C014 Assembly/Disassembly Manual

TABLE OF CONTENTS
Introduction ......................................................................................................................3
Roll, Leak and Brake Test................................................................................................4
Tightening and Torquing Bolts .........................................................................................5
Main Disassembly............................................................................................................6
Hub Disassembly ...........................................................................................................11
Input Carrier Disassembly..............................................................................................12
Input Carrier Sub-Assembly ...........................................................................................13
Hub Sub-Assembly ........................................................................................................14
Main Assembly...............................................................................................................15
Assembly Drawings .......................................................................................................19
Parts List ........................................................................................................................20

Fairfield Manufacturing Company, Inc.

P.O. Box 7940
U.S. 52 South
Lafayette, Indiana 47903
Phone 765-772-4000 Fax 765-772-4001
www.fairfieldmfg.com

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 INTRODUCTION

This manual is a step-by-step guide to assembly and disassembly of the C014 Torque-Hub unit.
It is designed for the customer or shop mechanic who is repairing this particular model of Torque-
Hub.

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 section of this
manual and on the illustrated parts breakdown of this unit.

Any specialized tools normally used to assemble this unit are noted in the assembly procedures
and diagrammed in the tooling section.

Users should familiarize themselves with the procedures for roll and leak testing and bolt
tightening and torquing found on the following two pages before getting started.

Standard safety practices should be followed during the disassembly and assembly procedures
described. Safety glasses and safety shoes should be worn. 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 the user of certain procedures or helpful hints that will aid in the disassembly
and assembly steps.

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 ROLL, LEAK AND BRAKE TESTING

Torque-Hub units should always be roll and leak tested before disassembly and after assembly to
make sure that the unit's gears, bearings and seals are working properly. The following
information briefly outlines what to look for when performing these tests.

NOTE: The brake must be released before performing the roll test. This can be accomplished by
pressurizing the brake using the Brake Leak Test procedure below.

THE ROLL TEST

The purpose of the roll test is to determine if the unit's gears are rotating freely and properly. You
should be able to rotate the gears in your unit by applying constant torque to the gearbox input. If
you feel more drag in the gears only at certain points, then the gears are not rolling freely 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 your unit seem to roll hard as long as
they roll with consistency.

THE LEAK TEST (MAIN UNIT)

The purpose of a leak test is to make sure the unit is airtight. You can tell if your unit has a leak if
the pressure gauge reading on your leak-checking fitting starts to fall after the unit 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, 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.

THE BRAKE TEST

Input Brake

Static Torque: 5000 in-lbs (565 Nm)

Full Release Pressure: 265 psi (18.2 bar)
Maximum Pressure: 1500 psi (103 bar)

If brake does not release at the full release pressure, brake has to be inspected, repaired or
replaced.

CAUTION: When applying release pressure, make sure that 4 motor mounting bolts are installed
to provide extra bolt clamp. If applying a release pressure near the maximum use the hydraulic
motor or something with a SAE “C” pilot to help stabilize the mounting adapter.

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 TIGHTENING AND TORQUING BOLTS
If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that 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 remaining bolts.

4. Now 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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 C014 MAIN DISASSEMBLY

1. Perform Roll Check, Leak Check and Brake Check if applicable prior to disassembling the
unit.

2. Drain oil from unit. Note the condition and volume of the oil.

3. Place the Torque-Hub on a bench with the cover side down.

4. Remove the Mounting Adapter (12) by removing the 4 Countersunk Bolts (14)

NOTE: The spring force from the brake will force the Mounting Adapter (12) out. Gradually
loosen each bolt so that the Mounting Adapter remains aligned during disassembly.

5. Remove Thrust Washer (13) from the Mounting Adapter (12) counterbore or from the end of
the Coupling (11).

6. Remove the O’ring (10A) from the Mounting Adapter (12)

7. Remove the Coupling (11).

8. Remove Retaining Ring (21) from the Coupling (11) bore.

9. Remove the Belleville Spring (10B) from the back of the Piston (10C)

10. Slowly and carefully add light air pressure to the brake port of the Spindle (1A) until the Brake
Piston (10C) is forced out of the spindle bore. Remove the Piston.

