W 6 78 96 93 104 07W 4 2 63 83 77 87 05 4 52 65 62 70 The Leak Test The purpose of a leak test is to make sure the unit is airtight perform leak test use the leak test fixture from the table below If the tool is not available the gearbox must be sealed to perform the test This can be accomplished by replacing one of the oil plugs in the cover with an air chuck DO NOT EXCEED 10 PSI PRESSURE DURING THE LEAK TEST Higher pressure will create a false sealing effect in assemblies with lip seals The unit has a leak if the pressure gauge reading on your leak check fitting starts to fall after the gearbox has been pressurized and allowed to equalize Leaks will most likely occur at the pipe plugs the main seal or wherever O rings or gaskets are located The exact location of a leak can usually be detected by brushing a soap and water solution around the ma
15. s 6 and Brake Rotors 3 from the Spring Housing 2 10 10 Remove the Pressure Plate 4 from the Spring Housing 2 11 Remove the Springs 23 and or 24 12 Remove the Dowel Pins 19 from the Spring Housing 2 13 Turn the brake over and support it such that the Brake Shaft 1 can be pushed out of the Spring Housing 2 without contacting the bench 14 Using retaining ring pliers carefully remove the Retaining Ring 11A from the Brake Shaft 1 Press the Brake Shaft 1 out of the Ball Bearing 10 out of the Brake 16 Using retaining ring pliers carefully remove the Retaining Ring 11 from the Spring Housing 2 Turn the brake over and press the Ball Bearing 10 from the Spring Housing 2 18 Drive the Seal 12 from the Spring Housing 2 This concludes the Main Disassembly 11 THIS PAGE LEFT BLANK INTENTIONALLY 12 ASSEMBLY Assembly Press the Seal 12 with the spring down into the Spring Housing 8 to the correct depth with the seal tool Oil the seal lip Install the Ball Bearing 10 on the outer race into the Spring Housing 8 The bearing must be seated against the bottom of the counter bore Turn the Spring Housing 8 over support the inner race of the bearing and allow sufficient clearance for the Brake Shaft 1 to be pressed thru Apply Loctite 603 to the bearing Press the Brake Shaft 1 thru the bearing until the shaft shoulder is solid against the bearin
16. using be sure to align the dowel pins Also insure that the CAST SLOTS in the Spring Housing 8 and Piston Housing 2 are aligned Install Lock Washers 14 and Socket Head Bolts 13 thru the Piston Housing 2 into the Spring Housing 8 Tighten the socket head bolts down evenly compressing the springs Once the piston housing and the spring housing have come together torque the Socket Head Bolts 13 to 55 60 ft lbs as shown on page 7 Install one Oil Plug 20 Apply hydraulic pressure to the empty brake port and check the release pressure per page 5 SPRING ASSEMBLY CHART 2 NO SPRING 24 23 sa eo COC This concludes the Main Assembly 15 Assembly Drawing Parts List Tem BRAKE SHAFT 2 a 2 BRAKEROTOR 4 PRESSURE PLATE a 2 mesmo 1 EE BRAKE PISTON Lo r BALL BEARING r r RETAWINGRING A fsa oo 8 SOCKET HEAD SCREW x ua s took washer o 1 oo o t o o o S o t 2 owen gt omero 2 mm O J gt gt J I SI k lt i A EA j3 x a 23 QTY ITEM 24 BRAKE PART No TLH1333316W TLH1333315W TLH1333313W TLH1333312W TL
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