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Eaton Airflex WSB11206, Installation, Operation And Maintenance Manual, Page: 5 / 40

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Eaton Airflex WSB11206 Installation, Operation And Maintenance Manual Download Page 5

EATON  

WSB11206  WCSB Tensioner / Brake with ORB Coolant Ports Installation, Operation and Maintenance Manual  E-CLCL-II009-E

  

August 2015

5

1.0 INTRODUCTION

Throughout this manual there are a number of 
HAZARD WARNINGS that must be read and  
adhered to in order to prevent possible personal 
injury and/or damage to the equipment. Three signal 
words "DANGER", "WARNING", and "CAUTION" are 
used to indicate the severity of the hazard, and are 
preceded by the safety alert symbol     .

 Danger 

Denotes the most serious injury hazard, and is 
used when serious injury or death WILL result from 
misuse or failure to follow specific instructions.

 Warning 

Used when serious injury or death MAY result from 
misuse or failure to follow specific instructions.

 Caution 

Used when injury or product / equipment damage  
may result from misuse or failure to follow  
specific instructions.

It is the responsibility and the duty of all personnel 
involved in the installation, operation and 
maintenance of the equipment on which this device 
is used to fully understand the  

 

       

Danger

,      

Warning

, and,      

Caution 

  

 

procedures by which hazards are to be avoided.

1.1 Description

1.1.1   The Airflex WCSB water-cooled tensioner / 

brake assembly is designed for constant tension 
applications. It is exceptionally well suited for high 
inertia stop ping and rapid heat dissipation. The 
WCSB tensioner / brake assembly incorporates 
both an air applied water-cooled tensioner and an air 
cooled spring set brake into one relatively compact 
unit. The water-cooled section is used for high 
energy, constant slip tensioning, while the spring 
set brake serves as an emergency stopping or 
parking brake. The design of the WCSB tensioner 
/ brake assembly permits mid-shaft or end-shaft 
mounting. The rugged construction ensures long, 
trouble free service.

1.1.2   WCSB tensioner / brake assemblies are available 

in various sizes and quantities of friction discs. 
The model number identifies the number of discs and 
the nominal disc diameter. For example, 324WCSB 
indicates three 24" diameter discs. Note that the 
air-cooled disc is typically larger in diameter by 2" 
when compared to the water- cooled disc, therefore, 
the model number will refer to the diameter of the 
water-cooled discs only. Additional notations are 
made in describing the model number to indicate 
the number of water-cooled (WC) disc assemblies 
and number of air cooled (AC) discs. For example, a 
436WCSB (3WC/1AC) would indicate three 
water-cooled discs and one air cooled disc, whereas 
a 436WCSB (2WC/2AC) would indicate two water-
cooled and two air-cooled discs.

1.1.3   When size, such as 36WCSB, is referred to in this 

manual, it means that the information given applies to 
all models using the 36" diameter water-cooled disc 
assembly; i.e., 236WCSB, 336WCSB, etc.

1.1.4 

All WCSB tensioner / brake assemblies referred to 
in this IOM have SAE O-ring Boss (ORB) ports for 
the coolant inlets and outlets. These ports utilize a 
straight thread and appropriately installed fittings 
have an O-ring for sealing versus the NPT tapered 
thread used previously and referred to in IOM 
WSB11200. The ORB ports provide superior sealing 
properties and reduce the risk of damage to the brake 
during fitting installation. 

1.1.5   The air applied pistons in the WCSB tensioner / brake 

assemblies are available in either single or dual piston 
designs. The WCSB tensioner / brake assemblies 
dual mounting flange / cylinder (112) and dual piston 
(33) assembly (112) offers precise tensioning control 
by dividing the piston / cylinder into inner and outer  
chambers that are isolated by intermediate seals 
(114). Also, for light tensioning loads, the inner 
chamber is used, not the outer chamber. See Figure 
1. This provides the ability to improve fine modulation 
of clamping pressure on the tensioner discs and 
improved control over our standard single chamber 
design. For very light tensioning loads, the outer 
piston can be used solely, with no pressure applied 
to the inner piston. For the largest tensioning loads, 
both pistons can be used together. If it is desirable 
to operate the WCSB tensioner / brake assembly at 
maximum tensioning load and not utilize the precise 
tensioning feature, the WCSB tensioner / brake 
assembly can be ordered without the intermediate 
piston seal (114).

