MILWAUKEE GEARBOX

Operation & Service Manual

RJ-OS-1 11/19

Milwaukee Gearbox 1

INTRODUCTION The purpose of this manual is to give general information on the correct methods of installing, operating and maintaining the Roto-Jet Milwaukee Gearbox. Note the following important information before attempting to operate the equipment. 1. The gear ratio marked on the dipstick should

match that on the nameplate. 2. The gearbox is shipped with initial fill of

recommended oil. 3. Units are not aligned. Coupling alignment

must be done during pump installation.

EQUIPMENT DESCRIPTION The Roto-Jet Milwaukee gearbox is a single-stage, parallel-shaft-type speed increaser, designed for horizontal installation. Heat is dissipated by the dynamically balanced fan blowing air into the finned housing. The nameplate information includes the gear ratio and serial number. This equipment is designed for and is expected to provide a normal long life. If there are any questions concerning the operation or repair, the customer should contact one of Roto-Jet's sales offices. Furnish serial numbers of the pump and gearbox and the gear ratio.

STORAGE If the gearbox is not to be placed in service immediately, it should be stored in a dry location and protected from dirt internally and externally. Pick an area where temperature is reasonably constant. Parts subject to attack by moisture, such as bearings, shafts, mechanical seals and other finished parts should be inspected periodically and coated with lubricant or rust inhibitor as required. When the increaser is operated for a period of time but must be placed in storage, the user should spin the gear every 30 days to redistribute the oil to the non-submerged parts. If spinning the shaft is not possible, oil should be brushed or sprayed on the gear teeth and bearings every 30 days. Any

openings such as breathers or shaft seal areas should be sealed with masking tape.

INSTALLATION Any gear-drive needs to be mounted on a sturdy foundation to minimize wear, abnormal bearing temperatures, vibration and coupling problems. Most Roto-Jet installations use baseplates where all components in the package are installed on a common base. At the job site, this baseplate would be leveled and mounted on concrete. It is good practice to grout this baseplate in place to achieve optimum stability. Normally, the gearbox is shipped mounted on the baseplate with the pump and the prime mover. The units are not aligned. Coupling alignment must be done after installation. If a coupling half is to be installed, check the coupling bore, shaft end and keyway edges for any bruises or burrs. Measure the shaft and bore of the coupling half while cold. The bore of the coupling must be expanded until it is at least .0005 in. per in. of diameter over the shaft surface, heat the coupling half carefully, slowly, and evenly (not over 500 degrees F) until bore is sufficiently expanded. Install the coupling cover. Place the coupling half on the shaft in its proper axial position, keeping keyways in line. It should move into place easily. If necessary, tap lightly with a rawhide mallet.

ALIGNMENT Flexible couplings need to be aligned both radially and axially. It is obvious that heavily loaded rotating shafts which are misaligned relative to one another will cause an abnormal and irregular overhung load. This condition in turn can cause abnormally high bearings loads and even irregular tooth contact. This latter condition could occur as the coupling misalignment takes up the clearance space within the bearings with a subsequent relative axial misalignment of the gear tooth surface.

Check for Angular Misalignment Driver and driven units will be lined up when dial indicator reading comes within 0.005 in. (.13 mm) maximum (hot alignment). Hot alignment check is done when units reach operating temperature.

Check for Parallel Misalignment Move or shim units so that parallel misalignment is brought within 0.005 in. (.13 mm) maximum at hot settings.

Milwaukee Gearbox 2

START-UP Gearboxes sold separately (not with the pump mounted on a common base) will have a shipping plug in place of the breather/filler cap. To install the breather/filler cap, remove the shipping plug from the housing cover and assemble the nipple (item 38), elbow (17), coupling (37), and breather (16). The gearbox must be filled with oil per Roto-Jet Spec. MP 830 (Mobile SHC 630) to dipstick level. The capacity of the gearbox is approximately 2-1/2 gallons (9.5 liters). Exact amount is set by the mark on the dipstick. Grease the coupling working parts with the lubricant specified by the manufacturer. The grease for the coupling should be worked thoroughly into the working parts prior to installing the cover, as centrifugal force tends to throw grease out against the coupling cover. During initial run, observe the equipment for any unusual vibration, noise, leakage, or hot bearings.

