Assembly Instructions
Warning: Standard safety practices must be followed during the procedures described herein. Eye protection is mandatory.
Clean exterior of unit prior to attempting disassembly. Remove unit to clean work area.
1) Lubricate planet bearings (27) and slip into planet gear (28). (fig. 9)
2) Lubricate thrust washers (26), place one washer on each side of the planet gear (28). Place planet gear and thrust washer into planet carrier (20). (fig. 9)
3) Lubricate planet pin (29) and insert into planet pin hole in planet carrier (20) from splined side of carrier. Drive planet pin (29) through thrust washers and planet gear, into opposite planet pin hole in carrier housing. (fig. 5 & 9)
4) Secure planet pin (29) with retaining rings (30) on each end of planet pin. (fig. 9)
5) Repeat steps 1-4 for installation of two remaining planet gears. At this point, carrier assembly is complete
6) Stand output shaft in vice or press and press thrust plug (8) into shaft (7). (fig. 2)
7) Using an appropriate tool, press bearing cups (11) and (15) into the housing. Important Note: Insure cups are square with counterbore before seating.
8) Press bearing cone (10) onto end of output shaft (7) using appropriate tool. Seat bearing cone against shoulder on shaft. Note: If flange shaft unit is being assembled the assembled seal carrier must be in position prior to installing bearing cone (10). (See instructions 20,21,22 for assembly detail)
9) Stand output shaft (7) and assembled cone securely in vice with input spline of shaft up.
10) Stand housing (12) on shaft. Seat bearing cone (10) against bearing cup (11) in housing.
11) Press bearing cone (16) onto end of shaft (7) or heat bearing cone (16) to approximately 180-200° and slip into place. (HECO recommends heating the bearing cone) Seat bearing cone against its cup in housing.
12) Install keyed washer (17) and lock washer (18) on threaded end of shaft. Apply never-seize or similar lubricant on threads and thread lock nut (19) onto shaft. It is important to rotate housing to seat bearings while tightening lock nut until housing resists rotation and end play is minimal (fig. 4 & 6) (250 in-lbs +-15%)
13) Locate tab on lock washer in line with slot on lock nut and bend tab into slot to prevent lock nut from loosening. (fig. 4)
14) Lubricate spline end of shaft (7), lay retaining ring (9) on end of shaft. Slide planet carrier assembly spline onto shaft spline. Reach through the planet carrier and seat retaining ring (9) into groove at end of shaft (7). (fig. 2) This is best accomplished using two long screwdrivers. (fig. 3)
15) Lubricate O-rings (14) Place one O-ring (14) around pilot on bearing housing. Note: Check for sharp edges or burrs on housing pilot.
16) Place internal gear (21) into mesh with planet gears (28) of planet carrier assembly. line up holes in internal gear with holes in housing (12).
17) Place other O-ring (14) on pilot of motor adapter (22). Note: Check for sharp edges or burrs on housing pilot.
18) Place motor adapter pilot into counterbore of internal gear (21). Line up holes in motor adapter with matching holes in internal gear. Insert eight grade 5 cap screws (24) with lock washers, in holes. Tighten to 60-75 ft.lbs. torque. (fig. 1) Note: 2/4C motor adapter requires eight grade 8 studs rather than cap screws. (fig. 1)
19) Turn unit over and stand on motor adapter end.
20) Lubricate backup ring (4), quad ring (5) and O-ring (6). Insert backup ring and quad ring in groove of seal carrier. (fig. 10) Place O-ring (6) on seal carrier pilot. (fig. 8) Note: High pressure seal carrier uses 1 poly seal in place of quad ring and backup ring. (fig. 11) Note: Check for sharp edges or burrs on housing pilot.
21) Press seal (2) into is counterbore in seal carrier. (fig. 10) The open face of the seal should be up. This seal functions as a wiper only and is installed to keep contaminants our of the unit.
22) Lubricate output shaft (7) and shaft seal (2). Place seal carrier (3) with backup ring, quad ring and O-ring installed, over output shaft (7) and carefully slide seal carrier into position. (fig. 8) Line up holes, insert six socket grade 8 head cap screws (1) in holes and tighten to 20-25 ft.lbs. torque. (fig. 7)
23) Tighten pipe plugs (13 & 23) into holes in housing (12) and motor adapter (22) using a thread sealing compound.
24) At this point unit assembly is complete. Note: Before placing unit in service, insure unit is filled with correct amount and grade of gear lubricant. See lubrication instructions of further information.
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