ey oO HB REPAIR AND MAINTENANCE INSTRUCTIONS HYDROMATIC KES (40” - 4660" IPAR™Mac, xrurc. Manufacturers of Parkersburg Products vox s7a / correvvitis, Kansas e7397 7.66 Ie eeHB-7-66 : CONTENTS SECTIONS _Page ee GonereN ee 1 Disassembl 2 ~ Replacement of Bearings And/Or Seals - - - - - 2 3 - Hydromatic Brake Case = ------------ 3 Reassembly: 7 : 4 - Hydromatic Brake Case - ------------ 3 5 - Replacement of Bearings And/Or Seals - - - ~ ~ 4 e 6 - Lubrication - ----------------- 7 ILLUSTRATION DRAWINGS, Checking Slope of Rotor Vane and Mating Stator Vane - U63908 Spacing Rotor With Equal Clearance Between Stators - U63910 Cutaway View - Hydromatic Brake =~ - = -------- 63911 ° cance EEE ‘On HYOROTARDER14 HB-7-66 MAINTENANCE AND REPAIR INSTRUCTIONS HYDROMATIC BRAKES (uo = 46 = 60") General When a Hydromatic Brake is taken out of service for any period of time, a surplus quantity of No. 2 Waterproof Grease should be pumped into all of the grease fittings to assure that all water in the seals and bearings will be purged from those areas. It is advisable to fill the brake with “lubricating ofl", if it is to be taken out of service for a prolonged period. This will prevent the formation of rust and scale within the brake. Numbers in parentheses given in these instructions are referred to as item numbers and correspond to those used on the attached Drawing C63911. These instructions apply to a number of various sizes (40", 46", and 60!) of Hydromatic Brake assemblies, all of which are typified by the attached Drawing C63911. When ordering parts, always give the assembly number and serial number which are stamped on the name plate of the Hydromatic Brake. NOTE: A - Principal differences between the typified Drawing C63911 and similar assenblies are in the shaft extensions, direction of rotation "TO BRAKE" from extended shaft side, and in the different sizes (40", 46", and 60") of Hydromatic Brakes. B - Most similar assemblies have the shaft extension on one side only (like the typified Drawing C63911), although the diameter of the shaft extension ard its length may vary. A few similar assemblies have the shaft extended on both sides. C - Some similar assemblies are equipped with special cover plates ‘on one or both sides to meet specific requirements. For any repair job, disassembly should proceed only to the point permitting replacement of damaged part or parts. AM] disassembly and assembly procedures should be undertaken with the shaft of the Hydromatic Brake vertical. It will be noted that No. 1 Permatex (16) is used as a sealing compound on many joints in this assembly. Whenever such a joint is broken in dis assembly, both surfaces comprising the joint must be scraped free of hardened Permatex (16), washed with solvent, and thoroughly dried before being reassembled with new Permatex (16). In all cases where joints are to be made up using Permatex (16), the coating should be evenly applied and allowed to air dry about five minutes before being made up.HB-7-66 -2- 1.8 2.1 2.2 2.3 2.4 2.6 ‘As disassembly proceeds, the various parts should be thoroughly cleaned, wrapped, and stored. 2-- Disassembly For Replacement of Bearings And/Or Seals. Remove eight Cap Screws (12) and slide Bearing Retainer Plate (15) over end of Shaft (1). Shim Set (14) exposed by operation 2.1 should be kept with Bearing Retainer Plate (15) removed. Remove eight Cap Screws (12) and insert two 3/4! dia. x 6! long jack screws into the two tapped puller holes provided in the Bearing Retainer (10). (The jack screw holes are in the outer bolt circle.) Draw up evenly on these two screws to draw Bearing Retainer (10) out of the bore of Stator (4) or (5). NOTE: A - Seals (11) and the cup of Bearing (13) will remain in the Bearing Retainer (10) and be removed with it. ‘Apply heat to cone of Bearing (13) and remove from its seat on Shaft (1). NOTE: A - If Bearing (13) is not to be replaced, it should be left undisturbed from its seat on Shaft (1) as removal of it will render it unfit for further