LUBRICATION The recommended lubricant for the gearbox is per Roto-Jet Spec. MP 830 (Mobil SHC 630). This oil is intended to be used in enclosed gear drives. It is suitable for applications in the temperature range of -50 degrees F (-45 degrees C) minimum ambient temperature to 300 degrees F (149 degrees C) maximum bulk operating oil temperature. The physical and chemical characteristics are shown below. It is formulated from synthesized hydrocarbon based fluids combined with additives to provide enhanced oxidation stability, corrosion protection, and gear load carrying ability.

Characteristic Mobil SHC 630 Gravity, API 34.4 Specific Gravity 60°F (15.6°C) .853 Pour Point °F (°C) -50 (-45) Flash Point °F (°C) 460 (238) Viscosity cSt at 40 °C cSt at 100°C SUS at 100°F SUS at 210°F

210/240

26.4 1110/1230

130 Viscosity Index 145 Color. ASTM L 1.0 ISO Viscosity Grade 220 Copper corrosion ASTM D 130 24 h at 212°F (100°C)

2A

The principal contaminants of the oil are metal particles from the bearings and gear teeth, and water condensation inside the gearcase and/or foreign

materials. These conditions are unavoidable in any gear unit and the most practical means of correction is periodic oil changes. After 2000 hours or 3 months, the oil should be drained from the housing, the interior flushed out and re-filled with fresh oil. Change lube oil every 3000 hours of operation or 6 months thereafter. Check oil level weekly when unit is at rest, and add oil to the dipstick level as required. Gear Oil: Mobil SHC 630

MAINTENANCE After 2000 hours or 3 months, the oil should be drained from the housing, the interior flushed out and re-filled with fresh oil. Change lube oil every 3000 hours of operation or 6 months thereafter. Check oil level weekly when unit is at rest, and add oil to the dipstick level as required. The lubricant change interval and care mentioned above is, of course, a vital segment of maintenance. Proper lubrication can help greatly to obtain long life from this type of equipment. It is recommended that a record be maintained of hot-check coupling alignment. Changes in the alignment can indicate a possible shift in foundation or some type of difficulty within the gearbox. An operator should always 'listen' for possible changes in the noise level of the increaser. This may be an indication of some sort of a problem. There may be trouble in the gearbox if the temperature of the oil or one of the bearings exceeds 250 degrees F (121 degrees C). One cause of high operating temperature is too much oil in the sump. Incorrect oil viscosity can also cause overheating. In dusty locations, the housing fins should be cleaned once each year to ensure efficient cooling.

Milwaukee Gearbox 3

DIMENSION DRAWINGS

Milwaukee Gearbox 4

EXPLODED DRAWING

Milwaukee Gearbox 5

COMPLETE PARTS LIST

Item No.

Part No.

Description

Qty

Item No.

Part No.

Description

Qty

1 0662214 Housing Base and Cover 1 25 060067738 Pipe Plug 1

2 See pg. 13 Drive Gear (Matched w/ item No. 12) 1 26 See Pg. 13 Dipstick 1

3 0658916 Bearing 2 27 060065631 Fitting 1

4 0658912 Gasket (Set of 4) 1 Set 28 060065632 Tube 1

5 0658913 Wave Spring (Set of 4) 1 Set 29 060076024 Key 1/2" Sq. x 3" 2

6 060065623 Retainer 2 30 060067736 Pipe Plug 5

7 060065624 Output & Input Shaft 2 31 060065633* Oil Pan 1

8 060076108 Key 3/8" Sq. x 2-1/2" (Not Shown) 4 32 060065634 Direction Tag (Not Shown) 1

10 060088724 Socket Head Capscrew 5/8-11 x 4-1/2 2 33 0658917 Bearing (Radial) 2

11 060098208 Hardened Washer 6 34 060065635 Input Shaft Retainer 1

12 See pg. 13 Driven Gear (Matched w/Item No. 2) 1 35 0658914 Lip Seal 1

13 060065626 Spacer 2 36 0658915 Excluder Seal 2

14 060065627 Output Shaft Retainer 1 37 060067305 Coupling 1

15 060065628 Slinger 1 38 060068113 Nipple 1

16 060065629 Breather/Vent 1 40 060088208 Setscrew 3/8-16 x 5/8 1

17 060067586 45° Street EII 1 41 060065637 Fan 1

18 060088840 Hex Head Capscrew 7/16-14 x 1-1/2 24 42 060088838 Hex Head Capscrew 7/16-14 x 3-1/2

3

19 0661091 Socket Head Capscrew 5/8-11 x 2 4 43 060065638 Spacer (supplied with Item 49) 3

