Assembly Procedure

Maintenance

Assembly Procedure

Assembly Procedure

Set-Up and Preparation

  1. 1.
    Lift the machined housing and position it in the rotary head working stand (Figure 1, item A) with the cover pointing upward.
    Figure 1
  2. 2.
    Remove the cover (Figure 1, item B), clean, and put aside in a clean area.
  3. 3.
    Turn the housing on its side using a strap and a hoist as shown. Use compressed air (Figure 2, item A) to remove contaminants and clean inside of the housing (item B) with paint prep thinner (S910).
    Figure 2
  4. 4.
    Use a strap to rotate the housing upside down to prepare for the installation of the spindle.

    NOTICE

    Component Damage

    Heating or freezing more than the specified limit can cause damage to the component.

    1. Do not heat the bearing cones hotter than 149 °C (300 °F ) unless it is specified.

    2. Do not freeze the bearing cups colder than -30 °C (-20 °F).

  5. 5.
    Heat the lower spindle bearing cone on an induction heater (or oil bath) to between 121 °C and 135 °C (250 °F and 275 °F).
  6. 6.
    While the bearing cone (Figure 3, item B) is heating in the induction heater (item A), begin freezing the lower spindle bearing cup (item C) to between -18 °C and -23°C (0 °F and -10 °F). Additionally, begin freezing the upper spindle bearing cup and both lower intermediate shaft bearing cups to the same temperature.
    Figure 3
  7. 7.
    Make sure of correct thread match between the bearing adjusting nut (Figure 4, item A) and the spindle (item B).
    Figure 4
  8. 8.
    Move the spindle cap to the bottom of the threads to confirm that there is no damage to the threads on the spindle.

    NOTE

    The threads on the spindle cap are left-handed.

Shrink Fit the Spindle Bearing Cone

WARNING

Burn Hazard

Hot components can cause serious injury.

  1. Use approved safety gloves when handling hot components.

  1. 1.
    Remove the hot spindle bearing cone (Figure 1, item B) from the induction heater with safety gloves (item A). Lower the spindle bearing cone carefully over the spindle (item C) until it rests against the spindle shoulder.
    Figure 1
  2. 2.
    Let the bearing cone cool and shrink-fit onto the spindle. Once cooled, apply a layer of Ronex-HD grease to the bearing cone.
  3. 3.
    Carefully press both oil seals into the lower spindle retainer. The seals must be correctly oriented.

    NOTE

    The oil seal has a two lip seal design. The primary seal lip is for oil retention, and the secondary lip is for preventing contamination from reaching the primary seal lip. The primary lips on both oil seals must be towards the inside of the rotary housing.

  4. 4.
    Make sure that the spindle retainer (Figure 2, item B) is flipped over to place it on the housing. Apply a layer of Ronex-HD grease to the seal lips and in between the oil seals (item A).
    Figure 2

Expansion Fit the Lower Housing Bearing Cup

  1. 1.
    Remove the bearing cup (Figure 1, item A) from the freezer and press the frozen lower spindle bearing cup into the housing. Make sure that the bearing cup is seated tightly against the mounting surface in the housing.
    Figure 1
  2. 2.
    After correct seating, let the bearing cup warm to ambient temperature. Apply a thin layer of Ronex-HD grease to the bearing cup running surface.
  3. 3.
    Carefully flip the spindle (Figure 2, item A) with the bearing cone sub-assembly as shown.
    Figure 2
  4. 4.
    Attach the spindle to the hoist with a lifting chain. Lower the spindle slowly into the rotary head housing until the bearing cone rests against its mounting cup race (item B).
  5. 5.
    Heat the oil seal wear sleeve (Figure 3, item A) to between 177 °C and 191 °C (350 °F and 375 °F ).

    NOTE

    Oil seal wear sleeve heats quickly, rotate it for even expansion to eliminate binding when it is installed.

  6. 6.
    Use approved safety gloves and put the wear sleeve (item A) over the spindle and seat it firmly on the shoulder of the spindle.

