Ensamble Travel Gear
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7/26/2019 Ensamble Travel Gear
1/69
Repair - Manual
Date
11/96
No.
7 - 8
Page
1
Supersedes
Travel GearDate of issue No. Page
Content: Page
1. General view 2 - 4
2. Disassembly 5 + 6
3. Determination of wear and tear 7
4. Assembly 8 - 31
Cata ogue Page No. -
H 285 S
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Fig. No.
Catalogue Page Sectional drawing Designation
02 49 O-ring
03 89 Circlip
04 88 Shaft seal
05 71 Seal ring
06 92 O-ring
07 75 Internal disk
08 76 External disk
09 90 Circlip
10 74 Cam
11 94 Screw
12 70 Housing
13 73 Seal ring
14 91 O-ring
15 85 Support ring
16 82 Support ring
17 81 Quadring
18 77 Piston
19 78 Spring
20 79 Spring
21 84 Support ring
22 83 Quadring
23 87 Shaft seal
24 93 O-ring
25 72 Seal ring
26 40 Circlip
27 27 Roller bearing
28 16 Drive shaft
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Fig. No.
Catalogue Page Sectional drawing Designation
29 58 Screw
30 21 Cover
31 57 Screw
32 1 Housing
33 64 Plug
34 65 Seal ring
35 66 Plug
36 67 Seal ring
37 14 Dipstick
38 28 Ball bearing
39 15 Spur wheel
40 41 Circlip
41 10 Sun gear
42 4 Support ring
43 6 Planetary carrier, assy.
44 62 Plug
45 63 Seal ring
46 61 Bolt
47 2 Internal geared double wheel
48 52 Eyebolt
49 5 Support ring
50 25 Roller bearing
51 12 Sun gear shaft
52 38 Circlip
53 44 Supporting disk
54 29 Ball bearing
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Fig. No.
Catalogue Page Sectional drawing Designation
55 48 O-ring
56 8 Planetary carrier, assy.
57 26 Roller bearing
58 17 Support ring
59 34 Shaft seal
60 20 Sealing cover
61 59 Bolt
62 11 Planetary gear
63 43 Circlip
64 23 Roller bearing
65 42 Circlip
66 9 Support ring
67 50 O-ring
68 19 Centering ring
69 37 Circlip
70 13 Planetary
71 24 Roller bearing
72 30 Stop washer
73 39 Circlip
74 7 Spacer
75 18 Planetary pin
76 36 Circlip
77 60 Plug
78 22 Intermediate ring
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2. Disassembly
1. Remove bolts (57) fastening the housing (1). Install 3 eye bolts M16
and lift of the complete housing (1) by means of an adequate lifting
device.
2. Lift off support ring (4) by means of a lifting device.
3. Install 3 eye bo9lts M16 to the axles of the planetary gears of the
planetary carrier assy.
Lift off the complete planetary carrier assy.
4. Lift off sun gear shaft (12) by means of a lifting solenoid device.
5. Turn the gear box upside down.
6. Remove the bolts (57).
7. Install 3 eye bolts M16 to support ring (17). By means of a lifting
device lift off the complete support ring.
8. Install 3 eye bolts M16 to planetary carrier assy. (8).
By means of an adequate lifting device lift off the complete assy. (8).
9. Lift off support ring (5) from the internal geared double wheel (2)
NOTE: The planetary pins (18) can be only removed by drilling a hole
dia. 20 mm smaller than the pin dia. not totally through.
Drilling length approx. 40 mm less than pin length.Then push out the pin.
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Disassembly of the brake
1. Connect a separate hydraulic pressure supply by means of an
union with thread M18 x 1.5 mm to the port, of normal pressure
supply for opening the brake, at housing (1).
Refer to the corresponding page Assembly of the brake
Build up a pressure of 40 bar.
