Oerlikon Torque-Hub CW18 Series User manual

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Torque-Hub®Planetary Final Drive
CW18 Series Service Manual
Rev 01/28/14

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While every precaution has been taken in the preparation of this document, Fairfield Manufacturing Co. Inc. assumes no
liability with respect to the use of the documentation described herein, or for any act or omission of Fairfield Manufacturing
Co. Inc. concerning this documentation. Torque-Hub®is a registered trademark of Fairfield Manufacturing Co. Inc.
Features and specifications are subject to change without notice.

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Planetary Final Drive Service Manual
Content
Introduction 4
Brake Test 5
Roll and Leak Test 8
Tightening and Torquing Bolts 11
Lubrication Information 12
Seal Installation Instructions 14
Disassembly Instructions Main Disassembly 18
Cover Disassembly 22
Input Coupling Disassembly 24
Input Brake Disassembly 26
Housing-Spindle Disassembly 28
Output Planet Gear Disassembly 32
Input Carrier Disassembly 33
Assembly Instructions Cover Subassembly 36
Input Carrier Subassembly 38
Output Planet Gear Subassembly 40
Input Coupling Subassembly 41
Housing-Spindle Subassembly 43
Main Assembly 46
Assembly Drawing 51
Parts List 52
Assembly Tools 54
General Information Contact Information 70

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Planetary Final Drive Service Manual
Introduction
This manual is a step-by-step guide to the disassembly and
assembly of the CW18 Torque-Hub®units with ratios of 51:1 or
lower. It is designed for the customer or mechanic who is repairing
this particular Torque-Hub® model.
Users of this manual should note that each part mentioned is
followed by an identification number enclosed in parentheses.
These part numbers may be referred to in the Parts List and
Assembly Drawing sections of this manual.
Specialized tools used to assemble this unit are noted in the
assembly procedures and diagrammed in the Assembly Tools
section.
Users should familiarize themselves with the procedures for roll and
leak testing, as well as bolt tightening and torquing found on the
following three pages before starting any repairs.
Standard safety practices should be followed during the
disassembly and assembly procedures described. Safety glasses
and safety shoes should be worn, and heavy, heat resistant gloves
should be used when handling heated components. Be especially
alert when you see the word CAUTION. This indicates that a
particular operation could cause personal injury if not performed
properly or if certain safety procedures are not followed. The word
NOTE is used to bring attention to certain procedures or helpful
hints that will aid in the disassembly and assembly process.

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Planetary Final Drive Service Manual
Brake Test
The Brake Test To perform a brake check, use a M12x1.5 metric fitting. Install a
hydraulic hand pump with pressure gauge into brake port in spindle
(1A) using metric thread fitting.
Place ROLL TEST Tool (refer to table on page 8) into input
coupling.
Apply 25 in-lbs torque. While trying to rotate tool, pump the handle
on the hydraulic hand pump and increase the pressure until the
brake releases. The brake is released when you are able to rotate
the tool.
Record the release pressure. If the brake does not release within
limits shown in the brake chart on page 6, check to see if it has the
proper number of springs using the SPRING CHECKING
PROCEDURE. Increase to maximum pressure (refer to brake chart
on page 6) and hold at that pressure for one minute. If the brake
does not leak or lose pressure, the unit has passed the brake test. If
the brake loses pressure, attempt to repair the leak using the leak
repair procedure at end of this procedure.
While brake is still released, roll check the unit for one revolution of
the output member by rotating the tool. Bleed off pressure slowly
while rotating the ROLL TEST Tool.
Record the pressure at which the brake locks up. Using a clean rag,
wipe off excess fluid from around the brake port and install the pipe
plug.
Continued on Next Page