    NOTE

    Make sure that the wear sleeve is seated evenly.

    Figure 3
  7. 7.
    Heat the output gear (Figure 4, item A) to between 107 °C and 121 °C (225 °F and 250 °F). When correct temperature is reached, refer to Shrink Fit the Output Gear to install the output gear.
  8. 8.
    After the output gear is installed, start heating the both intermediate gears to between 149°C and 163°C (300°F and 325°F) in preparation for building up the intermediate shaft sub-assemblies needed soon after the output gear is installed.
    Figure 4
  9. 9.
    Lubricate the O-ring (Figure 5, item A) and position on the mounting shoulder of the lower spindle retainer (item B).
  10. 10.
    Put the lower spindle retainer around the spindle. Do not to damage the seal lips Tighten the lower spindle retainer in position.
  11. 11.
    Install the plug into dedicated place in the side of the lower spindle retainer.
    Figure 5
  12. 12.
    Before rotating housing to the upright position, install the bottom and side housing plugs (Figure 6, item B), sight glass (item A), and strainer into their dedicated places in the housing.
    Figure 6

    WARNING

    Component damage

    Rotating the rotary head housing can cause damage to the components.

    1. Make sure that the pillow blocks are used with rotary head stand.

    2. Make sure that there is enough space when rotating the rotary head housing.

  13. 13.
    Use a strap and the hoist to rotate the housing (Figure 7, item A) carefully to the upright position.
  14. 14.
    Use a round plate and a small bottle jack (item C) (or scissor jack with a piece of wood) to support the spindle (item B) from the bottom so that both the lower spindle bearing cup and cone are pressed tightly together.

    NOTE

    The spindle must be supported tightly to make sure that correct placement of the output gear and to start the critical pre-loading of the spindle bearings explained later in this document.

    Figure 7
  15. 15.
    Insert key (Figure 8, item A) into the keyway of the spindle (item B). Retrieve both frozen lower intermediate bearing cups (item C) and quickly insert them into the housing.
  16. 16.
    Use a steel hammer and a brass drift to make sure that the bearing cups are seated tightly against the mounting surfaces in the housing (Do not to strike the bearing surface).
    Figure 8
  17. 17.
    After correct seating, let the bearing cups warm to ambient temperature. Apply a thin layer of clean grease to both bearing cup running surfaces.

Shrink the Fit Output Gear

  1. 1.
    Remove the hot output gear from the induction heater with the shackle.
  2. 2.
    Slide the output gear (Figure 1, item A) over the spindle with the keyway flush using protective gloves as shown.

    NOTE

    Make sure that the output gear is seated correctly on the shoulder of the spindle and the retaining collar grove is fully visible.

  3. 3.
    Put the retaining collar (item B) around the spindle to keep the output gear in place.
    Figure 1
  4. 4.
    Secure the retainer collar with bolts and elastic stop nuts. Use a hammer and small tipped drift pin to stake the bolt threads as close as possible to the nuts.
  5. 5.
    Let the output gear cool.

Shrink Fit the Intermediate Upper Bearing Cone and the Gear Assembly

WARNING

Burn Hazard

Hot components can cause serious injury.

  1. Use approved safety gloves when handling hot components.

  1. 1.
    Heat the two lower intermediate bearings cones (Figure 1, item A) to between 135 °C and 149 °C (275 °F and 300 °F) on the induction heater (item B).

    NOTE

    Do not let the bearing cones or gears to soak at temperatures above 149°C (300°F) for extended periods of time.

  2. 2.
    Use safety gloves and slide the heated lower intermediate bearing cone over the end until it rests against the shoulder of intermediate shaft (item C). Repeat for the other intermediate shaft.
    Figure 1
  3. 3.
    Put the keys in keyways of the intermediate shafts. Use safety gloves and slide the each hot output gear (Figure 2, item A) carefully over the intermediate shaft until they rest on the shoulders.
  4. 4.
    Make sure that the keys (item B) are correctly installed into the slots and flush with gear.
    Figure 2

Shrink Fit the Spacers and the Lower Intermediate Bearing Cones

WARNING

Burn Hazard

Hot components can cause serious injury.