20 060084118 Tapered Dowel 2 44 060065639 Shroud 1

21 060088345 Hex Head Capscrew 1/2-13 x 1-3/4 4 45 060098205 Lockwasher 4

22 060098206 Hardened Washer 4 47 060088839 Hex Head Capscrew 7/16-14 x 1 1

23 060093116 Drive Screw 6 48 060065641 Spacer(supplied with Item 49) 3

24 060065630 Nameplate 1 49 060065642 Shroud Guard 1

51 0662156 Elbow 90º 3/4 (Not Shown) 2 * NOTE: Part Number 060065633 is used on ratios 1.073 through 1.651. For ratios 1.780 and higher, use Oil Pan Part Number 060065651.

Milwaukee Gearbox 6

INPUT SECTION DRAWING

Milwaukee Gearbox 7

INPUT SECTION PARTS LIST

Item No.

Part No.

Description

Qty.

1 0662214 Housing Base and Cover 1

2 See pg. 13 Drive Gear (Matched w/ item No. 12) 1

3 0658916 Bearing 2

4 0658912 Gasket (Set of 4) 1 Set

5 0658913 Wave Spring (Set of 4) 1 Set

6 060065623 Retainer 2

7 060065624 Output & Input Shaft 2

13 060065626 Spacer 2

18 060088840 Hex Head Capscrew 7/16-14 x 1-1/2 24

31 060065633* Oil Pan 1

33 0658917 Bearing (Radial) 2

34 060065635 Input Shaft Retainer 1

35 0658914 Lip Seal 1

40 060088208 Setscrew 3/8-16 x 5/8 1

41 060065637 Fan 1

44 060065639 Shroud 1

49 060065642 Shroud Guard 1

* NOTE: Part Number 060065633 is used on ratios 1.073 through 1.651. For ratios 1.780 and higher, use Oil Pan Part Number 060065651.

Milwaukee Gearbox 8

OUTPUT SECTION DRAWING

Milwaukee Gearbox 9

OUTPUT SECTION PARTS LIST

Item No.

Part No.

Description

Qty.

1 0662214 Housing Base and Cover 1

3 0658916 Bearing 2

4 0658912 Gasket (Set of 4) 1 Set

5 0658913 Wave Spring (Set of 4) 1 Set

6 060065623 Retainer 2

7 060065624 Output & Input Shaft 2

12 See pg. 13 Driven Gear (Matched w/Item No. 2) 1

13 060065626 Spacer 2

14 060065627 Output Shaft Retainer 1

15 060065628 Slinger 1

18 060088840 Hex Head Capscrew 7/16-14 x 1-1/2 24

33 0658917 Bearing (Radial) 2

36 0658915 Excluder Seal 2

Milwaukee Gearbox 10

DISASSEMBLY/ASSEMBLY The following are recommended dismantling and assembly instructions for your gearbox. We urge that the instructions be read thoroughly before attempting to dismantle the unit. the component parts must be handled with care during the process. The work area should be clean and equipped with the required tools. The sequence given will be for complete disassembly. Quite possible visual inspection of the interior of the box will give information as to the basic cause of a problem and may influence disassembly techniques. Obviously, it is desirable to order any replacement parts needed, and such an order should be placed as soon as possible if spare parts are not on hand. When the time and expense of disassembly and reassembly is considered, it is always best to obtain new sets of gaskets, oil seals, wave springs, and bearings. In ordering parts, we must have the serial number and the nameplate on the exterior part of the housing. It will also help to give the serial number of the pump, if the gearbox was bought with the pump. Throughout the assembly sequence, it is good to observe carefully what may have occurred inside the gearbox and to keep a record of the position of any of the failed components. For instance, if there should be a bearing failure, make a record of the position in the gearbox that the failure took place and which side of the bearing is toward the outside. A white marker can be used to identify these positions. One other precaution: a better analysis can be made of failed parts if they are dirty in their failed condition.

DISASSEMBLY To disassemble the gearbox, refer to the parts drawing on page 4. D-1. Remove from the input side three capscrews

(42) one capscrew (47) and four lock washers (45) from the shroud (44). This will allow the shroud (44), spacers (43), shroud guard (49) and spacers (48) to be removed by hand.

D-2. Remove set screw (40) from fan (41). Using

wheel puller, remove fan (41). It may be necessary to apply heat to the fan (41) for easy removal.