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BRAKE CHART
9th DIGIT
IN
MODEL
CODE
(INPUT
BRAKE)
BRAKE
PART
NUMBER
NUMBER
OF
SPRINGS
RELEASE
PRESSURE
MIN (psi)
RELEASE
PRESSURE
MAX (psi)
FULL
RELEASE
PRESSURE
(psi)
MAXIMUM
PRESSURE
(psi)
BRAKE
TORQUE
(in-lbs)
1
AM902446A
11
100
138
145
3000
3754
2
AM902446B
16
144
182
210
3000
5411
3
AM902446C
19
170
214
250
3000
6386
4
AM902446G
13
118
149
171
3000
4422
J
AM902446A
11
102
129
145
3000
3110
K
AM902446B
16
147
184
210
3000
4481
L
AM902446C
19
174
217
250
3000
5288
M
AM902446G
13
120
151
171
3000
3662
A
902315A
6
92
123
130
3000
2940
B
902315B
9
138
184
190
3000
4410
C
902315
11
168
225
230
3000
5390
G
902315C
7
107
143
150
3000
3430
SPRING CHECKING PROCEDURE:
Install input brake bolts into holes in the brake piston. Tighten bolts
in such a way to ensure the brake piston remains straight while
being compressed into the brake cavity of the spindle.
Carefully remove the retaining ring from the spindle. Slowly remove
bolts from the input brake. Remove the cover plate from the end of
the input brake and count the number of springs in brake. If number
of springs matches the number in the BRAKE CHART, go to the
next step. If the number of springs does not match the number in
the BRAKE CHART above, install the correct number of springs.
Continued on Next Page

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Install the Brake Cover Plate using input brake bolts. Tighten
screws in such a way that to ensure the Brake Cover Plate remains
straight while being compressed into the brake cavity of the spindle.
Install the large retaining ring into the groove in spindle (1A),
making sure it is seated properly. Remove all remaining screws
from the brake piston and discard.
NOTE: USE CAUTION WHEN REMOVING SCREWS AS THEY
ARE SUBJECT TO SPRING PRESSURE. MAKE SURE THE
RETAINING RING IS SECURED BEFORE REMOVING BOLTS.
Re-test the input brake. If release and/or lockup pressures still do
not match the brake chart, contact the Oerlikon Fairfield service
department.
BRAKE LEAK REPAIR PROCEDURE:
Install input brake bolts into holes in the Brake Piston. Tighten
screws in such a way to ensure the Brake Cover Plate remains
straight while being compressed into brake cavity of Spindle.
Carefully remove the Retaining Ring from the Spindle. Using two
eyebolts threaded into opposite holes in the Brake Piston, remove
the Brake Piston from the Spindle.
Check O-rings, Backup Rings, and brake cavity in Spindle for
damage. If no damage is found, reinstall the Input Brake according
to the Input Brake Installation Procedure in the assembly
instructions chapter and perform pressure test again. If brake still
leaks, contact the Oerlikon Fairfield service department.
Reference: Sample Model CW18_ _ _ _ X _ _ _ _. The ‘X’ is the
brake option (Model Code). Consult Oerlikon Fairfield for other
brake options.
NOTE: Failure to perform this test may result in damaged or
ineffective brake parts.

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Planetary Final Drive Service Manual
Roll and Leak Test
Torque-Hub®units should always be roll and leak tested before
disassembly (if possible) and after assembly to make sure the unit’s
gears, bearings and seals are working properly. The following
information briefly outlines what to look for when performing these
tests.
The Roll Test The purpose of the roll test is to determine if the unit’s gears are
rotating consistently, easily and properly. It should be able to rotate
the gears in the unit applying constant force to the roll checker. If
more drag is felt in the gears only at certain points, then the gears
are not rolling consistently and easily and should be examined for
improper installation or defects. Some gear packages roll with more
difficulty than others. Do not be concerned if the gears in the unit
seem to roll hard as long as they roll with consistency. Rotate the
gearbox both clockwise and counterclockwise the same number of
turns as the ratio of the unit. The gearbox ratio is the same number
as the last three numbers on the ID tag.
Model Code
Roll Test Tool
CW18Ax1xxx
T184729
CW18Dx1xxx
T184729
CW18Dx2xxx
T180149
CW18Dx4xxx
T180149
CW18Dx8xxx
T180149

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Model Code
Roll Test Tool
CW18Ex1xxx
T184729
CW18Ex2xxx
T180149
CW18Ex4xxx
T180149
CW18Ex7xxx
T201476
CW18Ex8xxx
T205279
The Leak Test The purpose of a leak test is to make sure the unit is airtight.
To perform a leak test, use the leak test fixture from the table on
page 10. If the tool is not available, the gearbox must be sealed to
perform the test. This can be accomplished by assembling the
sealed input device onto the gearbox at the input end and replace
one of the oil plugs with an air chuck. DO NOT EXCEED 10 PSI
PRESSURE DURING THE LEAK TEST. Higher pressure will create
a false sealing effect in assemblies with lip-seals. The unit has a
leak if the pressure gauge reading on your leak check fitting starts
to fall after the gearbox has been pressurized and allowed to
equalize. Leaks will most likely occur at the pipe plugs, the main
seal or wherever o-rings or gaskets are located. The exact location
of a leak can usually be detected by brushing a soap and water
solution around the main seal and where the o-rings or gaskets
meet on the exterior of the unit and then checking for air bubbles. If
a leak is detected in a seal, o-ring or gasket, the part must be
replaced and the unit rechecked. Leak test at 10 psi for 20 minutes.
Continued on Next Page

