Eaton 146246A, Installation, Operation And Maintenance Manual

Page 1: ...lex replacement parts The use of non genuine Airflex replacement parts could result in substandard product performance and may void your Eaton warranty For optimum performance contact Airflex In the U S A and Canada 800 233 5926 Outside the U S A and Canada 216 281 2211 Warning Forward this manual to the person responsible for Installation Operation and Maintenance of the product described herein ...

Page 2: ... 5 1 Removal of WCB 21 5 2 Disassembly of WCB 21 5 3 Inspection of WCB componants 22 5 4 Assembly of WCB 18 24 36 WCB s w ith Stop Tubes 22 5 5 Assembly of WCB s w ithout Stop Tubes 23 6 0 COMPONENT MAINTENANCE 24 6 1 Cylinder Seal Replacement 24 6 2 Friction Lining Replacement for WCB s w ith screw ed on linings 25 6 3 Friction Lining Replacement for 8 14 WCB s Riveted Linings 26 6 4 Wear Plate R...

Page 3: ...Figure 1 8 WCB 14 WCB Figure 2 NOTE The coolant outlets should be positioned at the 12 o clock position PDF FORMAT 2 Copyright Eaton Corp 1995 All rights reserved ...

Page 4: ...Wear Plate 12 Clamp Tube 28 Gear 4 Socket Head Screw 13 Pressure Plate Ass y 29 Wear Spacer 5 Locknut 14 Pressure Plate 30 Reaction Plate Ass y 6 Stud 15 Washer 31 Reaction Plate 7 Friction Disc Ass y 17 Washer 33 Piston 8 Friction Disc 18 Locknut 34 Spring 9 Friction Disc Core 19 Cylinder 49 Socket Head Screw For part number listing see section 8 0 PDF FORMAT 3 Copyright Eaton Corp 1995 All right...

Page 5: ...18 24 36 WCB Single Disc Figure 4 PDF FORMAT 4 Copyright Eaton Corp 1995 All rights reserved ...

Page 6: ...18 24 36 WCB Dual Disc Figure 5 PDF FORMAT 5 Copyright Eaton Corp 1995 All rights reserved ...

Page 7: ...18 24 36 WCB Triple Disc Figure 6 PDF FORMAT 6 Copyright Eaton Corp 1995 All rights reserved ...

Page 8: ...Figure 7 18 24 36 WCB Quad Disc PDF FORMAT 7 Copyright Eaton Corp 1995 All rights reserved ...

Page 9: ...t Washer 51 Outer Support Ring 18 Locknut 57 Flat Head Screw 19 Cylinder 58 Wear Ring 21 Polypak Seal 59 Stop Tube 23 Polypak Seal 80 Stop Tube For part number listing see section 9 0 TABLE 1 Tensioner Mounting Register Diameters In mm Size Female Register Male Register 8WCB 8 375 8 378 212 7 212 8 12 125 12 122 308 0 307 9 14WCB 14 375 14 378 365 1 365 2 18 750 18 747 476 3 476 2 18WCB 18 250 18 ...

Page 10: ...iameter disc i e 114WCB 214WCB etc 1 1 2 Standard 8 and 14 WCB models have parts list numbers ending with B These units have riveted friction lining and no stop tubes or wear rings 1 1 3 Standard 18 24 and 36 WCB models have screwed on friction lining stop tubes and wear rings These units have part list numbers ending with E 1 1 4 Some earlier 18 24 and 36 WCB units have riveted friction lining an...

Page 11: ...discs 8 T orque is transmitted through the studs 6 to the mounting flange 2 The release springs 34 assist in disengagement and retraction of the piston and pressure plate High heat dissipation is accomplished by passing water through a special cavity behind copper wear plates 3 2 0 INSTALLATION Only qualified maintenance personnel should install adjust or repair these units Faulty workmanship will...

Page 12: ...erial and its mating surfaces the gear and splined bore of the friction disc assembly See Figure 9 2 3 Mounting 2 3 1 The WCB must be mounted to a clean rigid surface with hardened flat washers and screws of the grade quantity and size and tor qued to the values identified in Table 4 for each WCB size Mounting to a rigid surface minimizes any deflection during operation and ensures that the fricti...

