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VP 4.2 Format

WCB 11070

Installation, Operation
and Maintenance of
the Airflex

®

WCB2

Tensioner / Brake

April, 2002

(Revised August 2003)

204182

© Copyright Eaton Corp., 2003. All rights reserved.

Caution:

Use Only Genuine Airflex

®

Replacement Parts

The Airflex Division of Eaton Corporation recommends the use

of genuine Airflex replacement parts. The use of non-genuine

Airflex replacement parts could result in substandard product

performance, and may void your Eaton w arranty. For optimum

performance, contact Airflex:

In the U.S.A. and Canada:

(800) 233-5926

Local:

(216) 281-2211

Fax:

(216) 634-8341

Internet:

www.airflex.com

Warning

Forward this manual to the person responsible
for Installation, Operation and Maintenance of
the product described herein. Without access
to this information, faulty Installation, Operation
or Maintenance may result in personal injury or
equipment damage.

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Содержание Airflex 14WCB2

Страница 1: ...rts 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 Local 216 281 2211 Fax 216 634 8341 Internet www airflex com Warning Forward this manual to the person responsible for Installation Operation and Maintenance of the product described herein...

Страница 2: ...Periodic Maintenance 13 4 0 MAINTENANCE 14 4 1 Wear Limits 14 4 2 Wear Adjustment 15 4 3 Disassembly Procedures 18 4 4 Friction Material Replacement Sizes 8 and 14 19 4 5 Friction Material Replacement Sizes 18 24 36 and 48 19 4 6 Wear Plate replacement 20 4 7 Cylinder Seal Replacement 23 4 8 Bushing Replacement 24 4 9 Assembly Procedures 25 4 10 Corrosion Protection 26 WCB 11070 VP 4 2 Format 1 Co...

Страница 3: ... on Figure 1 2 7 4 Fastener Description and Assembly Torque 7 5 Air Inlet Size 8 6 Coolant Supply Data 10 7 Coolant Pressures 12 8 Maximum Outlet Coolant Temperature 13 9 Maximum Disc Speeds 13 10 Wear Measurement X Y Z Gaps 17 11 Wear Plate Fastener Torque 22 12 Inlet and Outlet Port Sizes 22 13 Wear Limits for WCB2 Components Ref Figs 1 2 and Section 4 0 27 WCB 11070 VP 4 2 Format 2 Copyright Ea...

Страница 4: ...w 15 Washer 33 Piston 5 Locknut 17 Flat Washer 34 Release Spring 6 Stud 18 Self Locking Nut 49 Socket Head Screw 7 Friction Disc Assembly 19 Cylinder 50 Inner Support Ring 8 Friction Disc 21 Polypak Seal Inner 51 Outer Support Ring 9 Friction Disc Core 23 Polypak Seal Outer 57 Flat Head Screw 10 Rivet 28 Gear Not included in P L 105 Pipe Plug 11 Washer WCB 11070 VP 4 2 Format 3 Copyright Eaton Cor...

Страница 5: ...Figure 2 WCB 11070 VP 4 2 Format 4 Copyright Eaton Corp 2003 All rights reserved April 2002 Revised June 2003 ...

Страница 6: ...3 When size such as 36WCB2 is referred to in this manual it means that the informa tion given applies to all models using the 36 diameter water cooled disc assembly i e 236WCB2 336WCB2 etc 1 1 4 Tensioners can be used with either closed loop or open loop water systems 1 1 5 This manual includes metric equiva lents usually shown in brackets following the U S measurement system value Be sure to use ...

Страница 7: ...r each specific tensioner 2 1 2 The tensioner reaction member such as the machine frame should have a machined register to allow for mounting and alignment control of the tensioner The mounting surface should be designed to provide full support of the face of the mounting flange 1 preventing deflection during operation 2 1 3 For proper operation and service life the tensioner reaction member must ...