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11. Remove the O’ring (10A) and Back-up Ring (10D) from the Piston (10C) groove.

12. Remove the Brake Friction Plate Stack (10E) from the Spindle (1A)

NOTE: Try to keep the friction plates in the same order by removing them all together and
then banding them together until re-assembly.

13. Remove the Brake Retaining Ring (10H), O’ring (10G) and Backup Ring (10F) from the
Spindle (1A) bore.

14. Remove the Input Shaft (9).

15. Turn over the Torque Hub so that the Cover is up.

16. Remove the Cover Retaining Ring (4) by prying the open end of the retaining ring out of the
groove with a screwdriver, then grasp the loose end with pliers and pull the retaining ring
completely out of the groove.

17. Remove the Cover (2) from the unit. This can be done by pulling the cover with a tool that
attaches to the drain plug holes or by using a long metal rod to tap it out from the other side.

NOTE: Be careful not to lose the Cover Thrust Washer (3) when removing the cover.

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18. Remove the O’ring (5) from the cover.

19. Remove the Input Sun Gear (6).

20. Remove the Input Carrier sub-assembly.

21. Remove 15 bolts (1P) that fasten the Bearing Carrier (1M) to the Hub/Spindle Sub-Assembly

NOTE: Heat may need to be applied to loosen the Loctite applied during assembly.

22. Before removing mark each Output Planet Shaft (1N) and planet shaft hole of the Hub/Spindle
sub-assembly so that the shaft can be reassembled into the same hole.

23. Using the tapped hole remove each Output Planet Shaft (1N). Do not lose the half-moon
shims (1K) that are on the back of the planet shaft. Keep each shim set with its respective
Output Planet Shaft.

24. Using a soft metal rod, tap the Main Bearing Cone (1C) from the Bearing Carrier (1M)

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25. Push the 3 Output Planet Sub-Assemblies towards the center of the Hub/Spindle Sub-
Assembly

26. Pull the Hub Sub-Assembly off of the spindle.

NOTE: This may require a hoist to break the seal (1B) loose.

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27. Slide each Output Planet Sub-Assembly out of the of the spindle window. Place each sub-
assembly with its respective Planet Shaft (1N) and Shim Set (1K) so that they are matched for
re-assembly.

28. Remove Output Planet Bearing Cones (1R).

29. Use a soft steel rod to tap out the Output Planet Bearing Cups (1Q).

30. Remove the Cup Spacer (1J) and Retaining Ring (1L).

31. Repeat for the other two Output Planet Sub-Assemblies.

32. Using a means of prying, remove the Main Bearing Cone (1C) from the Spindle.

This completes the Main Disassembly section of this manual.

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 C014 HUB DISASSEMBLY

1. Remove the Main Seal (1B).

NOTE: The main seal should not be reused when reassembling the unit.

2. Using a soft steel rod and a hammer, tap out the Main Bearing Cups (1C).

3. Use vice-grips to remove the 10 double-threaded wheel studs (22).

NOTE: Heat may need to be applied to loosen the Loctite applied during assembly.

This completes the Hub Disassembly.

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 C014 INPUT CARRIER DISASSEMBLY

1. Using a punch, drive the Roll Pin (8E) into the Planet Shaft (8D).

2. Slide the Planet Shaft (8D) from the Carrier (8A).

3. Using a punch, remove the Roll Pin (8E) from the Planet Shaft (8D).

NOTE: The used roll pins should be replaced during re-assembly.

4. Slide out the Planet Gear (8F) from the Carrier (1A). Remove the 16 Needle Rollers (8C)
from the Planet Gear Bore.

5. Remove the two Thrust Washers (8B) from the Carrier (8A).

6. Repeat steps 1-5 for the other two Planet Gears.

7. Remove Retaining Ring (15).

8. Remove Output Sun Gear (7) from the Carrier.

This completes the Input Carrier Disassembly.