  1. Use approved safety gloves when handling hot components.

  1. 1.
    Heat the spacers to between 163 °C and 177 °C (325 °F and 350 °F).
  2. 2.
    Put the spacers (Figure 1, item A) onto the intermediate shafts. Let the spacers to rest against the top of the intermediate gears.
  3. 3.
    Let the spacers shrink-fit onto the intermediate shafts.
  4. 4.
    Heat the lower intermediate shaft bearing cones to between 135 °C and 149 °C (275 °F and 300 °F). Slide each intermediate shaft bearing cone over the end of its respective intermediate shaft, until it rests against the shoulder of the spacer.
    Figure 1
  5. 5.
    Insert the oil seal (Figure 2, item A) into the spacer. Pay close attention to proper orientation. The primary lips on the oil seals must be toward the inside the space.
    Figure 2
  6. 6.
    Attach the intermediate shaft subassembly (Figure 3, item A) to the hoist with the lift chains. Lower the intermediate shaft subassembly carefully down into the pre-greased lower intermediate bearing cup (item B). Repeat for the other subassembly.
    Figure 3
  7. 7.
    Install the upper and the lower ball bearings (Figure 4, items B and D) onto the input pinions (item C) with a hydraulic press (item A).
    Figure 4
  8. 8.
    In the lower end of one input pinion shaft subassembly (Figure 5, item A), install a drive key (item A) followed by a snap ring to hold the key in place.
  9. 9.
    Make sure that the lubrication pump drive adapter fits correctly into input pinion subassembly (to be installed later).
    Figure 5

    NOTE

    This input pinion shaft sub-assembly with the drive key installed must be placed directly over the location provided in the housing where the lubrication pump is installed. If not, the lubrication pump does not circulate oil.

  10. 10.
    Apply a thin layer of Ronex-HD grease to the housing bores and the outer races on the lower input pinion bearings to help the input pinion shaft subassemblies (Figure 6, item A) slide easily into position.
  11. 11.
    Tap the intermediate shaft with a rawhide mallet (item A) to fully seat the bearing. Make sure of correct gear teeth engagement. Repeat for second subassembly as shown.
    Figure 6
  12. 12.
    Apply a layer Ronex-HD grease to the intermediate shaft seal lips (Figure 7, item A) , the rollers on the upper intermediate bearings (item B), and the outer races of the input pinion.
    Figure 7
  13. 13.
    Make sure that the mounting surfaces on the housing and cover are free of oil and grease. Apply a bead of silicone to the mounting surface of the housing.
  14. 14.
    Use applicable lifting eye bolts, chains, and hoist to put the cover (Figure 8, item B) carefully on the housing.

    NOTE

    Make sure that the dowel pin in the housing matches with the pattern of holes in the cover.

  15. 15.
    Install bolts on the cover and torque the bolts to 102 Newton meters (75 foot-pounds). Wipe-off any excess silicone (item A) from the outside of the rotary head.
    Figure 8

    CAUTION

    Risk of Injury

    Incorrect handling of heavy sectioned snap rings can cause serious injury.

    1. Use extreme caution when you work with heavy sectioned snap rings.

    2. Use the applicable reteaching type snap ring pliers and wear gloves and face shield protection in case of an accidental flying snap ring.

  16. 16.
    Insert snap-rings (Figure 9, item A) inside the housing cover to secure input pinion shaft subassemblies in place.
    Figure 9
  17. 17.
    Fill a small amount of silicone in the threaded bolt holes in the upper spindle bearing cavity area of the housing cover.

    NOTE

    Make sure that the silicone is flush with the top of the surface to prevent the upper spindle bearing cup from not seating correctly. The silicone keeps the gear oil in the housing from flushing out or contaminating the grease in the upper spindle bearing cavity.

    Figure 10
  18. 18.
    Apply oil seal lip with a layer of Ronex-HD grease and install the oil seal over the spindle (Figure 11, item A) and into the housing cover. Make sure for the correct seal orientation.