Страница 8: ...osition during installation Remove the gear Use only the proper number and grade fasteners shown in Table 4 Use of commercial grade Grade 2 fasteners where Grade 8 fasteners are specified may result in failure of the fasteners and a sudden and drastic reduction in brake torque Water inlets and outlets must be located as close as possible to the 6 o clock and 12 o clock posi tions respectively This...

Страница 9: ...he appropriate fasten ers If applied pressure was used to help position the discs during mounting exhaust the air pressure prior to tightening the fasteners Tighten the fasteners to the specified torque value See Table 4 Maximum allowable air pressure in the cylinder 19 is 150psi 10 2 bar 2 2 9 WCB2 tensioners should be covered to protect the unit from dirt rain overspray and other sources of exte...

Страница 10: ...sible when the outlet pressures are at or below the limits listed in Table 7 2 4 2 The coolant supply and discharge hose pipe and fitting sizes along with minimum flow rates for the tensioner rated horsepower are listed in Table 6 2 4 3 Coolant supply connections to the tensioner should provide a parallel flow through each section of the tensioner Series flow is not recommended as it can lead to o...

Страница 11: ...6 42 162 47 177 54 204 4 480 358 48 182 56 212 62 234 72 272 1 24 270 201 3 4 14 NPT 3 4 27 102 32 121 35 132 40 151 2 540 402 54 204 64 242 70 265 80 303 3 810 603 81 305 96 361 105 395 120 451 4 1080 805 108 406 128 481 140 526 160 602 1 36 650 485 1 1 4 11 NPT 1 65 246 76 288 84 318 98 371 2 1300 969 130 489 152 572 168 632 196 737 3 1950 1454 195 738 228 863 253 958 294 1113 4 2600 1937 260 97...

Страница 12: ...ne glycol mixtures and other cooling media 2 4 10 Open Loop Systems For efficient operation of the WCB2 an adequate supply of filtered fresh water is required See 2 4 1 2 4 2 Excessive water hardness promotes the formation of scale deposits which in time will affect the service life of the WCB2 unit Water of high acidity or high in corrosive salts may cause electrolytic corrosion between the dissi...

Страница 13: ... help to assure that all coolant cavities are water filled to help avoid overheating For operation in subfreezing temperatures ethylene glycol antifreeze must be added to the water The antifreeze content of the mixture is critical and should not exceed 50 by volume Excessive amounts of antifreeze will reduce cooling capacity and can cause cool ant leakage due to overheating Refer to Table 8 Maximu...

Страница 14: ...e in the cylinder can be purged With air pressure exhausted from the cylinder remove the pipe plug 105 at the 6 o clock position on the cylinder and apply low air pressure to assist in expelling any excess moisture After draining the cylinder reinstall the pipe plug applying a pipe thread sealant on the threads prior to installation Applied air pressure greater than 10psi should not be used when d...

Страница 15: ...ke sure that the machinery will remain in a safe position Failure to do so could result in serious injury or possibly death Only qualified maintenance personnel should install adjust or repair the WCB2 units Faulty workmanship will result in unreasonable exposure to hazardous conditions or personal injury Read these instructions thoroughly and review until you fully understand the parts replacemen...

Страница 16: ...ction discs are worn to the bottom of the wear groove or step the tensioner should be taken out of service and rebuilt with new components as required 4 2 2 Adjustment Procedure Wear adjustment can be conducted without full disassembly of the WCB2 tensioner The wear adjustment spacers are slotted to allow for easy removal with a chisel Before performing any maintenance work on the WCB2 unit make s...

Страница 17: ...Figure 7 Figure 8 Figure 9 Figure 10 WCB 11070 VP 4 2 Format 16 Copyright Eaton Corp 2003 All rights reserved April 2002 Revised June 2003 ...