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 C014 INPUT CARRIER SUB-ASSEMBLY

(Refer to the Exploded View on Page 12.)

1. Install Output Sun Gear (7) into the spline of the Carrier (8A).

2. Install Retaining Ring (15) into the groove in the Output Sun Gear (7) on the other end of the
Carrier (8A).

3. Apply a liberal coat of grease to the bore of one Input Planet Gear (8F).

4. Line the inside of the Planet Gear (8F) with 16 Needle Rollers (8C).

NOTE: The last roller installed must be installed end wise. That is, the end of the last roller
must be placed in between the ends of the two rollers, which form the space, and then slid,
parallel to the other rollers, into place.

5. Apply a coat of grease to two Thrust Washers (8B). Place the Thrust Washers against the
sides of the Carrier (8A) internal walls so that the Thrust Washer tang sits in the groove in the
carrier and the Thrust Washer bore lines up with the Planet Shaft bores of the Carrier.

6. Carefully slide the Planet Gear (8F) with the Needle Rollers (8C) between the Thrust
Washers (8B) in the Carrier (8A).

7. Slide the Planet Shaft (8D) into the Planet Shaft bore of the Carrier and through the Thrust
Washer (8B) and Planet Gear (8F) bores. Install the Planet Shaft so that the roll pin hole
lines up with the corresponding hole in the carrier.

8. Using a small rod, line up the roll pin hole in the Carrier (8A) with the roll pin hole in the Planet
Shaft (8D).

9. Drive a Roll Pin (8E) into the roll pin hole of the Carrier (8A) until it is flush with the outside of
the Carrier.

NOTE: Be sure not to hit the Planet Gears (8F) when driving in the Roll Pins (8E).

10. Repeat steps 3-10 for the other two Planet Gears (8F).

The Input Carrier Sub-Assembly is now complete.

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 C014 HUB SUB-ASSEMBLY
(Refer to the Exploded View on Page 11)

1. Set the Hub (1G) on a bench with the retaining ring groove up.

2. Press in the Main Bearing Cup (1C) with a tool similar to T-179926.

3. Turn over the Hub (1G) and press in the other Main Bearing Cup (1C) in the same manner.

4. Spread a thin layer of RTV sealant to seal bore of the Hub (1G).

5. Press the Main Seal (1B) into the Hub (1G) with a tool similar to T-172388.

NOTE: Take extra precautions to ensure that the hub is aligned during assembly, failure to
align the seal may cause an oil leak.

6. Apply Loctite 272 to the shorter length threads of the 10 Double-Threaded Studs (22).

7. Use a stud driver to install the 10 Double-Threaded Studs into the Hub (1G)

The Hub Sub-Assembly is now complete.

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 C014 MAIN ASSEMBLY
(Refer to the Exploded View on Pages 6-9)

1. Set the Spindle (1A) on the bench with the flange down.

2. Tap the Main Bearing Cone (1C) onto the Spindle (1A) until it is about ¼” below the planet
gear windows.

3. Install snap ring (1L) into an Output Planet Gear (1H).

4. Put the Spacer (1J) into the bore of the Output Planet Gear (1H). Take note of where the
numbers are stamped on the Output Planet Gear and make sure that the Spacer is on that
side of Retaining Ring (1L).

5. Press in the Output Planet Bearing Cup (1Q) so that it is fully seated against the Spacer (1J).
Use a tool similar to T-210515

6. Turn over the Output Planet Gear (1H) and press in an Output Planet Bearing Cup (1Q) in the
same manner.

7. Place an Output Planet Bearing Cone (1R) into each end of the Output Planet Gear and slide
the sub-assembly into one of the planet gear windows in the Spindle (1A).

8. Repeat steps 3-7 for the other two Output Planet Gears.

9. Push the Output Planet Gear Sub-Assemblies into the center of the spindle as far as they will
go.

10. Place Bearing Carrier (1M) on the bench with the counter bored holes facing down.

11. Press the Main Bearing Cone (1C) onto the Bearing Carrier using a tool similar to T-176703

12. Apply a film of P-80 THIX lubricant to the ID of the Main Seal (1B) that is in the Hub Sub-
Assembly.

NOTE: Proceed to the next step immediately, P-80 will dry after only a few minutes.