service. Remove Seals (11) from Bearing Retainer (10) by placing the Bearing Retainer (10) seal end down, on parallels to provide about 2-1/4" clearance between the end of Bearing Retainer (10) and the work bench. Using a punch, screw driver or similar tool, working from the bearing bore end of Bearing Retainer (10), to drive Seals (11) out of Bearing Retainer (10). NOTE: A= If Seals (11) are not to be replaced, do not renove them From Bearing Retainer (10) as removal will distort the seal cases and elements, and render them unfit for further service. Procedures outlined in Pafagraphs 2.1 through 2.5 will completely disassemble one side of the Hydromatic Brake and permit replacement of all parts normally requiring such service. NOTE: A - If replacement of one or more of these parts is the objective, new parts required should be installed and the disassembled side com- pletely reassembled per Section 5 before turning the Hydromatic Brake over to effect the disassembly of the other side, B - If the Hydromatic Brake is to be further or completely disassembled, turn the Hydromatic Brake over and disassemble the other side of the Hydromatic Brake per this section before starting further dis- assembly work as covered by Section 3.3.2 3.3 3.4 3.5 3.6 3.7 42 43 44 -3- HB-7-66 3 assembly Hydromatic Brake Case Procedures covered by this section must not be undertaken until both sides of Hydromatic Braké have been disassembled as per Section 2. Remove Machine Bolts (9) and Stud’ Dowels (6) holding Stators (4) and (5) together, insert four of Machine Bolts (9) in the tapped jack screw holes provided in one of Stators (4) or (5) and use as jack screws to remove Stator (4) or (5), with Cover Plate (17) attached. Remove Cap Screws (18) and lift Cover Plate (17) from Stator (4) or (5). After completing operation in Paragraph 3.2, the sub-assembly of’ Shaft (1), Keys (2), and Rotor (3) can be lifted out of remaining Stator ('4) or (5). Turn remaining Stator (4) or (5) over and repeat procedures in Paragraph 3.3. The Rotor (3) may be pressed from Shaft (1) using a press of at least 60 tons capacity, and the Keys (2) removed. NOTE: A - This operation should not be performed unless replacement of Rotor (3) or Shaft (1) is required. 8 - Before this operation is performed, note should be madé of the direction of rotation "To Brake". (Refer to Paragraph 1.3). Compare the SLOPE of the rotor vanes, looking at the assembled Shaft (1) and Rotor (3) from the extended end of Shaft '(1) with the SLOPE of Rotor Vanes as shown on Drawing 63908. See Para~ graph 4.4 regarding reassembly of Shaft (1) and Rotor (3). Procedures covered in Sections 2 and 3 will completely disassemble the Hydromatic Brake. 4 ~ Reassembly, Hydromatic Brake Case Before any reassembly procedures are begun, all parts to be used, either new or those removed in disassembly, should be thoroughly cleaned. All parts should be inspected and any nicks and/or burrs filed smooth. Assuming the Hydromatic Brake case has been completely disassembled per Section 3, procedures in this section will reassemble it. All work out- lined in this section must be completed before attempting to reassemble either side of the Hydromatic Brake per Section 5. Fit Keys (2) into keyways of Shaft (1), making sure they are seated solidly. Coat Rotor Seat and Keys lightly with white lead and press Rotor (3) onto Shaft (1).4B-7-66 -4- 45 47 4.8 5.2 5.3 NOTE: A - Check carefully to see that the slope of the rotor vanes are in the proper direction. It is possible to assemble Rotor (3) on Shaft (1) backwards. Remember that the Hydromatic Brake, when assembled, absorbs power in the direction of shaft rotation, looking at the driving end of the shaft. (Refer to Dwg. U63908).. B - In all press operations the pressure must be applied to the shaft with the rotor supported at_the hub or to the hub of the rotor with the shaft being supported. Pressures must never be applied beyond the 0,0, of the rotor hub, as damage to rotor vanes may result. Rap Rotor (3) evenly