D-3. Remove the six capscrews (18) from input

retainer (34). This will allow the input retainer (34), gasket (4) and wave spring (5) to be removed by hand. Remove lip seal (35) from input retainer using a brass rod.

D-4. Remove the six capscrews (18) from the

output retainer (14). This will allow the excluder seal (36), output retainer (14), gasket (4) and wave spring (5) to be removed by hand.

D-5. Remove the six capscrews (18) from one of

the remaining retainers (6). This will allow the retainer (6) and gasket (4) to be removed by hand. Repeat the step above to remove the remaining retainer (6).

D-6. Remove the following capscrews (Item 10, 19

& 21) from the housing cover (1). Be careful during the removal of the housing cover (1) from the housing base. There are two tapered dowels (20) that are in the housing cover (1), evenly lift the cover up with out damaging the machined surfaces.

D-7. At this time, output & input shaft assembly can

be removed from housing. Be careful not to damage the gear teeth (2, 12). Wrap something around the gear teeth (2,12) to protect them from being damaged.

D-8. Using a bearing puller, remove bearing (33),

spacer (13) and slinger (15) from the output shaft all at once.

D-9. Using a bearing puller, remove bearing (33)

and spacer (13) from the input shaft all at once.

D-10. Using a bearing puller remove bearing (3) from

back of input and output shafts. D-11. Remove oil pan (31) and dip stick (26) from

housing. D-12. It is recommended not to remove the gears (2

& 12) from the shafts (7), unless the shafts need to be replaced. It is very easy to damage the shafts during removal of the gears.

D-13. Clean all machined surfaces and wash the

following with cleaning solvents: a) Cover (1) b) Base (1) c) Two bearing retainers (6) d) Two bearing retainers (14 & 34) e) Oil pan (31) f) Two spacers (13) g) Two slingers (15) h) Two shafts and gears i) Dipstick (26) D-14. Inspect all parts for wear and damage.

Replace as required.

Milwaukee Gearbox 11

ASSEMBLY Check carefully for any dirt or damage before reassembly. Stone edges of split surfaces and bodies. A-1. Only if shaft or gears were replaced: Heat gear

(12)) to 300 degrees F (149 degrees C). Use Tempilstick 300 P/N 060095065 to prevent excessive heat. See header for ratio. Install on shaft (7) with key (8). Chamfer edges of keys if required.

A-2. Only if shaft or gears were replaced: Heat gear

(2) as in A-1. See header for ratio. Install on shaft (39) with key (8). Chamfer edges of keys if required.

A-3. Place the output shaft (smaller gear) with the

long hub side of the shaft facing up. Slide the spacer (13) onto the shaft. Heat radial bearing (33) to 250 degrees F (121 degrees C) using tempilstick 250, P/N 060095064. Quickly slide the bearing (33) onto the shaft and against the spacer (13) with the identification numbers up, slide slinger (15) on to shaft.

A-4. Turn the output shaft over with the short hub

side facing up. Heat angular bearing (3) to 250 degrees F (121 degrees C) using tempilstick 250, P/N 060096064. Place bearing (3) on to the shaft with the identification number up. Handle very carefully and store in protective paper until used.

A-5. Place the input shaft (larger gear) with the long

hub side of the shaft face up. Slide the spacer (13) onto the shaft. Heat radial bearing (33) to 250 degrees F (121 degrees C) using Tempilstick 250, P/N 060095064. Quickly slide the bearing (33) onto the shaft and against the spacer (13) with the identification number up.

A-6. Turn the input shaft over with the short hub

side facing up. Heat angular bearing (3) to 250 degrees F (121 degrees C) using tempilstick 250, P/N 060095064. Quickly slide the bearing (3) onto the shaft with the identification number up. Handle very carefully and store in protective paper until used.

A-7. Install Seal (35) to input shaft retainer (34). A-8. Place oil pan (31) into housing base (1) with

the deeper part of the pan on the opposite side of the dipstick.

A-9. Place the input gear (larger gear) assembly

into the housing base (1) on the deep side of

the oil pan. Place the output gear (smaller gear) assembly into shorter part of the oil pan (3) near dipstick. Shaft should be facing the opposite direction. Make sure gears clear oil pan.

A-10. Apply sealing compound to joints and place

housing cover (1) on top of the housing base (1). NOTE: The housing and cover are a matched set, make sure the stamped numbers are inline with each other. Bend oil pan (31) tabs if necessary to fit inside of the housing cover (1). The breather should be on top of larger gear (input) side.