NOTE: P-80 is a Rubber Lubricant that is manufactured by International Products

Corporation. It should be available for purchase at an industrial supply center.

11. Making sure that the studs are pointed up, very carefully lower the Hub Sub-Assembly over
the Spindle until the Main Bearing Cup (1C) starts to contact its respective Bearing Cone.

12. Place the Bearing Carrier (1M) with the Bearing Cone (1C) onto the top of the Spindle (1A) to
help keep the Hub Sub-Assembly aligned to the Spindle.

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13. Press the Hub Sub-Assembly onto the Spindle (1A) by pressing down on the Bearing Carrier.
(1M). An arbor press or hydraulic press (as long as the pressure is very low) maybe used to
press down on the bearing carrier.

NOTE: Take extreme caution to ensure that the Hub Sub-Assembly is being pressed squarely
onto the Spindle.

14. Remove the Bearing Carrier (1M) and set aside.

15. Using a long metal rod, reach through the area between the Output Planet Sub-Assemblies
and tap the front of the Main Bearing Cone (1C) on the spindle to ensure that it is fully seated
against its shoulder.

NOTE: Do not strike the bearing roller cage with the metal rod.

16. Line up the bore of Output Planet Sub-Assembly with the planet shaft hole in the Spindle (1A).
Insert a Planet Shaft (1N) so that the tapped holes are clocked towards the center of the
Spindle.

17. Tap the back of the Planet Shaft (1H) to make sure it is seated all the way down.

NOTE: If the Output Planet Sub-Assemblies were properly marked and none of the parts
were replaced and they are assembled into the same planet shaft hole, the following to two
steps can be skipped.

18. Use a depth micrometer to gage the amount that the Planet Shaft (1H) face is recessed below
the Spindle (1A).

19. Stack the Half Moon Shims (1K) to the thickness measured in the previous step plus .002”.

20. Place the shim stack (1K) onto the back of the Planet Shaft (1H)

21. Repeat steps 16-20 for the other two Output Planet Gear Sub-Assemblies.

22. Apply a heavy film of assembly oil to the Main Bearing Cones (1C) both on the Spindle (1A)
and on the Bearing Carrier (1M).

23. Install the Bearing Carrier (1M) onto the top of the Spindle (1A).

24. Apply Loctite 272 to the threads of the 15 Bearing Carrier Bolts (1P).

25. Install the Bearing carrier bolts (1P); tighten to a torque of 40-45 ft-lbs.

26. Install the Carrier Sub-Assembly into the Hub/Spindle Sub-Assembly.

27. Install the Input Sun Gear (6) into mesh in the center of the Input Carrier Sub-Assembly.

28. Apply a coat of grease to the Cover Thrust Washer (3) and place the Thrust Washer into the
counterbore in the Cover (2).

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29. Apply a coat of grease to the Cover O’ring (5) and place it into the O’ring groove on the
outside diameter of the Cover (2).

30. Place Cover (2) into the end of the Hub/Spindle Sub-Assembly. A rubber mallet may be used
to help push the Cover O’ring (5) onto its surface

NOTE: Try to keep the cover aligned to avoid cutting the o’ring on the retaining ring groove.

31. Install the Cover Retaining Ring (4) into the retaining ring groove of the Hub/Spindle Sub-
Assembly.

32. If the Drain Plugs (16 & 25) or ID Tag (17) are not installed in the cover, do so at this time.

33. Turn over the Torque Hub Unit.

34. Install the Brake Retaining Ring (10H) into the bore of the Spindle (1A)

35. Install the Brake O’ring (10F) and Back-up Ring (10G) into the groove in the Spindle (1A) so
that the O’ring is on top of the Back-up Ring.