Page 13: ...the shaft making sure that the dimension between the gear and the tensioner mounting surface A is maintained See Figure 1 and T able 1 Heating the gear uniformly to 250oF 121oC will expand the bore and ease assembly TABLE 6 Coolant Supply Data Size Thermal Rating 1 HP kW Water Inlet and Outlet Pipe Size Min Flow Rate 2 GPM dm3 min 100 Water Min Flow Rate 2 GPM dm3 min 70 Water 30 Ethylene Glycol b...

Page 14: ...or better is recom mended which is free of excess moisture 2 5 Coolant System Maximum allowable water pressure is 45 PSIG 3 1 bar Application of pressure exceeding maximum allowable may result in damage to the tensioner 2 5 1 Coolant supply connections to the tensioner should provide a parallel flow through each section of the tensioner Series flow is not generally recommended contact Airflex for ...

Page 15: ...onducted at the required flow rate for the rated HP dissipation and coolant quality as given in T able 6 Inlet pressure is not to exceed 45 PSIG 3 1 bar There should be no restrictions on the outlet side of the brake to cause any back pressure to the unit Coolant inlet and hose size should be as given in Table 6 Check for leakage at the O D and I D seal areas 2 5 5 The coolant supply temperature a...

Page 16: ...the friction discs to burst and result in extensive damage to the tensioner and or cause personal injury For proper cooling of the WCBtensioner it is required that the coolant inlet be located at the 6 o clock position and the outlet be located at the 12 o clock position This will assure that all coolant cavities are filled and will prevent overheating Refer to Figure 2 8 For operation in subfreez...

Page 17: ...ements have three adjustments Follow the wear spacer adjustment procedures in section 4 1 3 for each adjustment made Note Stop tubes may be added to 18 24 36 WCB multi disc elements that did not originally come equipped with stop tubes Or der Items 58 59 80 from parts list for WCB elements including stop tubes Part lists alpha numeric number ends with E See sec tion 9 0 4 1 3 Wear adjustment proce...

Page 18: ...tube Install required number of wear rings 58 and install one stop tube on every fourth stud without release springs and slide the reaction plate assembly onto the clamp tubes NOTE Quantity of wear rings re installed at each location should be same as quantity of wear spacers installed The stop tubes 80 on 324 WCB and 424 WCB units must be installed in the center or center two positions shown on f...

Page 19: ... in Section 7 0 If any wear limit has been reached or exceeded that component must be repaired or replaced Note Item numbers are shown on Figure 1 4 2 2 Single Disc Units Apply approximately 25 PSIG 1 7 bar air pressure to the cylinder to engage the tensioner Measure the gap X between the cylinder 19 and the pressure plate 13 or the gap Y between the pressure plate 13 and the mounting flange 2 as ...

Page 20: ...Figure 14 Figure 15 Figure 13 Figure 16 PDFFORMAT 19 Copyright Eaton Corp 1995 All rights reserved ...

Page 21: ... wear spacers 4 2 11 Place a release spring over every other clamp tube and slide the reaction plate assembly onto the clamp tubes 4 2 12 Slide the friction disc assembly onto the gear 4 2 13 For multi disc units repeat steps 4 2 5 7 and 4 2 5 8 for each additional friction disc and reaction plate 4 2 14 Place a release spring on every other clamp tube and slide the pressure plate and the cylinder...

Page 22: ...s mounting flange studs 6 facing up 5 2 Disassembly of WCB Note Item numbers are shown on Figures 3 4 5 6 and 7 5 2 1 Loosen the locknuts 18 ONETURN AT TIME and in an alternating crosswise pattern until the spring force is completely relieved Remove the locknuts and washers 17 and wear spacers Mark all of the water outlet ports for identification and orientation Deep well sockets are required See ...

Page 23: ...o the Wear Limit tables in section 7 0 Replace the cylinder if necessary 5 2 11 Noting how the lips of the seals are oriented in the piston grooves remove the seals 5 2 12 Thoroughly clean the seal grooves in the piston and apply a thin even coat of Parker O Lube to the seal grooves the seals the sealing surfaces of the cylinder and to the chamfer on the piston 5 2 13 See section 5 4 for inspectio...

Page 24: ...pound and install the locknuts 18 washers 17 5 5 7 Tighten the locknuts ONETURN AT A TIME and in an alternating crosswise pattern until the cylinder is seated firmly against the clamp tubes Torque the locknuts to the appropriate value See Table 4 The locknuts 18 must be tightened gradually to prevent damage to the tensioner components 5 5 8 Reinstall the tensioner per 2 0 5 6 Assembly of WCB s wit...