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Model Code
Leak Test Tool
CW18A11xxAxxx
T182969
CW18A11xxZxxx
T188489
CW18D11xxAxxx
T188489
CW18D12xx4xxx
T181663
CW18D14xxBxxx
T184035
CW18D18xx4xxx
T198122
CW18D21xxAxxx
T188489
CW18E11xxAxxx
T188489
CW18E11xx4xxx
T188489
CW18E12xx4xxx
T181663
CW18E14xxBxxx
T184035
CW18E17xx8xxx
T163056
CW18E18xx4xxx
T198122
CW18E54xxBxxx
T184035

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Planetary Final Drive Service Manual
Tightening and Torquing Bolts
If an air impact wrench is used to tighten bolts, extreme care should
be taken to ensure the bolts are not tightened beyond their specified
torque. The following steps describe how to tighten and torque bolts
or socket head cap screws in a bolt circle.
1. Tighten (but do not torque) bolt “A” until snug.
2. Go to the opposite side of the bolt circle and tighten bolt “B” until
equally snug.
3. Crisscross around the bolt circle and tighten the remaining bolts.
4. Use a torque wrench to apply the specified torque to bolt “A.”
5. Using the same sequence, crisscross around the bolt circle and
apply an equal torque to the remaining bolts.

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Planetary Final Drive Service Manual
Lubrication Information
General Properties The lubricant used in most Torque-Hub®drives should be
petroleum-based gear fluid containing anti-oxidation, anti-foaming
and extreme pressure additives. The lubricant should have a
minimum viscosity index of 95 cst and maintain a minimum viscosity
of 40 cst under normal operating conditions. Some applications
require special considerations; consult the machine manufacturer
and Oerlikon Fairfield for more additional information.
The table below lists the recommended viscosities for various
ambient operating temperatures. These recommendations are
based on temperature rise of 50° to 100°F at normal operating
conditions.
Continued on Next Page
Differential Planetary Simple Planetary
Ambient
Temperature
ISO Index
AGMA
Lubricant
Number
ISO Index
AGMA
Lubricant
Number
-40° to -5° F(1)
VG100
3EP
VG100
3EP
-5°to 40° F
VG150
4EP
VG100
3EP
40° to105° F
VG220/VG320
5EP/6EP
VG150/VG220
4EP/5EP
105° to 150° F(2)
VG460
7EP
VG320
6EP
Footnotes
1. For operation in this ambient temperature range, synthetic oil is recommended with a pour point of
10°F lower than the minimum ambient temperature.
2. For operation in this ambient temperature range, synthetic oil is recommended for proper lubricant
life at elevated temperatures.

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Maintenance Oil amounts for each series of Torque-Hub®drives are indicated in
the appropriate series literature. An initial oil change should be
made after the first 50 hours of operation. Subsequent oil changes
should be made at 1,000 hour intervals or annually, whichever
comes first.
Oil temperatures should be not higher than 160° to 180°F for
continuous operation, and no higher than 200°F for intermittent
operation. For special applications, high horsepower, high speeds
or wide temperature changes, please consult Oerlikon Fairfield.
Oil Fill Level When the Torque-Hub®unit is mounted horizontally, unless
otherwise specified, the gearbox should be filled half-full of oil.
Consult the appropriate series literature for approximate fill
volumes. Vertically mounted Torque-Hub®units may require special
lubrication procedures. Please contact Oerlikon Fairfield for
vertically mounted applications.

