Eaton Airflex WCSB3 Installation, Operation And Maintenance Manual Download Page 1 | Manualshive

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WSB 11210 - WCSB3 Brake Installation Operation and Maintenance

Airflex

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Summary of Contents for Airflex WCSB3

Page 1: ...WSB 11210 WCSB3 Brake Installation Operation and Maintenance Airflex Product Line ...

Page 2: ... Installation Opera tion or Maintenance may result in personal injury or equip ment damage Caution Use Only Genuine Airflex Replacement Parts The Airflex Division of Eaton Corporation recommends the use of genu ine Airflex replacement parts The use of non genuine Airflex replacement parts could result in substandard product per formance and may void your Eaton warranty For optimum performance cont...

Page 3: ...Sequence 16 3 5 Periodic Maintenance 17 4 0 MAINTENANCE 18 4 1 Wear Limits 18 4 2 Wear Adjustment 18 4 3 Disassembly Procedures 22 4 4 Friction Material Replacement 24 4 5 Wear Plate Replacement 24 4 6 Seal Replacement 27 4 7 Spring Replacement of outer inner apply springs 22 52 for Air Cooled Brake 28 4 8 Bushing Replacement 28 4 9 Assembly Procedures 29 5 0 ORDERING INFORMATION TECHNICAL ASSISTA...

Page 4: ...g Port Sizes 27 17 Wear Spacers 31 Figure No FigureTitle Page No 1 Cross Section and Item Numbers 5 1A Section A Section B 6 1B Section X X Section Y Y 6 1C Section Z Z Section 7 2 Proper vs Improper Alignment 9 3 Grease Requirement 10 4 ORB O ring Boss Port Illustration 12 5 Typical Closed Loop Liquid to Liquid Coolant System 13 6 Illustration of Dust Wear Grooves 19 7 W X Y and Z 1 Gap Locations...

Page 5: ...asher 18 Self Locking Nut 19 C R Cylinder 20 Hex Head Screw 21 PolyPak Seal inner 22 36WCSB Outer Apply Spring 23 PolyPak Seal outer 27 Spacer Tube 28 Gear 29 Wear Spacer Clamp Tube 30 Reaction Plate 33 Dual Piston 34 Release Spring 52 Inner Apply Spring 53 Spring Retainer Figure 1 Item Description 105 Brass Pipe Plug 112 Mounting Flange cylinder 114 PolyPak seal 116 Pressure Plate S A 117 End Pla...

Page 6: ...6 18 17 125 29 29 125 29 124 139 141 144 138 SECTION A SECTION B 16X SAE 20 SAE J1926 1 COOLANT PORTS SECTION Y Y SECTION X X 22 52 53 20 17 27 16X SAE 20 SAE J1926 1 COOLANT PORTS SECTION Y Y SECTION X X 22 52 53 20 17 27 Figure 1B Section X X Section Y Y Section A Section B Figure 1A WCSB3 Brakes ...

Page 7: ...allation operation and maintenance of the equipment on which this device is used to fully understand the Danger the Warning and the Caution procedures by which hazards can be avoided 1 1 1 The Airflex WCSB3 water cooled tensioner is designed for constant tension applications and is designed with a dual piston and cylinder on the water cooled tensioner It is exceptionally well suited for high inert...

Page 8: ...13 then continues to move away from the end plate subassembly and the clamp force is removed from the disc 119 that rides on the gear As the end plate subassembly 117 moves towards the stop plates the piston 33 and friction disc subassembly move by means of the air pressure initially applied Relieving the air pressure within the mounting flange cylinder reduces the clamp force applied to the frict...

Page 9: ...nting flange cylinder 112 preventing deflection during operation 2 1 5 For proper operation and service life the tensioner reaction member must be aligned to the shaft within the limits shown in Table 2 2 1 6 Refer to Table 3 for the setup dimension between the tensioner mounting surface and the end of the gear dimension A on Figure 1 Gears should be positioned to ensure that when the tensioner is...