WCSB tensioner / brake with ORB coolant ports

Summary of Contents for Airflex WSB11206

Page 1: ......

Page 2: ...SAE O ring boss type fittings If you are maintaining a WCSB assembly that has cooling ports threaded to accept NPT fittings refer to manual WSB 11200 for the appropriate part lists or contact the factory for additional information Caution Use Only Genuine Airflex Replacement Parts Eaton s Airflex division recommends the use of genuine Airflex replacement parts The use of non genuine Airflex replac...

Page 3: ...21 4 4 Friction Material Replacement 22 4 5 WC Wear Plate Replacement 23 4 6 Cylinder Seal Replacement 26 4 7 Spring Replacement 27 4 8 Assembly Procedures 28 4 9 Assembly Procedures 29 5 0 ORDERING INFORMATION TECHNICAL ASSISTANCE 31 5 1 Equipment Reference 31 6 0 PARTS 32 6 1 Basic Assemblies 24WCSB Parts 32 6 2 Basic Assemblies 36WCSB Parts 33 6 3 Basic Assemblies 48WCSB Parts 34 6 4 Sub Assemb...

Page 4: ... 13 Pressure Plate S A 16 Spring Housing 17 Flat Washer 18 Locknut 19 Cylinder 20 Hex Head Screw 21 Seal 22 Outer Spring Item Description 23 Seal 27 Spacer Tube 28 Gear 29 Wear Spacer 30 Reaction Plate S A 33 Dual Piston 34 Reaction Spring 52 Inner Spring 53 Spring Retainer 105 Pipe Plug 106 Sleeve Nut Item Description 112 Mounting Flange Cylinder 114 Seal 116 Pressure Plate S A 117 End Plate S A ...

Page 5: ...he air cooled disc is typically larger in diameter by 2 when compared to the water cooled disc therefore the model number will refer to the diameter of the water cooled discs only Additional notations are made in describing the model number to indicate the number of water cooled WC disc assemblies and number of air cooled AC discs For example a 436WCSB 3WC 1AC would indicate three water cooled dis...

Page 6: ...eans of the air pressure initially applied Relieving the air pressure within the mounting flange cylinder reduces the clamp force applied to the friction discs allowing the shaft to be free to rotate Modulation of the air pressure then controls applied torque of WCSB tensioner brake assembly As air pressure is exhausted from both the mounting flange cylinder 112 and the cylinder 19 the springs for...

Page 7: ...e positioned to ensure that when the tensioner is mounted the disc splines will not overhang the end of the gear when components are in both new and worn conditions The gear is typically bored and keyed for a resulting Class FN2S interference fit for inch shafting and ISO System S7h6 for metric shafting Contact Airflex Application Engineering for specific recommendations 2 2 Mounting 2 2 1 The WCS...

Page 8: ...directly on the release springs 34 Table 2 Fastener Description and AssemblyTorque ft lb Nm Item Description Specification 24WCSB 36WCSB 48WCSB 4 Wear Plate Screw Size 5 16 18 NC Gr 8 3 8 16 NC2 Gr 8 3 8 16 NC2 Gr 8 5 Locknut Quantity 90 108 120 Torque Dry 21 28 40 54 40 54 18 Locknut Size 1 1 8 7 NC Gr 8 1 3 8 6 NC Gr 8 1 3 8 6 NC Gr 8 106 Quantity 12 16 16 Torque Lubed 500 677 750 1016 750 1016 ...

Page 9: ...pring set brake should be observed Operation at pressures below minimum will result in WCSB tensioner brake assembly drag excessive heat and wear and damage to brake components Caution When applying operating pressure to only one of two ports on units with dual pressure pistons 33 the second piston pressure port must be open and vented to atmosphere Porting should be filtered to avoid contaminatio...

Page 10: ...t to locknut 2 4 3 4 Tighten the SAE fitting by hand into the threads of the ORB port until the back up washer contacts the face of the ORB port 2 4 3 5 To position the SAE fitting unscrew the SAE fitting up to one full turn then hold the SAE fitting in desired position and tighten locknut so that the back up washer contacts face of ORB port and forces the O ring on the SAE fitting within the boss...