36. Install the Input Shaft (9) so that the smaller diameter splines engage the Input Sun Gear (6).

37. Install the Coupling Retaining Ring (21) into the groove in the bore of the Coupling (11).

38. Install the Coupling (11) onto the end of the Input Shaft (9) such that the end with the external
splines is down.

39. Stack the Friction Plates (10E) so that the stators splines engage the Spindle Splines (1A)
and the rotor Splines engage the Coupling (11) splines.

NOTE: The friction plates must be stacked in the same way they were when removed. Stack
4 stators, then a rotor, and then a stator and keep alternating until all the rotors are used.
Then install the remaining two stators.

NOTE: The stator plates have 3 missing spline teeth. Line these teeth up with 3 cross holes
that are drilled in the Spindle (1A).

40. Place the Piston O’ring (10A) and Back-up Ring (10D) onto the Brake Piston (10C) so that the
O’ring is on the same side as the nose of the Piston.

41. Apply a layer of grease to the Piston O’ring (10A) and Back-up Ring (10D) as well as the
Brake O’ring (10F) and Back-up Ring (10G) in the Spindle (1A).

42. Install the Brake Piston (10C) into the bore of the Spindle (1A) a rubber mallet may be used to
help force the Piston into the bore.

43. Place the Belleville Spring (10B) into the counterbore in the back of the Brake Piston (10C) so
that the high side of the Belleville Spring is at the ID.

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44. Apply a layer a grease to Mounting Adapter O’ring (10A) and install into the groove in the
Mounting Adapter (12).

45. Apply a layer of grease to the Thrust Washer (13) and install into the counterbore of the
Mounting Adapter (12)

46. Install the Mounting Adapter (12) into the end of the Spindle (1A).

47. Fasten the Mounting Adapter (12) to the Spindle (1A) with the four Countersunk Bolts (14).

NOTE: Gradually tighten the Countersunk bolts so that there is even pressure on the
Belleville spring.

48. Tighten the Countersunk Bolts (14) to 12 ft-lbs

49. Install Brake Pressure Plug (23) into the brake port if not already installed.

50. Perform Roll Check, Leak Check, and Brake Check to help ensure proper assembly.

51. Fill the unit half full with oil.

Assembly is now complete

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ASSEMBLY DRAWING – C014

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 PARTS LIST

ITEM QTY DESCRIPTION

9 1 INPUT SHAFT
11 1 COUPLING
6 1 INPUT SUN GEAR
7 1 OUTPUT SUN GEAR
8D 3 INPUT PLANET SHAFT
8A 1 INPUT CARRIER
8F 3 INPUT PLANET GEAR
1H 3 OUTPUT PLANET GEAR
1N 3 OUTPUT PLANET SHAFT
1A 1 SPINDLE
1M 1 BEARING CARRIER
12 1 MOUNTING ADAPTER
2 1 COVER
1G 1 HUB
3 1 COVER THRUST WASHER
8C 48 NEEDLE ROLLER
1C 2 MAIN BEARING ASSEMBLY
1Q 6 OUTPUT PLANET BEARING CUP
1R 6 OUTPUT PLANET BEARING CONE
1K 3 SHIM KIT
1J 3 OUTPUT PLANET CUP SPACER
17 1 ID PLATE
1B 1 MAIN SEAL
10 1 INPUT BRAKE KIT
1L 3 OUTPUT PLANET RETAINING RING
15 1 INPUT CARRIER RETAINING RING
21 1 COUPLING RETAINING RING
4 1 COVER RETAINING RING
8E 3 ROLL PIN
18 2 DRIVE SCREW
1P 15 BEARING CARRIER BOLTS
14 4 COUNTERSUNK BOLTS
5 1 COVER O'RING
23 1 PRESSURE PLUG
16 1 DRAIN PLUG
25 1 DRAIN PLUG
13 1 MOUNTING ADAPTER THRUST WASHER
8B 6 INPUT PLANET THRUST WASHER
22 10 DOUBLE-THREADED STUD

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Fairfield Manufacturing Company, Inc.
P.O. Box 7940
U.S. 52 South
Lafayette, Indiana 47903
Phone 765-772-4000 Fax 765-772-4001
www.fairfieldmfg.com

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