all around with a soft hanmer to start on Shaft (1). Check carefully to see that Rotor (3) is square with Shaft (1) and that keyways in Rotor (3) are properly aligned with Keys (2). D ~ Rotor (3) must be properly centered on rotor seat of shaft (I). Measure the distance from the rotor faces to bearing shoulders of Shaft (1). These distances must be equal. Apply Permatex (16) to Stators (4) and (5) and assemble Cover Plates (17) to Stators (4) and (5), securing with Cap Screws (18), Recessed Washers (20) and Ring Washer (19). (Refer to Paragraph 1.6). With vanes of Stator (4) or (5) facing up, lower Shaft (1) and Rotor (3) sub-assembly into position in Stator (ls) or (5). Apply Permatex (16) to face of Stators (4) and (5), then join together with Stud Dowels (6) and secure with Machine Bolts (9). Procedures contained in Paragraphs 4.1 through 4.7 will completely reassemble the Hydromatic Brake case. Procedures in Section 5 may now be undertaken to complete the Hydromatic Brake assembly. 5 ~ Reassembly For Replacement of Bearings And/Or Seals. Before any reassembly procedures are begun, all parts to be used, either new or those removed during disassembly, should be thoroughly cleaned. All parts should be inspected and any nicks and/or burrs filed smooth, Assuming one side of the Hydromatic Brake has been completely disassembled Per Section 2, or the Hydromatic Brake case has been completely reassembled per Section 4, follow procedures in this section to reassemble one side of the Hydromatic Brake. Press Seals (11) into place in Bearing Retainer (10), paying particular attention to the direction of sealing Vip. (Refer to Drawing C639I1.)i 5.4 5.5 5.6 5.7 5.8 5.9 a HB-7-66 NOTE: A - Take every precaution to avoid damaging or distorting the seal case in this procedure. Always use a flat steel plate to dis- tribute pressure evenly. A light coating of oil on seal case will aid in seal installation. Wipe around lips of both installed Seals (11) with a small quantity of No. 2 Calcium Base Grease. Also fill space between Seals (11). Apply Permatex (16) to Bearing Retainer (10) and install Bearing Retainer (10) into bore of Stator (4) or (5), Exercise care to avoid damaging the sealing lip of Seals (11). Heat cone of Bearing (13) in oi] to approximately 250°F., drop in place against the shoulder on Shaft (1) and allow to shrink on its seat. Hold the cone of Bearing (13) firmly against the shoulder of Shaft (1) until cooled to about room temperature before proceeding. Install cup of Bearing (13) into bore of Bearing Retainer (10) and seat it firmly against cone of Bearing (13). The following procedures must be performed to determine the amount of Shims (14) to be installed between Bearing Retainer (10) and Retainer Plate (15). NOTICE: Follow procedures outlined in Paragraph 5.9 for properly centering Rotor (3) between Stators (4) and (5) if Hydromatic Brake tase has been disassembled per Section 3 and reassembled per Section 4. Use illustration Drawing U63910 as a guide for performing the following steps: 1 = Measure from back of cup of Bearing (13) to face of Bearing Retainer (10). Call this dimension "A". 2 = Measure from front face of Retainer Plate (15) to flange face of Retainer Plate (15). Call this dimension "BM. 3 ~ Subtract dimension "A! from dimension "B", Call this dimension "Cc". 4 = Add to dimension "C!! the thickness of the total required shaft end play (.005-.007). The answer being the total thickness of Shims (14) to be used between Retainer Plate (15) and Bearing Retainer (10). The Rotor (3) must be properly centered between the Stators (4) and (5), therefore, the following procedures must be performed with accuracy. NOTICE: Follow procedures outlined in Paragraph 5.8 if Hydromatic Brake has not been disassembled per Section 3 or if one side of Hydromatic Brake has been reassembled per Paragraphs 5.1 through 5.7 and Paragraphs 5.9 through 5.10. 1 = With shaft vertical, check through bottom outlet port of Stator (4) or (5) to see that sub-assembly of Shaft (1) and Rotor (3) is resting in its lowest position on the face of Stator (4) or (5). 