RAD Tool Repair Manual

RAD Tool Repair Manual
www.radtorque.com
210806
General Info
Contents:
Page 1
General Information
Page 2-5
Gearbox Repairs
Page 6-7
Air Motor Repairs
Tools Required;
Part No.
10551
10552
10553
10554
10555
Description
Threaded ring removal tool for RAD-350 (475 Nm) and RAD-550 (750 Nm) series.
Threaded ring removal tool for RAD-800 (1100 Nm) to RAD-1800 (2400 Nm) series.
Threaded ring removal tool for RAD-30 (4000 Nm) to RAD-50 (6800 Nm) series.
Complete Metric Allen Wrench Set
Snap Ring Removal Tool
Also Required:
Manual Shop Press
10 Ton Hydraulic Press
Hammer
Safety Glasses
Mechanics Magnet
#4 Bench Vise
Drive Pin Punch Set
Flathead Screwdriver
RAD tool Manuals
Feeler gauge
Drill Bits
Power Drill
Mechanics Pick Set
Solvent Based Parts Washer
.001" Shim Stock
Customized jigs available for proper pressing during dissasembly and reassembly.
Contact New World Technologies Inc. 1-800-983-0044
Legend:
Good
Look carefully
Do not attempt operation / No good
The information contained within this manual is confidential!
Page 1
RAD gearbox repair
procedures
Upon receiving a RAD tool that is in need of repair, it is necessary to carry out the following
procedures:
DO NOT RUN THE TOOL!
Examine and record the condition of the tool judging by its outward appearance.
Example: Deformed reaction arm, excessive denting and scarring and in odd cases, cracks in the
annulus housing.
To begin disassembly follow these proceduresStep 1
Remove the four screws joining the gearbox to the air motor with allen wrench of appropriate size.
(See fig. 1)
fig.1
Page 2
RAD gearbox repair
procedures
Step 2
Remove adapter plate by removing the fasteners, using allen wrench of the appropriate size. (See fig. 2)
fig.2
fig.3
Step 3
Remove the 2 indexing balls and springs with a magnet. (See fig. 3)
Step 4
Mount the reaction arm into the bench vise (fig.4), insert the gearbox and remove the ring using the threaded ring removal tool*.
fig.4
fig.4.1
Or mount the gearbox assembly into the appropriate model jig* and remove the aluminium threaded
ring with the threaded ring removal tool* (See fig.4.1) (supplied by New World Technologies)
Step 5
Remove the primary sun gear and the following stages below it, along with the tools alignment pin
and the hardened washers. Then, by holding the gearbox assembly upside down the internal stages
should drop out*. (See fig. 5 and 5.1)
*These components will come
out easily if they are not
damaged. If they are damaged
the use of a press may be
required. It is suggested that
the stages be kept in order
upon removal.
fig.5
Page 3
fig.5.1
RAD gearbox repair
procedures
Step 6
To remove the final stage, an internal snap ring must be pried out from the annulus housing with a
snap ring removal tool. Upon doing, this the final stage will slide out of the annulus housing.
( See figs. 6 and 7)
fig.6
fig.7
If there is considerable damage, the use of a shop press will be required .
Step 7
Upon complete disassembly of your RAD Tool, each stage, the annulus housing and the adapter plate
must be de-greased using a parts washer. Thoroughly clean and then dry each part. Proper cleaning
will aid in checking for wear and failures. See examples of failures below.
Damaged gear teeth
New gear
Damaged
gear
Damaged
output carrier
New output
carrier
Damaged annulus
Look for fine
cracks in top
plate and
output carrier
Page 4
RAD gearbox repair
procedures
Step 8
Remove the screws from each stage assembly with allen wrench. (See fig. 8 and 9)
fig.8
fig.9
Step 9
Separate the output carrier from the top plate using a press. (See fig. 10)
fig.10
fig.11
Needle bearings
and planet gears
Step 10
Once stage assembly is apart, ensure all needle bearings are accounted for and replace any
damaged components if required. Inspect everything very closely! (See fig.12)
fig.12
Page 5
Re-assemble in reverse order. Use Loctite
242 (removable strength) on all fasteners
and ensure all internal components are
lubricated using an NLGI-1, all
temperature grease.(-40 F to+ 750 F)
RAD air motor repair
procedures
Always check the condition of the air motor components when servicing the tool.
Step 1
Remove the 4 screws of the handle cap with allen wrench and take off the cap and gasket.
Step 2
Using a punch inserted into the hex end of the rotor, carefully tap the rotor and end plate assembly*,
the rotor / end plate assembly should pop out. *30 to 50 series only! (See fig.13)
fig.14
fig.13
*For the SL - NG series tools, simply push the entire assembly straight out by hand. (See fig.14)
Step 3
Remove all internal components of the air motor and inspect each part carefully for condition
(See fig. 15)
Thoroughly de-grease internal components with a spray-on de-greaser such as LPS Zero-Tri (See fig.16). Inspect
each part very carefully , noting the shape and condition of the vanes, checking the endplate/rotor assembly for
scoring or burn marks. Clean the interior of the air motor housing as well, and press out the cylinder assembly if there
is evidence of failure (burns on front plate, scoring/rust in cylinder). Note: ONLY separate the rotor from the
endplate if the end plate is damaged; the tolerances between the two are VERY PRECISE (.0018mm to
.0023mm). Too much or little clearance will destroy any new part you may have replaced!!
fig.15
Page 6
fig.15.2
RAD air motor repair
procedures
Step 14
Re-assembly of air motor consists of pressing on rear end plate to rotor (if necessary).
The spacing between the rotor and the end plate is critical, the clearance should be .0018mm to
.0023 mm. The rotor must spin smoothly (See figs. 16 and 17)
rotor
.0018 mm to .0023
clearance between
rotor and
endplate.Check with
feeler gauge, .0020 is
too much clearance!
endplate
fig. 16
fig. 17
Step 15
Replace blades into the slots on the rotor and slide cylinder over rotor and on to rear end plate
making sure the spring pin is joining the end plate and the cylinder. (See fig. 18 and 19)
spring pin
fig. 18
fig. 19
Step 16
Place front end plate on to air motor cylinder, aligning it with the front spring pin. And drop complete
unit into the air motor handle with the hex side down. (See fig. 20 and 21)
To finish assembly, replace back cap with 4 screws and apply Loctite 242 to fasteners.
Front
spring
pin
Page 7
RAD air motor
failure examples
By sanding this scored rotor using a
lathe, this part can be salvaged
Scoring of this endplate
indicates it needs to be replaced
Page 8
Scoring of inner cylinder renders
this part unusable
New cylinder