    NOTE

    The primary lip on the oil seal must be toward the inside of the upper spindle bearing cavity for grease retention in the cavity. Use a drift to seat it.

  19. 19.
    Lubricate the O-ring with a thin layer of Ronex-HD grease (item A) and slip over the bearing holder into the O-ring groove.
    Figure 11
  20. 20.
    Apply a thin layer of Ronex-HD grease (Figure 12, item A) to the upper intermediate bearing rollers and to the inside surfaces of the intermediate bearing cavities. Also apply to the outside and the inside diameters of the bearing holder.
    Figure 12
  21. 21.
    Slide the bearing holders into position in the housing cover and then fully seat them.
  22. 22.
    Apply a thin layer of Ronex-HD grease to the roller mounting surface and the outside diameter of the upper intermediate bearing cup. Install the bearing cups into the bearing holders.
  23. 23.
    Slide the intermediate bearing cup (Figure 13, item A) down to engage the bearing cones. Make sure that the upper intermediate bearing assemblies are fully seated together using a drift to seat them.
    Figure 13
  24. 24.
    Apply a thin layer of Ronex-HD grease to the outside diameter of intermediate bearing adjusters and insert them into the bearing holders.
    Figure 14
  25. 25.
    Install adapters, grease fittings, and relief fittings.
    Figure 15
  26. 26.
    Install bolts and washers in the two opposite corners of the bearing holders (Figure 16, item A) and the bearing adjusters.
  27. 27.
    Tighten the bolts with the impact wrench (item B) for the bearing holders, but only snug the bolts for the bearing adjusters.
    Figure 16

Set the Intermediate Bearing Pre-load

NOTE

The following steps are important to set the bearing preload correctly.

  1. 1.
    Make sure that the intermediate bearings rollers are seated using a ratchet with tool inserted into the splines of the pinion to rotate the input pinion shaft.
  2. 2.
    Torque the two bolts that holds the bearing adjuster to have a final torque that stabilizes at 20 newton meters (15 foot pounds). This torque value is achieved in three or four graduated steps followed alternately with a required turning of the input pinion shaft in both directions between each graduated torque step. This action determines the correct shim thickness to achieve 0.1 mm (0.004 in) preload.
    Figure 1
  3. 3.
    With the bolts from the previous step tightened to a consistent 20 Newton meters (15 foot-pounds), measure individually the gaps between the surfaces of each bearing adjuster and the holder. Select the correct thickness of the shims from the shim pack for each gap.
  4. 4.
    Test each shim set in its applicable gap for a tight fit to make sure that a 0.00127-centimeter (0.0005-inch) feeler gage can not be slipped between the shim in the gap and bearing adjuster.
  5. 5.
    Remove torqued bolts and bearing adjuster from the bearing holders.
  6. 6.
    Install correct shim sets (Figure 2, item A) over the corresponding bearing adjuster and slip the O-rings into grooves on the bearing adjusters.
    Figure 2
  7. 7.
    Apply the outside diameters of both bearing adjusters with a thin layer of Ronex-HD grease and reinstall into the bearing holders. Torque the bolts for both bearing holders and both bearing adjusters to 203 Newton meters (150 foot-pounds).
    Figure 3
  8. 8.
    Install an elbow with a relief fitting (Figure 4, item A) into the housing cover. Loosely fit the oil filler plug with the O-ring into position.
    Figure 4

Expansion Fit the Upper Spindle Bearing Cup

  1. 1.
    Press the frozen upper spindle bearing cup (Figure 1, item A) into the housing cover. Make sure that the bearing cup is seated tightly against the mounting surface in the housing cover.
  2. 2.
    If necessary, use a steel hammer and a bronze drift to make sure that the cup is fully seated.
    Figure 1

Shrink Fit the Upper Spindle Bearing Cone

WARNING

Burn Hazard

Hot components can cause serious injury.