Page 10: ...se channel in the friction disc splines with MOLUB ALLOY 936SF Heavy grease or equivalent as shown in Figure 3 Try to maintain the grease level at 1 8 3mm below the top of the friction disc splines as shown in Figure 3 For reference the recommended grease is Eaton Part Number 000153X1182 Caution Excessive lubricant in the grease channel and on the gear teeth may contaminate friction disc material ...

Page 11: ... open and vented to atmosphere Porting should be filtered to avoid contamination of the piston cylinder during single piston actuation 2 3 1 Maximum allowable pressure is 120 psig 8 2 Bar in the spring set brake cylinder 19 and 120 psig 8 2 Bar in the air applied mounting flange cylinder 112 See Section 3 2 for other limitations 2 3 2 Use only clean filtered air a 40 micron filter or better is rec...

Page 12: ...ts utilize a straight thread and an O ring for sealing ORB ports provide superior sealing properties and reduce the risk of damage to the brake during fitting installation An ORB port can be identified by the machined spot face and a chamfer for sealing of the O ring See Figure 4 Follow the fitting manufacturer s recommendation for the proper method of installation and tightening Torque to values ...

Page 13: ...or each size tensioner per Table 8 Caution Do not plug any ports or plumb the cooling passages in series Parallel arrangement of hoses similar to that shown in Figure 5 is required for proper coolant flow 2 4 10 The number of flexible hoses required for both the inlet and outlet ports of each size tensioner is given in Table 9 Table 7 Coolant Pressure psi bar Size Maximum Static Maximum Inlet 436W...

Page 14: ... 9 for the quantity of hoses required for the 436WCSB3 Reference Table 6 for the percentage flow required at the outlet for the 436WCSB3 2 4 14 2 Figure 5 illustrates the supply lines hoses and the return lines hoses are equal in length and flow controls are located on the return lines to balance flow 2 4 15 The maximum coolant supply temperature at the inlet should be 100 F 38 C or lower The cool...

Page 15: ... using water as a coolant the mini mum ambient temperature is 45 F 7 C Caution The tensioner is never to be operated without the coolant supply attached and coolant running through the unit 3 2 Pressure and Speed Limits 3 2 1 Maximum allowable coolant pressure is 40 psig 2 8 bar for size 36WCSB3 units The use of an accumulator or pressure relief valve may be desirable to reduce the effect of press...

Page 16: ...ot allow the brake disc temperature to exceed 180 F 82 C 3 3 8 Repeat steps 3 3 4 thru 3 3 7 for the number of cycles shown in Table 12 to allow for adequate wear in of the air cooled brake Allow the brake disc to completely cool to ambient temperature prior to testing the torque capacity of the brake or returning it to service 3 4 Operational Sequence 3 4 1 Ensure that the coolant system is opera...

Page 17: ...ully released Dragging discs may be caused by wear or contamination of the gear or disc splines lack of spline lubrication disc imbalance warped discs or misalignment Correct as required 3 5 5 Pneumatic and electrical control interlocks should be periodically checked for proper settings and operation 3 5 6 If leakage or blockage of any water cooled chamber is suspected a static or dynamic test may...

Page 18: ...ired or replaced 4 2 Wear Adjustment Wear adjustment is periodically required as the friction material and mating surfaces wear Wear adjustment reduces the running clearances between these surfaces to help maintain the holding force of the brake for the spring applied feature and to maintain the responsiveness of the brake by limiting the travel of components Mechanical limits within the brake des...

Page 19: ...an zero and there is no clearance between each side of the disc 119 and the corresponding friction material Pressure in the mounting flange 112 has been exhausted if gap Z 2 See Figure 7A located between the mounting flange and the pressure plate 116 is equal to 250 6 35mm and gap W is greater than zero d Measure gaps between the components at positions W X Y 1 and if applicable Y 2 and Y 3 See Fi...

Page 20: ...se components using Table 14 as a reference Warning If wear adjustment is not made the piston may extend out of the mounting flange cylinder 112 beyond an acceptable operating range resulting in loss of torque and or seal 21 23 and or 114 damage If the Y or Z dimensions have been reached or any of the friction discs are worn to the bottom of the wear groove the tensioner should be taken out of ser...