2. Remove circlip (89).
3. Slowly reduce the hydraulic pressure to 0 bar.
4. Install 3 eye bolts M8 to seal ring (71) and lift out seal ring.
5. Remove O-ring (92).
6. Remove outer- and inner disks.
7. Remove circlip (90).
8. Remove cam (74).
9. Remove bolts (94).
10. Remove housing (70) disk carrier.
11. Install 2 eye bolts M8 x 100 mm to seal ring (73).
Remove seal ring (73).
12. Remove complete piston (77).
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3. Determination of wear and tear
All parts have to be checked for cracks by means of suitable method.
mm
540.022
ABore 540 JS6
540.078
440.068Shaft 440 p6
440.108
280.087
BBore 280
280.109
109.001Shaft 110 j6
110.013
400.039
CBore 400 J7
399.982
320.098Shaft 320 p6
320.062
229.978
DBore 230 N6
229.949
130.014Shaft 130 j6
129.989
215.0145
EBore 215 JS6
214.986
120.025Shaft 120 k6
120.003
180.018
FBore 180 J6
179.993
100.025Shaft 100 k6
100.003
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4. Assembly (Nos. in brackets correspond with Nos. on the
sectional drawing on page 2)
1. Heat up the bearing seat in the housing (1) to approx. 80 C. Fig. 1/2
Install the lower roller bearing (27).
2. Heat up the bearing (28) to 80 C. Install the lower Fig. 1/3
bearing (28) to spur wheel.
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3. Turn spur wheel (15) upside down.
4. Install 3 eye bolts M20 to the spur wheel. Fig. 4
Lift up the spur wheel and put a plate (A), wood or
steel, approx. 40 mm thick under the assembled bearing (28).
Put spur wheel on the plate.
5. Install 3 eye bolts M16 to the housing (1). Lift up the housing by Fig. 5/6
means of 2 lifting devices and place the housing over the spur wheel.
NOTE: With caution guide the bearing seats of bearings (27) from the
side over the spur wheel.
Align the hub of spur wheel (15) to the seat of the upper bearing (28) in
housing (1).
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6. Heat up inner race of bearing and seat in housing (1) to 80 C. Fig. 7
Install the upper bearing (28).
7. Heat up bearing (27) to 80 C and install it to drive shaft (16). Fig. 8
8. Take off outer race from bearing (27).
9. Heat up inner race of the lower bearing (27) to 60 C and install Fig. 9/10
drive shaft (16).
10. Heat up seat of outer race of bearing (27) in the housing to 60 C. Fig. 11
Install outer race of bearing (27).
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11. Install circlip (40) Fig. 12
12. Pre-assembly of ring (72) Fig. 13
- 2 pieces shaft seals (87)
- 1 piece O-ring (93)
CAUTION: Pay attention to the correct mounting position of the sealing lips.
130
10
101
80
119
124
A
2
1
12
B
For the illustration of the shaft seals manufacture a mounting sleeve according to the
illustration.
Apply Loctite 574 on the contact surface shaft seals (87) and ring (72).
Install the shaft seals.
Fill up the space between the sealing lips with grease.
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13. Install ring (72) to housing (1). Fig. 14/15
Mounting aids: 1. 2 pieces eye bolts M8 x 100 mm
2. Mounting sleeve manufactured according to
illustration.
Material: St. 52
(1) | 10
(2)
160
|
100
(1) Cover
(2) Tube
200 |
3. Mounting bar
Material: copper
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14. Install two support rings (84) and one quad ring (83) to Fig. 16
piston (77). The quad ring must be placed between the
support rings.
15. By means of grease install springs (78) and (79) to the Fig. 17
Piston (77).
The grease keep the springs in the mounting position.
36 pieces (greater diameter)
30 pieces (smaller diameter)
Distribute the 30 pieces that in every 6th hole of the piston there
is only a spring with greater diameter.
16. Install piston (77) to the housing (1). Fig. 18/19
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17. Pre-assembly of seal ring (73). Fig. 20/21
Install support ring (85) and O-ring (91). The support ring
must be placed above the O-ring.