  1. Use approved safety gloves when handling hot components.

NOTE

Do not let the bearing cones soak at temperatures above 149 °C (300 °F) for an extended time period.

  1. 1.
    Heat the upper spindle bearing cone (Figure 1, item A) to between 121 °C and 132 °C (250 °F and 270 °F). Install the bearing cone immediately upon reaching the desired temperature.
  2. 2.
    Apply a thin layer of high-pressure grease (item B) to the bearing cup contact surface.
    Figure 1
  3. 3.
    Before installing the upper spindle bearing cone (Figure 2, item B), make sure that the small floor or scissor jack is still fully supporting the spindle subassembly (item A). Put the heated upper spindle bearing cone onto the spindle using protective gloves.
    Figure 2

Setting the Spindle Bearing Pre-load Rolling Torque

NOTICE

Rotary Head Damage

Incorrect preload on the Main Bearing Assembly reduces the service life of the rotary head.

Repeated problems with the Swivel Head Packing Assembly, such as water leaks and missing packing rings, could be an indication of loss of preload on the Main Bearing Assembly.

Insufficient preload lets the upper spindle bearing inner race spin below the lock nut during drilling and breakout operations. The spinning of the race quickly wears away the bottom of the lock nut, and any existing preload lost results in endplay. The endplay in the Spindle Assembly is harmful to bearings and other components.

Excessive preload overloads the bottom spindle bearing, which leads to loss of preload and early failure.

Reapplying preload to the spindle bearing causes early bearing failure.

  1. Apply correct preload on the Main Bearing Assembly.

  2. Make sure not to reapply the preload on the spindle bearing after the rotary head is operated for any period of time.

NOTE

Repeated problems with the Swivel Packing Assembly, such as water leaks and missing packing rings can occur due to loss of pre-load at the Main Bearing and Spindle Assembly.

The bearing should be cooled to the ambient temperature before setting the pre-load. If the bearing is warm or hot, then when it cools, a loss of pre-load can occur.

Special tools necessary for this setting are from the Rotary Head Rebuild Tools Kit list and used in the following steps:

  1. 1.
    Install the adjusting nut (Figure 1, item A) on the spindle and use the spindle rotation tool to tighten the adjusting nut so that it firmly contacts the surface of the upper spindle bearing cone.
  2. 2.
    Remove the support (item B) from the bottom of the spindle.
    Figure 1
  3. 3.
    Insert the input pinion tool (Figure 2, item A) into the motor adapter spline (item B).
    Figure 2
  4. 4.
    Install two angles (Figure 3, item A) 180 degrees apart on the rotary head housing with two cap screws and flat washers. Tighten the two cap screws after alignment to the wings on the adjustment locking ring tool (item B).
  5. 5.
    Make sure that the adjustment locking ring tool in place engaging notches in the adjusting nut (item C).

    NOTE

    Make sure that the additional adjusting nut to hold the locking ring tool in place.

    Install the adjustment locking ring tool in the notches on the adjusting nut.

    NOTE

    The wings on the tool contact the surfaces of the angles to prevent the adjusting nut from turning during spindle rotation. Tightening the adjusting nut will increase the pre-load on the spindle bearing when the input pinion tool is rotated. Using the overall gear reduction makes tightening the adjusting nut easier.

    Spindle bearings must have the correct pre-load. The method used measures the difference in rolling torque necessary to turn the spindle from the initial condition to the final condition. Rolling torque increases incrementally as the bearing adjusting nut is tightened.

    Figure 3

    NOTE

    Do not strike or otherwise impact a bearing assembly. The bearing can be damaged leading to the failure of the bearing.