A-11 Align the dowel pin holes and drive in the

tapered dowels (20). Make sure the tapered dowels are seated completely.

A-12. Install two retainers (6) gaskets (4) and

capscrews (18) to the lowehalf of housing: Torque 50 ft., lbs. (68 N-M). Tap the shaft towards the installed retainer (6) to allow gear assembly to seat in that direction. Tap outer race of bearing (33) to seat. Do not tap hard, just enough to be sure bearings are seated.

Milwaukee Gearbox 12

FIGURE A-13, HOUSING COVER TORQUE SEQUENCE A-13 Install the six socket head cap-screws (10) & (19) snug, do not torque at the time. Now install four hex head cap-screws (21). **Snug, do not torque at this time. A-14. Install two wave springs (5), gasket (4), retainer (34) and cap-screws (18) on input shaft. **Snug, do not torque at this time. A-15. Install two wave springs (5), gasket (4), retainer (14) and cap-screws on the output shaft. **Snug, do not torque at this time. A-16 Install gaskets (4) and retainers (6) and cap screws (18) on the blind sides of the gearbox. ** Snug, do not torque at this time. NOTE: See figure A-13 for torque sequence. This sequence must be followed to control the proper bore dimensions. Revised Steps ** ** Go back through fasteners installed in steps A13-A16 and torque (see figure A-13 torque sequence) as follows: ** (A-13) Torque the six socket head cap-screws (10) & (19) to 140 ft. lbs. (190 N-M) and torque four hex head cap-screws (21) to 65 ft. lbs. (88 N-M) per figure A-13. ** (A-14), (A15) & (A16) Torque cap-screws (18) on all bearing caps to 50 ft. lbs. (68 N-M).

A-17. Check shaft for smooth, free rotation by hand. A-18. Install two excluder seals (36) onto input and output of shaft. Be careful not to damage the seal bore during installation. A-19. Heat fan (41) hub to 250F (121C) and quickly slide on input shaft (larger gear). Line fan up with set hole in the shaft. Install set screw (40) into fan. A-20. Bolt shroud guard (49), shroud (44), cap-screw (47) and washer (45) to the housing of the input shaft. Install the remaining parts consisting of spacer (48 & 43), lock washer (45) and cap-screw (42). A-21. Add oil to gear box to the recommended level on the dipstick. A-22. Again rotate shaft by hand for smooth, free rotation. Note: Radial movement should NOT exceed .002” Torqueing during Steps A-13 through A-15 may interfere with proper bearing pre-loading, leave excessive clearances and allowing radial shaft movement.

Milwaukee Gearbox 13

RECOMMENDED SPARE PARTS

Part Name Part No. Qty. Gear & Pinion Set See Below 1 set Gaskets, 4 pieces 0658912 1 set Wave Spring, 4 pieces 0658913 1 set Lip Oil Seal 0658914 1 Excluder Seal 0658915 2 Ball Bearing, 7311 Angular contact

0658916 2

Ball Bearing, 311 M Maximum Capacity

0658917 2

Mobilube SHC 630, Five Gallons

060080025 1

Dipstick See Below 1

Gear Ratio Dipstick Part

No. Gear & Pinion Set Part No.

1.073 1.151

0661546-1 0661546-2

0658902 0658903

1.235 1.327

0661546-3 0661546-4

0658904 0658905

1.426 1.533

0661546-5 0661546-6

0658906 0658907

1.651 1.781

0661546-7 0661546-8

0658908 0658909

1.923 2.081

0661546-9 0661546-10

0658910 0658911

NOTE: The gear & pinion set consists of items #2

and #12 only.

CONVERTING AN INCREASER TO A DECREASER

WARNING

The gearbox is typically used as a speed increaser. It CANNOT be used as a speed decreaser unless it is built as a decreaser.

1. The angular contact thrust bearings must be

moved to the other side of the gear on each shaft as shown on the following drawing. The direction of thrust is reversed.

2. The fan and lip seal must be on the input

shaft. 3. The labyrinth seal is on the output shaft. 4. The position of the wave springs are not

affected. 5. Stamp "DECREASER" on the fan shroud.

Milwaukee Gearbox 14

GEARBOX AS A SPEED DECREASER

Specification in this manual are subject to change without prior notification. Manual # RJ-OS-1 (11/19) 2019

For optimum service and technical assistance, please contact our factory for the distributor or representative

nearest to your project:

Trillium Flow Technologies Tel 801-359-8731 Fax 801-530-7828