18. Apply oil on the contact surface seal ring (73) and housing (1). Fig. 22/23
Install 2 eye bolts M8 x 100 mm to the seal ring (73) and install
the seal ring to the housing.
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19. Install circlip (90). Fig. 24
20. Install cam (74) Fig. 25
21. Install the 2nd circlip (90) Fig. 26
22. Install housing (disk carrier) (70). Fig. 27/28
Align the bore holes in the housing (70) according to the
bore holes in the housing (1) see white arrow marking on
the illustration.
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23. Install 4 pieces bolts (94) M12 (socked head) equally Fig. 29/30
distributed by 90 one to the other.
Tighten crosswise.
Tightening torque: 120 Nm.
Install the other 8 bolts (94) and tighten.
24. Connect separate hydraulic pressure supply by using an union Fig. 31/32
with M18 x 1.5 mm thread.
On the opposite the respective port has to be closed, by a plug.
Build up pressure to approx. 40 bar.
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25. Pre-assembly of seal ring (71). Fig. 33/34
Manufacture mounting sleeve according to the illustration
Material: St 52
| 10
97
|
80
(1) Rod
(2) Cover
108
(1)
(2)
|
Apply Loctite 573 on the contact surface of shaft seal (88) to seal ring (71).
Install shaft seal (88) according to the illustration.
Fill up space between the sealing lips with grease.
Install protection sleeve for the protection of the sealing lips of seal shaft (88)
when installing the seal ring.
Manufacture the protection sleeve according to the illustration.Material: adequate synthetic material e.g. nylon GSM.
D1 D2 D3 D4
97.000 mm 87.000 mm 85.500 mm 110.000 mm
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26. Install O-ring (92) to the housing (1). Fig. 35
27. Install seal ring (71) to the housing. Fig. 36/37
28. Install circlip (89). Fig. 38
29. Remove the protection sleeve. Fig. 39
30. Release hydraulic pressure and remove the separate
hydraulic pressure supply.
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Pre-assembly of planetary carrier assy. (8).
1. Put bearing (29) to cantering ring (19). Fig. 1
2. Install 5 pieces of O-ring (48).
3. Install supporting disk (44).
4. Install circlip (38).
5. Install O-ring (50) to planetary carrier assy. (8). Fig. 2
Before heat up the seat of the cantering ring (19).
6. Apply Loctite 574 on the contact surface of centering ring (19) Fig. 3
to the planetary carrier assy. (8).
7. Install centering ring (19) to the planetary carrier assy. Fig. 4
8. Install circlip (37). Fig. 4
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9. Put intermediate rings (22) into the bore for the planetary pins. Fig. 5
10. Pre-assembly of the planetary gears (13): Fig. 6
Heat up planetary gears (13) to approx 80 C Install lower bearing (24). Put in stop washer (30). Install 2 pieces of circlips (39). Put in spacer (7). Install upper bearing (24).Heat up the pre-assembled gears to approx. 80 C
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11. Install pre-assembled and heated up gears to the planetary carrier (8). Fig. 7
Required as working aids:
1. Flat iron bar 220 x 50 mm, 15 mm thick. Material: St 52
80
M16
2. 1 piece eye bolt M16 x 200 mm
3. 1 piece eye bolt M16 x 40 mm
The flat iron bar is required to protect the lower bearing (24) against
falling out, when lifting the gear.
Hook up the planetary gear at the eye bolt M16 x 200 mm that is
installed to the flat iron bar.
Install the second eye bolt M16 x 40 mm to the planetary gear..Here you can introduce an iron bar to align the planetary gear when
installing, see illustrations.
12. Install mounting pin (has to be manufactured) dia 116.000 mm Fig. 8
for aligning of the planetary gears.
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13. Cool down planetary pins (18) by means of liquid nitrogen Fig. 9
and install them to planetary carrier assy.
Mounting aid: one piece eye bolt M16 x 150 mm
14. Install circlip (36). Fig. 10
15. Heat up bearing (25) to approx. 80 C and install it to the Fig. 11
planetary carrier assy. (8).