Page 11: ...ure plate reaction plate and end plate during WCSB tensioner brake assembly operation Hose lengths running between the manifold and the inlet or outlet ports should be equal in length if possible Reductions in the recommended line diameter should be avoided to prevent excessive line pressures 2 4 9 Avoid the use of sharp bends and elbows that will restrict water flow Loops and bends in the lines m...

Page 12: ...pH value 7 0 to 9 0 Caution Open loop systems should be thoroughly flushed with clean fresh water after operation to reduce the corrosive effects of contaminants on internal components 2 4 14 Closed Loop Systems For efficient operation of the WCSB tensioner brake assembly in a closed loop system ethylene glycol coolant conforming to SAE Standard J1034 should be used For preparation of the proper c...

Page 13: ... of antifreeze will reduce cooling capacity and can cause coolant leakage due to overheating Refer to Table 5 Caution Maximum ambient temperature is 110o F 43o C Minimum ambient temperature for closed loop systems using ethylene glycol antifreeze is 0o F 18o C For open loop systems using water the minimum temperature is 45o F 7o C Table 6 Maximum Disc Speeds Maximum Maximum Free Slip Speed Wheelin...

Page 14: ... specified in Table 7 but DO NOT ALLOW THE BRAKE TO SLIP FOR MORE THAN THE TIME SPECIFIED Caution Slipping the WCSB tensioner brake assembly at increased time intervals speeds or pressures other than specified will result in damage to WCSB tensioner brake assembly components 3 3 6 After the WCSB tensioner brake assembly has engaged slipped for upto the maximum slip time specified in Table 7 quickl...

Page 15: ... exhaust the air pressure in the mounting flange cylinder 112 after engaging the spring set brake Note The spring set brake is intended for parking or emergency braking only Warning Dynamic braking with the air cooled spring set brake is not recommended except for emergency stopping situations or during initial wear in High heat generated during dynamic braking can result in damage or failure of t...

Page 16: ...the spring pressure on the WCSB tensioner brake assembly during static coolant pressure testing Engagement of the brake during testing could develop surge pressures exceeding the maximum allowable within the coolant cavities resulting in possible damage to the seals 3 5 6 2 Dynamic Flow Test a Dynamic flow testing of the WCSB tensioner brake assembly should be conducted at the required flow rate f...

Page 17: ...eached Warning Failure to perform adjustments when required may result in loss of adequate brake torque and potential injury to personnel or damage to equipment Be certain to inspect the brake periodically to evaluate for wear and adjust as necessary 4 2 1 WCSB tensioner brake assembly Inspection and Evaluation To determine when WCSB tensioner brake assembly adjustment is required the WCSB tension...

Page 18: ... 4 00 101 6 36 3 88 98 55 36 4 00 101 6 48 4 85 123 19 48 5 00 127 6 52 Spring Spring Free Height WCSB Brake Size Minimum Free Height WCSB Brake Size Original Free Height 24 4 95 125 73 24 4 00 101 6 36 6 5 165 1 36 4 00 101 6 119 Friction Disc Friction Material Maximum wear is 0 045 1 12 per surface WCSB Brake Size Original Thickness 0 09 2 24 Total 24 1 00 25 4 36 1 25 31 7 48 1 25 31 7 4 2 1 2 ...

Page 19: ...B tensioner brake assembly that have three or more water cooled discs Y 3 is the measurement between the reaction plate 30 and the end plate 117 e Record the W X Y 1 Y 2 and Y 3 values measured for each of the gaps and compare them against the values listed in Table 9 f If the value measured for any Y gap Y 1 Y 2 Y3 is equal to or less than the Y min value the WCSB tensioner brake assembly should ...

Page 20: ...ithout full disassembly of the WCSB tensioner brake assembly Warning Before performing any maintenance work on the WCSB tensioner brake assembly make sure that the machinery will remain in a safe position Failure to do so could result is serious injury or possibly death 4 2 2 1 Wear spacers should be removed in complete sets only one from each stud location Mark the spacers to be removed to avoid ...

