Ensamble Travel Gear

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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2 7 - 8 11/96 Repair - Manual


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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.


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


51 12 Sun gear shaft

52 38 Circlip

53 44 Supporting disk

54 29 Ball bearing


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Fig. No.


55 48 O-ring

56 8 Planetary carrier, assy.


58 17 Support ring

59 34 Shaft seal

60 20 Sealing cover

61 59 Bolt

62 11 Planetary gear

63 43 Circlip


65 42 Circlip

66 9 Support ring

67 50 O-ring

68 19 Centering ring

69 37 Circlip

70 13 Planetary


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


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



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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


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.



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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).



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28. Check the upper bearing for correct mounting position seat.


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).



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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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