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16. Turn the pre-assembled planetary carrier assy. upside Fig. 12/13/14
down and put it on a wooden support.
For turning two lifting devices are required.
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17. Heat up bearing (26) to approx. 80 C and install it to the Fig. 15
planetary carrier assy: (8).
18. Install shaft seal (34) to support ring (17). Fig. 16/17
The shaft seal (34) should be pressed in by means of a
hydraulic press.
If suck a press is not available a mounting tool according
to Fig. 16 has to be manufactured.
Fill up space between the seal lips with grease NLGI grade 3
(Lithium).
19. Install sealing cover (20) with 12 pieces bolts (59) M12. Fig. 18
Tightening torque: 120 Nm
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20. Install support ring (5) to the internal geared double wheel (2). Fig. 19
Before heat up seat of support ring (5) in the double wheel up
to approx. 70 C.
21. Install pre-assembled planetary carrier assy. (8) to the internal Fig. 20
geared double wheel (2).
Install 3 pieces of eye bolts M16 to the planetary carrier assy. to
hook it up in lifting device.
22. Apply Loctite 574 on contact surface internal geared double Fig. 21
wheel and support ring (17).
Install support ring (17) to double wheel.
Install bolts (57) M16, wrench size 24 and tighten.
Tightening torque: 295 Nm.
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23. Turn the complete double wheel assy (2). Fig. 22/23
Required:
2 Lifting devices
2 eye bolts M36
2 eye bolts M16
Adequate slinging means
24. Heat up inner race of bearing (29) up to approx. 70 C. Fig. 24
Install sun gear shaft (12).
Mounting aid: magnetic lifting device according to illustration.
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25. Install pre-assembled planetary carrier assy. (6). Fig. 25
Working aid: 3 pieces eye bolt M16.
When lowering, rotate sun gear shaft and planetary gears for
easier meshing of gears.
For the pre-assembly of planetary carrier assy. (6) refer to page 30.
26. The distance between two holes on the pitch circle of fastening Fig. 26/27
bolts (57) at one spot is nearly double as otherwise.
This spot must be placed exact opposite of the triangular opening
of the support ring (4).
Mark the center point (M) at the double wheel and at the support ring.
When installing align the ports that the both center points (M) are
placed face to face.
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27. Heat up the seat of housing (1) at support ring (4) to Fig. 28/29
approx. 80 C.
Install the pre-assembled housing (1) to double wheel (2).
Align housing (1) according to marked center point (M) at
the double wheel.
Working aid: 3 pieces eye bolt M16
Apply Loctite 574 on the contact surface between double wheel (2)
and housing (1)
Install bolts (57).
Tightening torque: 295 Nm.
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28. Check the upper bearing for correct mounting position seat.
29. Install circlip (41). Fig. 30
30. Check, if it is possible to lift the sun gear shaft (10) a little bit Fig. 31
in vertical direction.
For this install an eye bolt M12 x 120 mm to the sun gear shaft.
Lift sun gear shaft by means of a mounting bar.
31. Measure the protrusion at housing (1) and cover (21). Fig. 32/33
Nominal play: 0.1 to 0.3 mm.
If required re-machine cover (21).
32. Apply Loctite 574 on the contact surface of cover (21) and Fig. 34
housing, and install cover with bolts (58) M16 (Hexagon socket).
Tightening torque: 295 Nm.
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Pre-assembly of planetary carrier assy. (6).
1. Apply Loctite 641 onto contact surface of cover (9) and Fig. 1
planetary carrier assy. (6).
Install cover (9).
2. Heat up planetary gears (11) up to approx. 80 C. Fig. 2
Install lower circlip (43).
Install bearing (23).
Install upper circlip (43).
Heat up pre-assembled planetary gears up to 80 C.
3. Install pre-assembled planetary gears (11) to planetary Fig. 3
carrier assy. (6).
4. Install sun gear shaft (10). Fig. 4
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5. Install circlip (42). Fig. 5