  6. 6.
    Before tightening the adjusting nut, put a mark on the nut and corresponding mark on the spindle. With a torque wrench attached and lock nut adjustment tool temporarily removed, insert the input pinion tool (Figure 4, item A) into the spline of the pinion shaft. Carefully measure and record the initial torque necessary to rotate the pinion counterclockwise.
  7. 7.
    With a torque wrench attached, engage the spindle rotation tool on the adjusting nut on the spindle, carefully measure and record the initial torque necessary to rotate the spindle clockwise (turning the spindle counterclockwise at this stage may loosen the adjusting nut).
    Figure 4
  8. 8.
    Ideally, the pre-load on the spindle bearings is 0.2 millimeter to 0.25 millimeter (0.008 inch to 0.010 inch). Turning the input pinion counterclockwise approximately 1.75 to 2.00 complete revolutions incrementally, while the adjusting nut is locked preventing its rotation, equates to 0.2 millimeter (0.010 inch) pre-load. This equates to a 43° to 48° shift between the original marks made on the nut and the spindle.
  9. 9.
    After each incremental turn of the input pinion tool, the lock nut adjustment tool must be removed temporarily to let the spindle bearings roll back and forth several times to seat the rollers. Before reinstalling the lock nut adjustment tool for further adjustment, measure and record rolling torque at the pinion and the spindle itself as described in the steps above.
  10. 10.
    Make sure the slow rolling torque necessary to turn the spindle itself has risen 386 Newton meters to 441 Newton meters (285 foot-pounds to 325 foot-pounds) above its initial reading.
  11. 11.
    Make sure the slow rolling torque that is measured at the input pinion is between 26 Newton meters to 30 Newton meters (19 foot-pounds to 22 foot-pounds) above its initial reading.
  12. 12.
    Once the adjusting nut is tightened to reach the final slow rolling torque requirement, remove the lock nut adjustment tool. Put tongued washer over the spindle and engage the tongue into slot in the spindle. When aligned, install the lock bolts and torque to 23 Newton-meters (17 foot-pounds)
    Figure 5

Shrink the Fit Wear Sleeve

WARNING

Burn Hazard

Hot components can cause serious injury.