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Planetary Final Drive Service Manual
Seal Installation
The seal installation tool can be purchased from MORCOR LTD at
[e-mail] part number MGT045.
To begin the procedure, all of the sealing components; Seal Rings
(metal rings); O-Rings and the housings must be clean and free of
Oil, Grease, Dirt or Dust. Always check to make sure that there are
no nicks or burrs in the housing area that could damage the Load
Ring during installation. The use of DENATURED ALCOHOL (also
known as Wood Alcohol or Shellac Thinner) and a lint free cloth is
recommended for cleaning all of these areas. NOTE: Follow all
Material Safety Data Sheet guidelines.
After all components have been wiped clean and have dried, the O-
Rings should be placed back on the Seal Rings in their proper
position. The O-Rings must be seated completely and tightly on the
Seal Ring. Always make sure that the O-rings are not twisted or
distorted by inspecting the mold flash (seam) on the outside
diameter to see that is running “true” with the circumference.
Eliminate O-Ring twist by gently pulling a section of the O Ring (2)
rapidly away from the Seal Ring (1) and letting it “snap” back.
Warning: Do not place the Seal Rings face down on any hard or
abrasive surface to accomplish this! Once the O-Rings are back on
the Seal Rings, quickly swab out the housing with a clean lint free
cloth generously soaked it with Denatured Alcohol. This is to
temporarily lubricate the bore. Then, with the same cloth, quickly
swab the outside (O- Ring area) of the seal half to temporarily
lubricate the O-Ring.
Continued on Next Page

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With all surfaces of the O Ring (2) wet with alcohol use the
Installation Tool (9) to position the Seal Ring (1) and the O-Ring (2)
squarely against the Housing (5) as shown. Use sudden and even
pressure to pop (push) the Toric Ring under the Retaining Lip (3) of
the housing.
NOTE: It is important for the O-ring as well as the housing bore to
be wet with Alcohol during this process. Visually inspect the
positioning of the O-Ring and Seal Ring relative to each other, as
well as relative to the housing. Always make sure that everything is
seated symmetrically.NOTE: Misaligned seals and improperly
seated O-Rings can cause leakage or premature failure.
If small adjustments are necessary; do not push directly on the Seal
Ring (1) use the Installation tool (9) to push down or use the
Adjustment Tool (11) to pull up. NOTE: Never use sharp
instruments such as screwdrivers. They can cause permanent
damage to the O-Ring and/or Seal Ring, which may lead to rapid
failure. For twists or obvious bulges in the O-Ring or if the Seal Ring
is "riding up" on the O-Ring and cannot be adjusted, always remove
the seal half and repeat the procedure, beginning with the cleaning
process.
Continued on Next Page

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After a successful installation always wait a few minutes for the
Alcohol to completely evaporate, before assembling. The Alcohol is
necessary as a lubricant during the installation process, but for
assembly the area must be clean and dry in order for the O- Ring to
properly "crush" into its final position. After the two seal halves have
been installed in their respective housings and just prior to
assembly, the faces should be thoroughly cleaned with Denatured
Alcohol. Next, apply a thin film of oil (EP90 the same oil that will be
used to fill the assembly) to the faces of the Seal Rings with a clean
lint free cloth. Warning: Be careful not to get oil on the O- Rings!
The seal set is now ready to be drawn together in the assembled
unit.
Check the assembled height (A) in a least four places spaced 90°
apart.

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DISASSEMBLY

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Planetary Final Drive Service Manual
Main Disassembly
Continued on Next Page

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1. Perform a roll check and a leak check prior to disassembling the unit.
2. Remove the three magnetic Pipe Plugs (1U/14) and drain the oil out of the gearbox.
NOTE: Record the condition and volume of the oil.
3. Remove Bolts (27/13) from the Cover Subassembly.
4. Lift the Cover Subassembly off of the unit.
Continued on Next Page

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5. Remove the Input Shaft (7) if applicable.
6. Lift out the Input Carrier Subassembly from Hub-Spindle Subassembly.
7. Remove the Second Stage Sun Gear (12).
8. Lift the Ring Gear (4/6) off of the Housing Spindle Subassembly.
9. Remove the O-ring (5) from between the Housing (1G) and the Ring Gear (4/6).
CAUTION: Safety glasses must be worn during these next steps.
10. Remove the four External Retaining Rings (3C) that are holding the spindle Planet Gears
(3A) in place.
11. Carefully pry the Planet Gears (3A) off of the spindle posts. Be careful to not damage the
Thrust Spacer (2).
12. Remove Thrust Spacer (2) from Housing Spindle Subassembly.
NOTE: Skip steps 13, 14 and 15 if unit does not have Adaptor Mount (24).
Continued on Next Page