Страница 18: ...1 45 3 0 24 0 74 1 95 1 45 2 04 1 75 4 0 32 0 82 1 95 1 45 2 04 1 75 24 1 0 09 0 59 2 92 2 42 2 0 18 0 68 2 92 2 25 3 0 27 0 77 2 92 2 25 2 58 2 08 4 0 36 0 86 2 92 2 25 2 58 2 08 36 1 0 12 0 42 2 75 2 31 2 0 24 0 42 2 75 2 31 3 0 36 0 42 2 75 2 31 2 75 2 31 4 0 48 0 42 2 75 2 31 2 75 2 31 48 1 0 15 0 57 3 37 2 95 2 0 30 0 72 3 37 2 95 3 0 45 0 87 3 37 2 95 3 37 2 95 4 0 60 1 02 3 37 2 95 3 37 2 9...

Страница 19: ...ting structure 4 3 3 Using soft slings rig the tensioner and slide the WCB2 off of the gear Avoid placing slings or straps directly on the release springs 34 4 3 4 Transport the tensioner to a clean working area and position the unit on a flat surface with the mounting flange 1 facing down 4 3 5 If the gear 28 requires replacement remove it from the shaft with a portable jack using the threaded ho...

Страница 20: ...set using a washer on the clinched end of the rivet Figure 12 illustrates machine setting and Figure 13 illustrates setting the rivet manually When setting manually use an arbor press and keep the setting tool square to avoid splitting the rivet The clinched end of the rivet must have a washer in place prior to clinching Failure to use the washer or use of excessive force when clinching the rivet ...

Страница 21: ...roper safety precautions 4 5 6 Tensioner friction disc assemblies 7 of size 36 and larger require that the friction material be machined flat after assembly to allow for even contact and minimize wear in Machine the friction surface perpendicular to the bore splines within 003 and parallel to the opposite face within 010 Use appropriate safety equipment and dust collection systems when machining f...

Страница 22: ... For size 48 refer to procedure 4 6 5 1 for proper sealant application proce dure For all other sizes skip to section 4 6 6 after application of sealant Loctite Superflex 596 Silicon Sealant will begin to set up and skin over in approximately 10 minutes The wear plate must be fastened to the mating component within 10 minutes of apply ing the sealant 4 6 5 1 The 48WCB2 incorporates a dual groove f...

Страница 23: ...ning inlet port See Table 12 for water port sizes 4 6 9 2 Slowly fill with water to purge all air from water cavities 4 6 9 3 Install pipe plug s in the outlet port s and apply appropriate water pressure 40 psi 2 7 bar for size 36 and 48 WCB2 units and 45 psi 3 1 bar for all other sizes measured at the inlet Maintain this pressure for a minimum of 30 minutes 4 6 9 4 Check for leakage at O D and I ...

Страница 24: ...ng no more than 15 PSIG 1 0 bar to the cylinder Application of a higher pressure may cause damage to the components 4 7 6 To complete the removal of the piston from the cylinder open all air inlets Alternately insert a 0 50 12 mm diameter by 6 150 mm long wood dowel into each air inlet and gently tap the piston with a mallet so that it moves evenly out of the cylinder Be careful not to damage the ...

Страница 25: ...have been properly installed If excessive leak ing is found disassemble the piston cylinder adn inspect the seals or sealing surfaces for damage repair or replace components as required 4 8 Bushing Replacement Note Some pressure plate and reaction plates have bushings installed in the reaction holes Typically corrosion resistant units and older size 36 tensioners See Figure 20 If applicable replac...

Страница 26: ...ase spring 34 over every other clamp tube For sizes 24 36 and 48 install a release spring over every clamp tube 4 9 8 Place friction disc assembly onto the reaction plate Repeat the sequence of steps 4 9 5 through 4 9 8 until all friction discs reaction plates and release springs are assembled 4 9 9 Noting the location of the water inlets in the mounting flange lift the pressure plate 13 into posi...

Страница 27: ...ORMATION TECHNICAL ASSISTANCE 5 1 Equipment Reference 5 1 1 In any correspondence regarding Airflex equipment refer to the information on the product nameplate and call or write Eaton Corporation Airflex Division 9919 Clinton Rd Cleveland Ohio 44144 Tel 216 281 2211 Fax 216 281 3890 Internet www airflex com Loctite Locquic and Superflex are registered trade marks of Loctite Corporation Polypak is ...

