PDF Service Repair Manual Yale A866 Series HFK - 663 KB

This service and repair manual covers the Yale A866 Series HFK 100-600 models.
It is a comprehensive guide for technicians, detailing procedures for maintenance, troubleshooting, and major repairs.
The manual contains specifications and diagrams necessary for servicing these machines correctly.
Keep your Yale equipment in optimal working condition with this essential resource.
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                                                                P.N- 272490600

                          Technical Information for YALE Service Centres


             This manual is addressed exclusively to the skilled technicians of the YALE service network


                                                         REDUCTION GEAR
                                                   SERIES HFK 100 - 200, 400 - 600
                                                       SERIES GR 92 - 96 - 97


                                                                 Section: INDEX

GENERAL SAFETY PRESCRIPTIONS


            Never do any cleaning, lubricating or servicing with the battery connected.


       Do not wear rings, watches, jewellery, loose clothing such as scarves, unbuttoned or
unzipped jackets or shirts that could get caught up in moving parts. Operators should wear
approved safety clothing: hard hat, non-slip footwear, gloves, safety glasses, etc..


       Do not use petrol, diesel fuel or other flammable liquids as detergents: use instead non-
flammable, non-toxic commercial solvents.


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   3.2 MEASURING INSTRUMENTS


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   4.4 REMOVING THE CROWN WHEEL AND THE AXLE SHAFT

   Position the reduction gear on the rotary stand.

   Screw the 2 wheel nuts onto the relative bolts and hold the axle shaft against rotation with a lever.

   Unscrew the hex bolt using a 24 mm wrench and remove the disk from the axle shaft (Figure 6).


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Assemble a shim pack of the required thickness (see section 2).Insert the shims (pos. 1) into the bearing seat.
Fit the outer race of the bearing (pos. 2) in the bearing seat (Figure 17).


IMPORTANT
MAXIMUM PERMISSIBLE DEVIATION FROM THE MEASURED VALUE IS + 0.05 mm (0.002 in.) - 0.05 mm (0.002 in).

AXLE SHAFT BEARING
Fit the shims (pos. 1) (recovered during dismantling) in the bearing seat for an initial adjustment.
Fit the bearing outer race (pos. 2) in the bearing seat (Figure 18).

Fit the shims (pos. 3) (recovered during dismantling) in the second bearing seat for an initial adjustment. Press the bearing
outer race (pos. 4) into the bearing seat (Figure 18).


IMPORTANT
DO NOT REUTILIZE DAMAGED SHIMS.


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PROCEDURES THERE MUST BE NO CLEARANCE BETWEEN THE BEARINGS.
IT SHOULD BE POSSIBLE TO TURN THE AXLE SHAFT BY HAND.

After setting the preload on the bearings, re-check the backlash.
If backlash is outside the permissible limits, the adjustment procedure must be repeated.


        ATTENTION
During backlash adjustment procedures, add (pos. 1 and 2) or remove shims from both bearing seats “1” and “2”
(Figure 32).

After having preloaded the bearings and adjusted the backlash, remove the axle shaft once again in order to fit the thread
guard and the radial seal. See paragraphs 12 and 13.

6.12 FITTING THE THREAD GUARD ON THE REDUCTION GEAR CASE

Spray the seating of the thread guard with rapid detergent type LOCTITE No. 706 from a distance of about 30 cm, holding the
spray can upright. Allow the detergent time to act then wipe away the dissolved dirt with a clean rag. Spray the surface again
and this time leave the product to dry (Figure 33).


        ATTENTION
Avoid contact with eyes and skin! Do not spray near naked flames or incandescent parts!

Coat the thread guard seating with LOCTITE No. 270 and then press the thread guard (pos. 1) fully home using tool “S”.

6.13 FITTING THE RADIAL SHAFT SEAL IN THE REDUCTION GEAR CASE

Remove the axle shaft and remove the outer race of the taper roller bearing from the reduction gear case using a puller.

Coat the outside diameter of the radial seal of the shaft (pos. 1) with a light film of LOCTITE No. 574 and then fit the seal in
the case using installation tool “T” (Figure 34).


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2.1 TABLE OF COMPONENTS - REDUCTION GEAR GR-96

The components illustrated on the facing page are described in the following table.
Key:
Ref. Component reference in exploded view
Component description Function of component


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- From the side of the reduction gear case, insert the bearing ring B and then insert quadrant C so that the tapered side of
the quadrant engages with the tapered side of the ring; screw the nut onto rod A on point G, tighten with the wrenches to
force the bearing rings together in the reduction gear housing. (Fig. 4)

2) Tool for installing taper roller bearings on pinion (5), Plastic mallet - Fit the taper roller bearing to the pinion shaft, position
the tool on the bearing and use the mallet to drive the bearing against the pinion (Ref. H fig. 5), fit the spacer on the shaft.


3) 30 mm hex wrench, Regular pliers, Hammer, Tool (5) -
Insert the taper pin in the reduction gear seat from the inside (Fig. 5), insert the second taper roller bearing on the top of the
pin and use the hammer and special tool to drive the bearing fully home against the race.
Insert the two keys (Ref. M) in the locations in the shaft, clean the shaft thoroughly and smear on Loctite 542 then fit the
crown wheel (Ref. L).
Smear Loctite 242 on the shaft threads and fit the nut (Ref. N).
Lock the crown wheel (Ref. L) against rotation with the pliers and tighten the nut with the torque wrench to 6 Kgm (59Nm)
(Fig. 7).


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