Page 21: ...s that secure the brake and support bracket to the mounting structure 4 3 3 Using soft slings rig the WCSB tensioner brake assembly and slide the WCSB tensioner brake assembly off of the gear Avoid placing slings or straps directly on the release springs 34 4 3 4 Transport the WCSB tensioner brake assembly to a clean working area and position the unit on a flat surface with the mounting flange 112...

Page 22: ...l the screws in an even cross wise pattern Screws in friction blocks should be installed from the centermost position in the block then progressing towards the outer edges of the block One at a time install and torque each screw immediately after application of Loctite then proceed to the next screw Warning Loctite may cure prior to properly tightening the screw if not tightened to the proper torq...

Page 23: ...ary 4 5 4 For wear plate replacement kits that contain Loctite Superflex 596 Sealant proceed to section 4 5 6 for assembly instructions 4 5 5 Assembly with Gasket Tape for sizes 24 and 36 Note The End Plate 117a Pressure Plate 14 and Reaction Plate s 31 will be referred to as IRON in the following paragraphs Refer to Figure 22 for item number references shown in parenthesis 4 5 5 1 Preparation and...

Page 24: ...uter diameter of the IRON again using the edge of the water cavity as a guide 4 5 5 5 Proceed to Section 4 5 7 to complete the wear plate 3 replacement Caution Before the gasket tape is covered with the wear plate the sealing surface should be protected to prevent contamination from dust dirt or oils No additional cleaning or liquid should be applied to the surface of the IRON or gasket tape 4 5 6...

Page 25: ...uts 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 For the first 16 screws bring the initial torque of each screw up to 33 of the torque value shown in Table 2 using the tightening sequence shown in Figure 15 Install and torque the remaining screws in any reasonable crosswise pattern to 33 of the torque value shown in Table 2 ...

Page 26: ...eat procedure from section in front of 4 5 1 4 5 16 Follow steps in Section 4 9 to reassemble the WCSB tensioner brake assembly 4 5 17 Machining of the wear surfaces is required for the 36WCSB and 48WCSB tensioner brake assemblies after replacement of the wear plates or the adjoining friction material See Figure 16 for machining specifications Clean all wear surfaces after machining to remove any ...

Page 27: ...g flange cylinder 112 and check for large cylinder seal leakage Allow the smaller port in the mounting flange cylinder to remain open to check for potential leakage from the large cylinder to the small cylinder 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 psig 6 9 bar within 10 minutes the seals have ...

Page 28: ...rial with the disc 119 resulting in low stopping torque 4 8 Reaction Plate Bushing Replacement size 36 only 4 8 1 Disassemble the WCSB tensioner brake assembly per Section 4 3 4 8 2 Refer to Table 8 to determine if the reaction plate bushings 54 require replacement 4 8 3 Heat up the area around each bushing to soften the Loctite Drive out the old bushings 4 8 4 Clean the bores in the mating compon...

Page 29: ...y 116 over the clamp tubes noting the position of the water inlet in relation to the ports in the mounting flange cylinder The inlet ports should be as close as possible to the 6 o clock position noted in 4 9 1 4 9 6 Pre fill the grease channel in the friction disc subassembly 7 splines with MOLUB ALLOY 936 SF Heavy grease or equivalent as shown on Figure 3 4 9 7 Lower a friction disc subassembly ...

Page 30: ...e the springs over bosses or in the spring pockets in the pressure plate as shown in Figure 18 for 24WCSB tensioner brake assemblies Figure 19 for 36WCSB tensioner brake assemblies and Figure 20 for 48WCSB tensioner brake assemblies If applicable position the spring retainers 53 on top of the springs to hold the springs into position 4 9 21 Lower the spring housing and cylinder over the springs an...

Page 31: ...at the brake will have adequate running clearances when released Refer to Figure 7 and Table 9 Additional machining of friction discs or wear plates may be required to achieve proper running clearances if gaps Wnew and Znew are not found to be within the ranges shown on Table 8 Correct as required 4 9 28 Prior to installation air test the cylinder seals for leakage per Section 4 6 9 4 9 29 Install...