Страница 28: ... tube 13 30 54 Reaction Holes Maximum wear is 0 031 0 80 mm Wear will be in the form of elongation of the holes Original hole diameters are shown on the table below 19 Cylinder Seal Area Maximum radial wear is 0 005 0 13 mm Wear will be in the form of grooves where the seals contact the cylinder wall 34 Spring Spring Free Height Minimum free height shown on the table below Original free height sho...

Страница 29: ... 12 000153X0727 12 18 Locknut 000110X0030 12 000110X0030 12 000110X0030 12 000110X0030 12 19 Cylinder 512693 1 512693 1 512693 1 512693 1 21 Polypak Seal 000402X0021 2 000402X0021 2 000402X0021 2 000402X0021 2 23 Polypak Seal 000402X0022 2 000402X0022 2 000402X0022 2 000402X0022 2 28 Gear not included with assembly 302813 1 302907 1 413208 1 414111 1 29 Wear Spacer N A N A 308388 02 12 308388 02 2...

Страница 30: ...X0073 12 000110X0073 12 000110X0073 12 000110X0073 12 19 Cylinder 513264 1 513264 1 513264 1 513264 1 21 Polypak Seal 000402X0023 2 000402X0023 2 000402X0023 2 000402X0023 2 23 Polypak Seal 000402X0024 2 000402X0024 2 000402X0024 2 000402X0024 2 28 Gear not included with assembly 411672 1 410970 1 412433 1 413195 1 29 Wear Spacer N A N A 308396 12 308396 24 308396 36 30 Reaction Plate Sub Assy Inc...

Страница 31: ... 18 Locknut 000110X0075 16 000110X0075 16 000110X0075 16 000110X0075 16 19 Cylinder 513988 1 513988 1 513988 1 513988 1 21 Polypak Seal 000402X0005 2 000402X0005 2 000402X0005 2 000402X0005 2 23 Polypak Seal 000402X0006 2 000402X0006 2 000402X0006 2 000402X0006 2 28 Gear not included with assembly 416538 1 416536 1 416535 1 416537 1 29 Wear Spacer N A N A 308397 16 308397 32 308397 48 30 Reaction ...

Страница 32: ...00067X0042 16 18 Locknut 000110X0075 16 000110X0075 16 000110X0075 16 000110X0075 16 19 Cylinder 514516 1 514516 1 514516 1 514516 1 21 Polypak Seal 000402X0042 2 000402X0042 2 000402X0042 2 000402X0042 2 23 Polypak Seal 000402X0044 2 000402X0044 2 000402X0044 2 000402X0044 2 28 Gear not included in assembly 416794 1 416795 1 416688 1 416797 1 29 Wear Spacer N A N A 308398 16 308398 32 308398 48 3...

Страница 33: ...0073x0410 1 Outer O ring O N A N A N A N A N A 000073x0411 1 6 1 2 1 Parts Breakdown of WCB2 Mounting Flange Sub assemblies Item Numbers shown in Figure 1 2 21 Model 8 WCB2 Mounting Flange S A 14 WCB2 Mounting Flange S A 18 WCB2 Mounting Flange S A 24 WCB2 Mounting Flange S A 36 WCB2 Mounting Flange S A 48 WCB2 Mounting Flange S A Part Description Part No Qty Part No Qty Part No Qty Part No Qty Pa...

Страница 34: ...6618 5 outer support Ring 51 N A N A 413106 4 413108 5 414033 01 9 416673 10 Hex Head Screw 4a N A N A N A N A N A 000153X0843 120 Inner O ring I N A N A N A N A N A 000073x0410 1 Outer O ring O N A N A N A N A N A 000073x0411 1 6 1 2 4 Parts Breakdown of WCB2 Friction disc Sub assemblies Item Numbers shown in Figure 1 2 Model 8 WCB2 Friction Disc S A 14 WCB2 Friction Disc S A 18 WCB2 Friction Dis...