  1. Use approved safety gloves when handling hot components.

  1. 1.
    Heat the wear sleeve (Figure 1, item A) to between 121 °C and 135 °C (250 °F and 275 °F) on the heater (item B). Use protective gloves and put the heated sleeve (item C) over the spindle. Let the sleeve cool and shrink fit onto the spindle. Apply a thin layer of clean grease to the outer surface of the sleeve.
    Figure 1
  2. 2.
    Insert both grease fitting and relief fitting into the swivel housing.
  3. 3.
    Apply the shoulder area of the swivel housing (Figure 2, item A) with a layer of Ronex-HD grease (item A). Lubricate the O-ring heavily and position over mounting shoulder of the swivel housing. Fill the upper spindle bearing cavity with Ronex-HD grease. Make sure to get the grease in between and around the bearing rollers.
    Figure 2
  4. 4.
    Orient the swivel housing (Figure 3, item A) with the lubrication fitting facing the front of the rotary head housing (item B) for easy field lubrication access.
  5. 5.
    While taking care not to damage the O-ring seal, insert and torque the bolts on the swivel housing.
    Figure 3
  6. 6.
    Lubricate the oil seals (Figure 4, item A) with a generous layer of Ronex-HD grease. Correctly orient the oil seal to hold the grease inside the housing cavity. Use a piece of very thin greased shim material wrapped around the upper end of the spindle and install first oil seal into the swivel housing using extreme care to not damage the seal lips. Use a small steel hammer and bronze flat bar (item B) to seat the seal into bore. Do not damage or deform the seals during installation.
    Figure 4
  7. 7.
    Insert the second seal (Figure 5, item A) on the spindle (Figure 5, item B) and orient it to hold the grease inside the cavity. Use a small steel hammer and bronze flat bar to seat the seal into bore. The seal must be flush with top of bore as shown.
    Figure 5
  8. 8.
    Put a drip shield (Figure 6, item A) around the spindle. Put the plastic locking ring (item B) into the groove at the base of the spindle threads.
    Figure 6
  9. 9.
    Lubricate the spindle threads with a very thin layer of clean grease. Put the O-ring (Figure 7, item A) into groove at the top of the spindle (item B) to help seal the spindle cap. Apply the O-ring with grease after installation.
    Figure 7
  10. 10.
    Put the spindle cap (Figure 8, item A) over the spindle and hand thread as far as possible.
    Figure 8
  11. 11.
    Install and tighten the spindle nut stop tool assembly to the top of the housing, contacting one of the arm extensions of the spindle nut holding tool. This prevents the spindle cap from turning as the spindle is turned with the input pinion, tightening the spindle cap.
  12. 12.
    Use the input pinion tool with an attached ratchet to turn the input pinion shaft, using the overall gear reduction to tighten the spindle cap. Turn the input pinion clockwise while the spindle cap is still locked preventing its rotation. While verifying the plastic lock ring remains in its assigned groove, tighten spindle cap until it makes good firm contact with the spindle and compresses the top O-ring. Remove all rotary head assembly tools.
    Figure 9
  13. 13.
    To determine the appropriate amount of shims from the shim kit needed between the mounting surfaces of the spindle cover and swivel housing to give the correct amount of squeeze on the air seal packing, install the spindle seal tool into the spindle cap. With the tool in position, temporarily install the spindle cover (Figure 10, item A) on top of the tool. Measure with a feeler gage the gap between the mounting surfaces of the swivel housing and the swivel cover for the correct shim required. When this is determined, remove the spindle cover and tool.
    Figure 10
  14. 14.
    Insert one swivel 30-X packing (Figure 11, item A) into the spindle cap and one into the swivel cover (item B).
    Figure 11
  15. 15.
    Apply Loctite C5-A anti-seize lubricant to the exposed edge of the packing inside of the spindle cap and both contact surfaces on the wear bushing.
  16. 16.
    Insert the wear bushing (Figure 12, item B) inside of the spindle cap (item A). (When the swivel cover is mounted, the wear bushing is between the two swivel packings.
    Figure 12
  17. 17.
    Install the correct thickness of shims (Figure 13, item A) from the shim kit between the spindle cover and the swivel housing. Use long threaded dowel rods to help align the spindle cover.
  18. 18.
    Secure the swivel cover (item B) in place with bolts. When shimmed and tightened correctly, the air seal packing will be squeezed by 7/32 inch.
    Figure 13
  19. 19.
    Insert the adapters into the housing cover for both motors.
  20. 20.
    Lubricate the shoulder area of the motor adapter (Figure 14, item B) with a thin layer of Ronex-HD grease. Put the O-ring into the shoulder area and apply with grease heavily. Align the motor adapters with the SAE port (item A) for the lubrication pump hosing toward the back of the rotary head housing for the best hose routing.
    Figure 14
  21. 21.
    Apply Ronex-HD grease (Figure 15, item A) lightly to the mounting shoulder on the motor covers and install the O-rings. Install the covers and insert the bolts. Torque the bolts.
    Figure 15
  22. 22.
    Install the lubrication pump (Figure 16, item A) drive adapter onto the keyed shaft of the lubrication pump and make sure that the shaft key is correctly installed. Lightly grease the O-ring groove on the housing and install the O-ring.
    Figure 16
  23. 23.
    Install lubrication pump (Figure 17, item B) below the housing.
  24. 24.
    Insert the bolts and torque together. Attach the suction hose (item A) from the strainer to the pump with fittings. Attach the fitting to the charge side of the lubrication pump, and attach the hoses to the motor adapter fittings).
  25. 25.
    Secure the hoses to the housing with a clamp as shown.
    Figure 17
    Figure 18
  26. 26.
    Insert the rotation tachometer sensor (Figure 19, item A) into the side of the casing. Thread the sensor into the housing until it contacts the intermediate gear teeth. Un-thread the sensor two turns and lock it into position using a jam nut.
    Figure 19
  27. 27.
    Remove the filler cap and fill the housing (Figure 20, item A) with new, filtered 80/90W gear oil until the sight glass is at least half full. Reinstall and tighten the filler cap. Examine for leaks. Hand-grease both the intermediate bearing cavities and the upper spindle bearing cavity until the grease is observed exiting out of the relief fittings.
    Figure 20