Page 25: ...oose remove it completely clean the threads on the stud and the threads in the mounting flange Apply Locquic Primer Grade T to the stud threads After the threads have dried assemble to the mounting flange using Loctite 262 The end of the stud must not extend past the mounting surface of the mounting flange Loctite 262 must be shaken prior to application Loctite 262 may irritate sensitive skin Refe...

Page 26: ...der is seated firmly against the clamp tubes T orque the locknuts to the appropriate value See Table 4 The locknuts 18 must be tightened gradually to prevent damage to the tensioner components 6 1 19 Connect air supply line 6 1 20 Perform an air test by applying 80 PSIG 5 5 bar to engage the tensioner Shut off the air supply If the air pressure does not drop below 70 PSIG 4 8 bar after 10 minutes ...

Page 27: ... or excessive wear of the brake components 6 3 2 Drill out the old rivets and discard the old friction discs 6 3 3 Refer to Figure 20 and carefully examine the counterbored holes in the friction disc segments 512308 One set of counterbored holes is tapered and designed to accept the rivet head while the other set of counterbored holes is flat bottomed and designed to accept the clinched end of the...

Page 28: ...aces may occur 6 4 3 Inspect the water passages and if necessary use a wire brush to clean them If repainting is necessary sand blast the water passages and paint the surfaces with Glid Gard Epoxy 5256 5257 or equivalent Dry film thickness should be 0 007 0 18 mm Be careful not to allow the paint to get into the seal grooves or onto the nubs If nubs are severely corroded wear plates may not be pro...

Page 29: ...13 for water port size 6 4 9 2 Slowly fill with water to purge all air from water cavities 6 4 9 3 Install a pipe plug in the outlet port and apply 45 PSIG 3 1 bar water pressure measured at the inlet Maintain this pressure for 30 minutes 6 4 9 4 Check for leakage at O D and I D seal areas NO leakage is allowed 6 4 9 5 If the assembly leaks check the torque on each screw and retest If leaks still ...

Page 30: ...rs are shown in Table 8A 12 Clamp T ube Reaction Area Maximum wear is 0 015 0 38 mm Wear will be in the form of a notch or step on the side of the tube 9 28 Friction Disc Core and Gear Gear Backlash Maximum allowable total backlash is 0 040 1 0 mm If step is worn in gear gear must be replaced 7 0 WEAR LIMITS TABLE 15 Original Reaction Hole Diameters In Pressure Plate and Reaction Plate Size Diamet...

Page 31: ...3 1 512300 03 1 512400 01 1 13 14 Pressure Plate 512502 1 512502 1 512377 1 512377 1 14 17 Flat Washer 00067x0041 6 000067x0041 6 000067x0040 6 000067x0040 6 17 18 Locknut 000110x0024 6 000110x0024 6 000110x0030 6 00110x0030 6 18 19 Cylinder 512483 1 512483 1 512296 1 512296 1 19 21 Polypak Seal 000402x0001 1 000402x0001 1 000402x0003 1 000402x0003 1 21 23 Polypak Seal 000402x0002 1 000402x0002 1 ...

Page 32: ...2 000402x0021 2 000402x0021 2 21 23 Polypak Seal 000402x0022 2 000402x0022 2 000402x0022 2 23 24 Warning Decal 203627 1 203627 1 203627 1 24 25 Name Plate 307640 1 307640 1 307640 1 25 26 Drive Screw 000153x0644 8 000153x0644 8 000153x0644 8 26 28 Gear 302813 1 302907 1 413208 1 28 29 Wear Spacer N A N A 307643 02 12 307643 02 24 29 30 Reaction Plate Sub assembly N A N A 513232 02 1 513232 02 2 30...

Page 33: ...x0023 2 000402x0023 2 000402x0023 2 000402x0023 2 21 23 Polypak Seal 000402x0024 2 000402x0024 2 000402x0024 2 000402x0024 2 23 24 Warning Decal 203627 1 203627 1 203627 1 203627 1 24 25 Name Plate 307640 1 307640 1 307640 1 307640 1 25 26 Drive Screw 000153x0644 8 000153x0644 8 000153x0644 8 000153x0644 8 26 28 Gear 411672 1 410970 1 412433 1 413195 1 28 29 Wear Spacer N A N A 307989 01 12 307989...