Страница 35: ...00 03 1 513300 03 1 14 Pressure Plate 512377 1 512377 1 512377 1 17 Flat Washer 000067X0040 6 000067X0040 6 000067X0040 6 18 Locknut 000110X0030 6 000110X0030 6 000110X0030 6 19 Cylinder 512296 1 512296 1 512296 1 21 Polypak Seal 000402X0003 1 000402X0003 1 000402X0003 1 23 Polypak Seal 000402X0004 1 000402X0004 1 000402X0004 1 28 Gear not included with assembly 415454 1 415302 1 416303 1 29 Wear ...

Страница 36: ...12 Clamp Tube 13 Pressure Platesub Assy Item 3 14 14 Pressure Plate 17 Flat Washer 18 Locknut 19 Cylinder 21 Polypak Seal 23 Polypak Seal 28 Gear not included in assembly 29 Wear Spacer 30 Reaction Plate Sub Assy Includes Items 3 31 50 51 31 Reaction Plate 33 Piston 34 Release Spring 50 Inner Support Ring 51 Outer Support Ring 57 Flat Head Screw 105 Pipe Plug Individual parts breakdown for standar...

Страница 37: ...03 1 512508 03 1 14 Pressure Plate 512502 1 512502 1 512502 1 17 Flat Washer 000067X0041 6 000067X0041 6 000067X0041 6 18 Locknut 000110X0024 6 000110X0024 6 000110X0024 6 19 Cylinder 512483 1 512483 1 512483 1 21 Polypak Seal 000402X0001 1 000402X0001 1 000402X0001 1 23 Polypak Seal 000402X0002 1 000402X0002 1 000402X0002 1 28 Gear not included with assembly 415313 1 415314 1 416457 1 29 Wear Spa...

Страница 38: ... Clamp Tube 13 Pressure Platesub Assy Item 3 14 14 Pressure Plate 17 Flat Washer 18 Locknut 19 Cylinder 21 Polypak Seal 23 Polypak Seal 28 Gear not included in assembly 29 Wear Spacer 30 Reaction Plate Sub Assy Includes Items 3 31 50 51 31 Reaction Plate 33 Piston 34 Release Spring 50 Inner Support Ring 51 Outer Support Ring 57 Flat Head Screw 105 Pipe Plug Individual parts breakdown for standard ...

Страница 39: ...AIRFLEX FOR DETAILS 12 Clamp Tube 13 Pressure Platesub Assy Includes Items 3 14 50 51 14 Pressure Plate 17 Flat Washer 18 Locknut 19 Cylinder 21 Polypak Seal 23 Polypak Seal 28 Gear not included in assembly 29 Wear Spacer 30 Reaction Plate Sub Assy Includes Items 3 31 50 51 31 Reaction Plate 33 Piston 34 Release Spring 50 Inner Support Ring 51 Outer Support Ring 57 Flat Head Screw 105 Pipe Plug In...

Страница 40: ...0153x0854 12 18 Locknut 000110x0076 12 19 Cylinder 514039 1 21 Polypak Seal 000402x0023 2 23 Polypak Seal 000402x0024 2 28 Gear not included with assembly 414343 1 29 Wear Spacer 308407 36 30 Reaction Plate Sub Assy Includes Items 3 31 50 51 54 514130 02 3 31 Reaction Plate 514040 3 33 Piston 513924 1 34 Release Spring 416751 02 48 50 Inner Support Ring 413107 24 51 Outer Support Ring 413108 40 54...

Страница 41: ...5 16 000110x0075 16 19 Cylinder 512809 1 512809 1 21 Polypak Seal 000402x0005 2 000402x0005 2 23 Polypak Seal 000402x0006 2 000402x0006 2 28 Gear not included with assembly 416435 1 416495 1 29 Wear Spacer 308400 32 308400 05 48 30 Reaction Plate Sub Assy Includes Items 3 31 50 51 54 513284 02 3 513284 02 4 31 Reaction Plate 512813 3 512813 4 33 Piston 513872 1 513872 1 34 Release Spring 416751 01...