Page 21: ... 15 13 72 Value shown is GAP after wear adjustment New or rebuilt brakes may vary slightly from this value due to tolerances Record of Wear Measurements GAP W X Y 1 Y 2 Y 3 Z 1 Z 2 Date Date Date Date Date Date If Recorded value is Equal or greater than W adjust Equal or less than X adjust Greater than Y min Greater than Zero Equal to 250 6 35mm Then Adjust Adjust Inspect friction disc Check Z 2 O...

Page 22: ...ing Be sure to collect all wear spacers 29 and all support beam wear spacers 139 when removed Spacers lodging in between tensioner components could prevent the tensioner from properly engaging or releasing 4 2 2 4 Prior to tightening the locknuts verify that the support beams and clamp tubes and support are located properly over the step on the mounting flange cylinder and alignment bushings to pr...

Page 23: ...TOP PLATE 125 SUPPORT BEAM SPACER 139 SPACER RETAINER 141 CENTERLINE OF WASHER 142 SCREW 143 NUT 145 125 139 141 NOTE SUPPORT BEAM SPACER SPACER RETAINER MOUNT OVER THE SUPPORT BEAM AND STUDS THE ENDS OF EACH STOP PLATE OVERLAP THE SUPPORT BEAM SPACER AS SHOWN SEE DETAIL A DETAIL A NOTE THE SMALL SCREW HOLE AT ONE END OF A STOP PLATE SHOULD LINE UP WITH THE MIDDLE SCREW HOLE OF THE SPACER RETAINER...

Page 24: ...to the proper torque value For water cooled disc assemblies tighten screws to 15 ft lb 20Nm Screws securing the air cooled brake friction discs 118 or blocks mounted on the pressure plate 13 and end plate subassembly 117 should be tightened to 20 ft lb 27 Nm after application of Loctite 262 to the screw threads Install the screws in an even crosswise pattern Screws in friction blocks should be ins...

Page 25: ... up is required reference Figure 10 A to mask the inner outer lands that will receive the gasket tape for sealing Caution Use only clean dry air for blow off Caution Follow manufacturer s instructions and proper safety precautions for the use of solvent based cleaners acetone mineral spirits or general purpose for oil grease remover 4 5 4 2 Preparation and cleaning the Copper Wear Plate Ensure tha...

Page 26: ...replaced the torque tightening instructions are as follows Note The torque of the screws nuts 4 5 that attach the wear plate 3 to the mounting flange 1 reaction plate 30 pressure plate 13 is a four step process a Step One For the first 16 screws bring the initial torque of each screw up to 33 of the torque value shown in Table 15 using the tightening sequence shown in Figure 12 Install and torque ...

Page 27: ... be damaged Repair and repeat procedure from 4 5 2 4 5 8 6 Follow steps in Section 4 8 to reassemble the tensioner Caution After replacement of wear plates 3 a wear in period is required per Section 3 3 for the friction couple to achieve rated torque 4 6 Seal Replacement Note The cylinder piston seals 21 23 can be replaced with the brake fully assembled and simply removing the cylinder 19 while th...

Page 28: ...outer port should remain open to atmosphere Apply 120 psi 8 2 bar to the cylinder 19 to disengage the spring set brake Check for leakage from the inner cylinder area to the outer cylinder area in the mounting flange cylinder Shut off the air supply and check for pressure drop from the cylinders If air pressure does not drop below 100 psi 6 8 bar within 10 minutes the seals have been properly insta...

Page 29: ...y enough liquid to entirely fill the space between the parts Install the bushings by twisting the bushing while pushing it down until it is flush with the casting surface Inspect to see that a ring of liquid adhesive is visible at the parting line Reapply Loctite if required Allow the Loctite to cure for 15 minutes before moving the sub assembly Caution The bushing 54 shall be held in place so it ...