2 = Through the top outlet port of Stator (#) or (5) use feeler gauges to measure the distance between the face of Rotor (3) and the face of Stator (4) or (5). This will be the total rotor movement between Stators (4) and (5). Call this dimension "M" and note it down for later use.HB-7-66 oe 5.10 5. 5.18 5.14 3 - Use Illustration Drawing U63910 as a guide for performing the following steps: Measure from back of cup of Bearing (13) to face of Bearing Retainer (10). Call this dimension "A", 4 - Measure from front face of Retainer Plate (15) to flange face of Retainer Plate (15). Call this dimension "i 5 ~ Subtract dimension "B"' from dimension "A". Call this dimension "0". 6 = Subtract dimension "0" from half of dimension "M"'. Call this nen, ension 7 = Add to dimension "E" half (approximately .003") of the total required shaft end play (.005'-.007"). The answer being the total thickness of Shims (14) to be used between Retainer Plate (15) and Bearing Retainer (10). Place correct amount of Shims (14) (per Paragraph 5.8 or Paragraph 5.9) on Retainer Plate (15), then assemble Retainer Plate (15) to Bearing Retainer (10) and secure in place with Cap Screus (12). Procedures to this point will completely reassemble one side of the Hydro- matic Brake. After completing assembly of one side per these instructions, turn Hydromatic Brake over and repeat procedures in Paragraphs 5.1 through 5.8 and Paragraph 5.10 to assemble the other side. With both sides of Hydromatic Brake reassembled (per Paragraphs 5.1 through 5.11), check to see that Rotor (3) is properly centered between Stators (4) and (5) by measuring from each side of Rotor (3) to face of Stators (4) and (5). This can be done by using feeler gauges through both outlet ports of Stators (4) and (5). NOTE: A - Measure shaft end play by placing a jack under the shaft and raising it to its limit of travel. Using feeler gauges through bottom outlet port, measure the distance between faces of Rotor (3) and stator (4)'or (5). B - Lower shaft to its lowest position and repeat procedure in NOTE A above for a couple of times to make sure of obtaining the true amount of shaft end play. (C= Having obtained the total shaft end play and the amount that the Rotor (3) is out of center between Stators (4) and (5), adjust Shims (14) on both sides of Hydromatic Brake to properly center Rotor (3) between Stators (l4) and (5) with required .005'-.007" shaft end play. Install GreaseFittings (24) and (25) in their respective tapped holes of each Bearing Retainer (10) and Retainer Plates (15). Procedures contained in Section 5 will completely reassemble both of Hydromatic Brake. Lubricate Bearings (13) and Seals (Il) as per lubrication instructions in Section 6.6.1 6.2 6.3 ous HB-7-66 Lubricat Lubrication instructions are included on the name plate of the Hydronatic Brake, but they will be repeated here for convenience. When in use, the Seals (11) in the Hydronatic Brake should be lubricated before and after each round trip with several strokes of the grease compressor through Grease Fitting (24). The Roller Bearing (13) should also be lubricated before and after cach round trip, through Grease Fitting (25), with two or three strokes of the grease compressor. Use No. 2 Water Resistant (Calcium Base) cup grease for both Seals (11) and Bearing (13). After repairs have been made to a Hydromatic Brake that entails the removal of the Seals (11) and/or Bearings (13), it is important that a sufficient quantity of grease be pumped into both Bearings (13) and Seals (11) to entirely fill all cavities around both the Bearings (13) and Seals (11) before brake is placed in operation. Where such repairs are made in a field shop, both the shop personnel and drilling crew may sometimes depend on each other to do this, with the result that neither does it. When there is any question. or doubt, lubricate it. 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