Page 32: ... 24 416751 09 24 23 Seal 000402X0024 4 000402X0024 4 000402X0024 4 27 Spacer Tube 308206 09 12 308206 09 12 308206 09 12 28 Gear Not Included 410970 412433 413195 29 Wear Spacer 308348 24 308348 48 308348 72 30 Reaction Plate Sub Assembly 515661 02 1 515661 02 2 33 Dual Piston 514545 1 514545 1 514545 1 34 Release Spring 416751 02 12 416751 02 24 416751 02 36 52 Inner Spring 416751 10 24 416751 10...

Page 33: ...00402X0006 4 000402X0006 4 000402X0006 4 27 Spacer Tube 308150 06 16 308150 06 16 308150 06 16 28 Gear Not Included 416821 416842 416676 29 Wear Spacer 308313 32 308313 64 308313 80 30 Reaction Plate Sub Assembly 515617 01 1 515617 01 2 33 Dual Piston 514485 1 514485 1 514485 1 34 Release Spring 416751 01 16 416751 01 32 416751 01 48 52 Inner Spring 416751 08 64 416751 08 64 416751 08 64 53 Spring...

Page 34: ...0044 4 27 Spacer Tube 308440 03 16 308440 03 16 308440 03 16 28 Gear Not Included 416795 416688 416797 29 Wear Spacer 308315 32 308315 64 308315 80 30 Reaction Plate Sub Assembly 515601 02 1 515601 02 2 33 Dual Piston 514484 1 514484 1 514484 1 34 Release Spring 416751 04 16 416751 04 32 416751 04 48 53 Spring Retainer 416674 16 416674 16 416674 16 105 Pipe Plug 000077X0021 1 000077X0021 1 000077X...

Page 35: ...85 90 000153X0842 72 000153X1223 120 4a Wear Plate Screw N A N A 000153X1216 36 N A N A 5 Locknut 000153X0642 90 000153X0844 108 000153X0844 120 50 Inner Support Ring 413107 3 414032 01 6 416618 5 51 Outer Support Ring 413108 5 414033 01 9 416673 10 I Inner O ring N A N A N A N A 000073X0410 1 O Outer O ring N A N A N A N A 000073X0411 1 6 4 3 Parts Breakdown of WCSB End Plate Sub Assemblies Item ...

Page 36: ...Installation Operation and Maintenance Manual E CLCL II009 E August 2015 36 Reaction plate S A 30 End plate S A 117 Pressure plate S A 116 Friction disc S A 118 51 50 3 31 4 3 50 4a 9 8 117a 5 4a 14 51 57 7 Figure 22 WCSB tensioner brake with ORB coolant ports ...

Page 37: ...late 3 Ring 50 Ring 51 O D I D Sheet 24WCSB 107727E Part No 000153X0642 000153X0685 508459 413107 413108 308581 01 308581 02 204063 Quantity 90 90 2 6 10 2 2 1 36WCSB 107662E Part No 000153X0843 000153X0844 416527 414032 01 414033 01 308581 01 308581 02 204063 Quantity 108 108 2 12 18 2 2 1 Inner Outer Wear Support Support Inner Outer Locitite Instruction Size Kit P N Description Screw 4 Lock Nut ...

Page 38: ... Maintenance Manual 24WCSB 108057B Part No 513307 308348 000294X0407 000153X1168 204170 Quantity 2 12 36 1 1 36WCSB 108047B Part No 513396 308313 000294X0405 000153X1168 204170 Quantity 2 16 72 1 1 48WCSB 108048B Part No 416691 308315 000294X0405 000153X1168 204170 Quantity 18 16 90 2 1 7 7 WC Friction Disc Kit Crossion Resistant Parts Included in Kit Wear Flat Head Loctite 936SF Model Kit P N Des...

Page 39: ...oner Brake with ORB Coolant Ports Installation Operation and Maintenance Manual E CLCL II009 E August 2015 39 WCSB tensioner brake with ORB coolant ports 8 0 REVISIONS Original Publication Date August 2014 Revision Date Change ...

Page 40: ... 2015 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 Airflex Division 281 Fa Sai Road Waigaoqiao Free Trade Zone Shanghai 200131 China Tel 8621 5048 4811 Fax 8621 5048 4911 ...

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