Страница 42: ...cludes Items 3 14 50 51 54 14 Pressure Plate 17 Flat Washer 18 Locknut 19 Cylinder 21 Polypak Seal 23 Polypak Seal 28 Gear not included with assembly 29 Wear Spacer 30 Reaction Plate Sub Assy Includes Items 3 31 50 51 54 31 Reaction Plate 33 Piston 34 Release Spring 50 Inner Support Ring 51 Outer Support Ring 54 Pressure Plate Bushing Reaction Plate Bushing 57 Flat Head Screw 105 Pipe Plug N A 412...

Страница 43: ...ring O N A N A 6 2 2 Sub assemblies Corrosion Resistant 6 2 2 2 Parts Breakdown of WCB2 Pressure Plate Sub assemblies Item Numbers shown in Figure 1 2 21 Model 8 WCB2 Pressure Plate S A 14 WCB2 Pressure Plate S A 18 WCB2 Pressure Plate S A 24 WCB2 Pressure Plate S A 36 WCB2 Pressure Plate S A 48 WCB2 Pressure Plate S A Part Description Part No Qty Part No Qty Part No Qty Part No Qty Part No Qty Pa...

Страница 44: ...Ring 50 413107 3 414032 01 6 outer support Ring 51 413108 5 414033 01 9 Hex Head Screw 4a N A N A Inner O ring I N A N A Outer O ring O N A N A Bushing 54 203866 04 12 203863 03 16 6 2 2 4 Parts Breakdown of WCB2 Friction disc Sub assemblies Item Numbers shown in Figure 1 2 Model 8 WCB2 Friction Disc S A 14 WCB2 Friction Disc S A 18 WCB2 Friction Disc S A 24 WCB2 Friction Disc S A 36 WCB2 Friction...

Страница 45: ...8 14 WCB2 Figure 21 48 WCB2 18 24 36 WCB2 WCB 11070 VP 4 2 Format 44 Copyright Eaton Corp 2003 All rights reserved April 2002 Revised August 2003 ...

Страница 46: ...23 2 000153x1147 192 513657 8 308388 02 36 204097 1 Parts included in kit Loctite 262 Sealant Flat Head Screw 57 Frction Disc 8 Wear Spacer 29 Instruction Sheet 124 107821B 000153x1016 1 000294x0407 36 508725 2 N A 204097 1 224 107821BA 000153x1016 2 000294x0407 72 508725 4 308396 12 204097 1 324 107821BB 000153x1016 3 000294x0407 108 508725 6 308396 24 204097 1 424 107821BC 000153x1016 4 000294x0...

Страница 47: ...6 204130 1 336 107822CB 000153x1168 3 000421x0407 432 513658 48 000153x1182 1 308425 32 204130 1 436 107822CC 000153x1168 4 000421x0407 576 513658 64 000153x1182 4 308425 48 204130 1 148 108058C Contact Airflex for details 248 108058CA 348 108058CB 448 108058CC 7 3Cylinder Seal Kits Parts included in kit Dow Corning R 55 O ring Lube Lip Seal Inner 21 Lip Seal Outer 23 Instruction Sheet Model Kit P...

Страница 48: ...71 3 000153x1223 120 204063 1 416618 10 416673 20 416690 2 7 5 Wear Plate Kits for Reaction Plate Parts included in kit Screw 49 Washer 15 Nut 5 Loctite 596 Instruction Sheet Wear Plate 3 Inner Support Ring 50 Outer Support Ring 51 Model Kit P N Part No QTY Part No QTY Part No QTY Part No QTY Part No QTY Part No QTY Part No QTY Part No QTY 8 107671E 000030x5408 42 000067x0036 42 000153x1049 42 000...

Страница 49: ...ton s plant a repaired or replacement part This warranty does not extend to normal wear parts or components of the Prod uct such as friction material and friction surfaces LIMITATION OF WARRANTY THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN ORAL OR IMPLIED ANY IMPLIED WARRANTY OF MER CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE SPE CIFICALLY EXCLUD...

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