Page 30: ...tion and repeat for the 6 9 o clock positions Four pair of studs is required for a total of 8 studs Note When building up the tensioner the reaction plates 30 and the end plate 117 should be aligned so the coolant inlets and outlets are at the 12 3 6 9 o clock positions with reference to the Eaton Airflex logo and drain plug 105 as defined in 4 9 4 above and the reaction holes line up The clamp tu...

Page 31: ...cation adjacent to support beam 138 on each stud 4 9 15 Assemble the friction discs 118 to the end plate subassembly 117 and pressure plate 13 per the following Position the friction material to align the screw holes Apply Loctite 262 to the screw threads and tighten the screws 121 to 20 ft lb 27 Nm Install the screws in an even crosswise pattern Screws in friction disc should be installed from th...

Page 32: ...23 with Molykote 55 O ring lubricant and install them into the seal grooves on the spring housing 16 Note the orientation of the seal lips per Figure 13 4 9 25 Lubricate the seal surfaces in the mounting cylinder 19 and lower the cylinder onto the spring housing Orient the cylinder so that the Eaton logo is near the 12 O clock position in line with the water outlets 4 9 26 Position the spacer tube...

Page 33: ...Equipment Reference 5 1 1 In any correspondence regarding Eaton Airflex Equipment refer to the information on the product nameplate and call or write Eaton Hydraulics Group USA Airflex Products 9919 Clinton Road Cleveland Ohio 44144 Tel 216 281 2211 Fax 216 281 3890 www eaton com hydraulics Loctite and Loc Quic are registered trademarks of Henkel Corporation Castrol Molub Alloy 936SF Heavy is a re...

Page 34: ...t included with Assembly 417009 1 29 Wear Spacer Clamp Tube 308620 48 30 Reaction Plate 515635 02 2 33 Dual Piston 515657 2 34 Release Spring 416751 15 24 52 Inner Apply Spring 416751 08 64 53 Spring Retainer 416504 16 105 Pipe Plug 000077x0021 1 112 Mounting Flange Cylinder 515645 1 114 Seal 000402x0040 2 116 Pressure Plate S A 515635 03 1 117 End Plate S A 515635 04 1 118 Friction Disc 513396 2 ...

Page 35: ...t Ring 414032 01 12 51 Outer Support Ring 417435 4 51 Outer Support Ring 417459 4 36 WCSB3 End Plate Sub Assembly 117 Item Description Part Number Qty End Plate 515634 1 54 Bushing 204240 03 8 3 Wear Plate 417437 2 4 Screw 4 000153x0842 108 5 Locknut 5 000153x0844 108 50 Inner Support Ring 414032 01 12 51 Outer Support Ring 417435 4 51 Outer Support Ring 417459 4 36 WCSB3 Friction Disc Sub Assembl...

Page 36: ... A and Figure 14 36WCSB3 Wear Plate Kits for Reaction Plate Parts Inner Support Outer Support Included Screw Flair Nut Wear Plate Ring Ring PTFE Gasket PTFE Gasket in Kit 4 5 3 50 51 O D I D Model Kit Part No Part No Qty Part No Qty Part No Qty Part No Qty Part No Qty Part No Qty Part No Qty 36WCSB3 108164A 153x0843 108 153x0844 108 417437 2 414032 01 12 417435 8 308581 01 2 308581 02 2 417459 8 N...

Page 37: ...N Airflex WSB 11210 WCSB3 Installation Operation and Maintenance E CLCL 11001 E October 2013 37 IOM WSB 11210 for WCBD3 Original Publication Date October 2013 Revision Date Change WCSB3 Brakes 8 0 REVISIONS ...

Page 38: ...E October 2013 Eaton Hydraulics Group USA Airflex Division 9919 Clinton Road Cleveland OH 44144 1077 Tel 216 281 2211 Fax 216 281 3890 Eaton Hydraulics Group Asia Pacific 281 Fa Sai Road Waigaoqiao Free Trade Zone Shanghai 200131 China Tel 8621 5048 4811 Fax 8621 5048 4911 ...

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