Page 34: ... Polypak Seal 000402x0006 2 000402x0006 2 000402x0006 2 000402x0006 2 23 24 Warning Decal 203627 1 203627 1 203627 1 203627 1 24 25 Name Plate 307640 1 307640 1 307640 1 307640 1 25 26 Drive Screw 000153x0644 8 000153x0644 8 000153x0644 8 000153x0644 8 26 28 Gear 415871 1 416069 1 414054 1 414132 1 28 29 Wear Spacer N A N A 307094 02 307094 32 307094 32 29 30 Reaction Plate Sub assembly N A N A 51...

Page 35: ...18 5 60 Locknut 000153x1061 15 60 Washer 00067x0001 Sub assembly breakdown for 8 WCB s Sub assembly Item Qty Description Part Number Mounting Flange Sub assembly P N 512508 01 Item 1 Fig 1 2 1 Mounting Flange 512496 3 1 Wear Plate 512507 4 42 Socket Head Screw 000030x5407 5 42 Locknut 000153x1049 Friction Disc Sub assembly P N 512512 Item 7 Fig 1 8 2 Friction Disc 512509 9 1 Friction Disc Core 512...

Page 36: ...ore 510745 9 2 Friction Disc 508725 57 48 Flat head screws 000294x0407 Sub assembly breakdown for standard 18 WCB s with screwed on linings Sub assembly Item Qty Description Part Number Mounting Flange Sub assembly P N 513232 01 Item 1 Fig 3 6 2 1 Mounting Flange 513207 3 1 Wear Plate 412953 4 80 Hex Head Screw 000153x0726 5 80 Locknut 000153x0642 50 4 Inner Support Ring 413105 51 4 Outer Support ...

Page 37: ...ate 3 Wear Plate 4 Hex Head Screw 5 Locknut 50 Inner Support Ring 51 Outer Support Ring Friction Disc Sub assembly P N 513965 01 8 1 Friction Disc Core 513667 9 16 Friction Blocks Contact Airflex 57 144 Flat head screws 000294x0407 10 5 Sub assembly breakdown for high coefficient friction discs Friction Disc Sub assembly Standard lining Item Qty Description Part Number 18WCB 513963 02 8 1 Friction...

Page 38: ... 2 Friction Disc 415227 Rivet Tool Sold Seperately 8WCB 1 Rivet tool 000153x1095 14WCB 1 Rivet tool 000153x1096 Note For 18 24 36 WCB s with riveted lining order friction disc sub assembly from section 10 0 11 0 KITS 11 1 11 2 Friction Lining Kits for 18 WCB models with screwed on friction lining EACH FRICTION LINING KIT INCLUDES THE FOLLOWING Model Kit Part Number Quantity Each Description Part N...

Page 39: ...lex for details 224WCB 107821BA LO CO 324WCB 107821BB LO CO 424WCB 107821BC Friction Lining Kits for 36 WCB models with screwed on friction lining Each friction lining kit includes the following Model Kit Part Number Quantity Each Description Part Number 136WCB 107822B LO CO ContactAirflex for details 236WCB 107822BA LO CO 336WCB 107822BB LO CO 436WCB 107822BC PDF FORMAT 38 Copyright Eaton Corp 19...

Page 40: ...tion Plate Kit 107672E 60 Plain Washer 000067x0001 60 Gr 8 1 4 Screw 000153x1018 60 Flange Nut 000153x1061 1 Loctite Superflex 000153x1071 1 Instruction Sheet 204063 2 Wear Plate 415212 18WCB Basic Kit 107726A 160 Locknut 000153x0642 160 Screw 000153x0726 1 Loctite Superflex 000153x1071 1 Instruction Sheet 204063 2 Wear Plate 412953 8 Inner Ring 413105 8 Outer Ring 413106 18WCB Reaction Plate Kit ...

Page 41: ...ate Kit 107662E 108 Screw 000153x0843 108 Locknut 000153x0844 2 Loctite Superflex 000153x1071 1 Instruction Sheet 204063 2 Wear Plate 414026 12 Inner Ring 414032 12 Inner Ring 414032 01 18 Outer Ring 414033 18 Outer Ring 414033 01 Cylinder Seal Kits Each Kit Includes the following Size Part Number Large seal Small seal 8WCB 107671C 000402X0002 1 EACH 000401X0001 1 EACH 14WCB 107672C 000402X0004 1 ...

Page 42: ...ct exists Eaton shall thereupon correct any defect at its option either by repairing any defective part or parts or by making available at Eaton s plant a repaired or replacement part This warranty does not extend to normal wear parts or components of the Product such as friction material and friction surfaces LIMITATION OF WARRANTY THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARR...