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Lufkin Gearbox PDF
Lufkin Gearbox PDF
TABLE OF CONTENTS-------------------------------------------------------i
LIST OF FIGURES AND TABLES --------------------------------------- iii
1 INTRODUCTION ---------------------------------------------------- 1
1.1 SCOPE.............................................................................. 1
1.2 SAFETY PRECAUTIONS............................................... 1
1.3 EQUIPMENT DESCRIPTION ........................................ 1
1.3.1 Factory Testing.......................................................... 1
1.3.2 Gearing ...................................................................... 2
1.3.3 Bearings..................................................................... 2
1.3.4 Instrumentation.......................................................... 2
1.3.5 Housing ..................................................................... 2
1.3.6 Lubrication ................................................................ 2
1.3.7 Accessories................................................................ 2
2 SAFETY SUMMARY------------------------------------------------ 4
2.1 GENERAL SAFETY PRECAUTIONS........................... 4
2.2 SAFETY EQUIPMENT................................................... 5
2.2.1 Wear Proper Safety Equipment................................. 5
2.2.2 Reduce Danger of Damage to Hearing...................... 5
2.3 REDUCE RISK OF ACCIDENTAL SHOCK ................. 5
2.4 RESUSCITATION........................................................... 5
2.5 POSSIBLE MISUSES OF EQUIPMENT........................ 5
3 INSTALLATION ----------------------------------------------------- 6
3.1 RECEIPT OF SHIPMENT............................................... 6
3.2 STORAGE........................................................................ 6
3.2.1 Corrosion Protection During Inoperative Periods ..... 6
3.3 LIFTING, HANDLING ................................................... 7
3.4 FOUNDATION................................................................ 7
3.5 TRANSPORT BUSHING ................................................ 7
3.6 ALIGNMENT .................................................................. 7
3.6.1 General ...................................................................... 7
3.6.2 Anticipation of Shaft Operating Positions................. 8
3.6.3 Alignment Sequence.................................................. 8
3.6.4 Alignment Checking.................................................. 9
3.7 TOOTH CONTACT CHECK .......................................... 9
4 OPERATION -------------------------------------------------------- 10
4.1 LUBRICATION ............................................................. 10
4.2 OIL TYPE AND GRADE .............................................. 10
4.3 CUSTOMER CHECK BEFORE START-UP................ 10
4.4 START-UP PROCEDURE ............................................ 11
4.5. CUSTOMER CHECK AFTER START-UP .................. 11
4.6 ALARM SWITCHES..................................................... 11
6 DISASSEMBLY------------------------------------------------------15
6.1 GENERAL......................................................................15
6.1.1 Lock out/Tag Out Procedure ...................................15
6.1.2 Visual Inspection .....................................................15
6.2 TOOLS REQUIRED ......................................................15
6.3 SPARE PARTS ..............................................................16
6.4 REMOVAL OF GEAR COVER ....................................16
6.5 REMOVAL OF HIGH SPEED PINION........................16
6.6 REMOVAL OF LOW SPEED GEAR ...........................17
6.7 REMOVAL OF TORQUE SHAFT................................17
8 BEARING INSPECTION------------------------------------------22
8.1 BEARING TYPE ...........................................................22
8.2 BEARING CONDITION ASSESSMENT.....................22
8.2.1 Bearing Clearance ...................................................22
8.2.2 Bearing Contact and Correction ..............................23
8.2.3 Bearing High Spots..................................................23
8.2.4 Flaking of Babbitt....................................................23
8.2.5 Scoring.....................................................................23
8.2.6 Wiping .....................................................................24
8.3 REPLACEMENT BEARINGS ......................................24
9 REASSEMBLY ------------------------------------------------------25
9.1 PREPARATION.............................................................25
9.2 REASSEMBLY SEQUENCE ........................................25
9.2.1 Gear Assembly ........................................................25
9.2.2 Bottom Section ........................................................25
9.2.3 Middle Section.........................................................26
9.2.4 Top Section..............................................................27
page ii NFVQ2419D
9.3 RESISTANCE TEMPERATURE DETECTORS .......... 28
10 TROUBLESHOOTING ------------------------------------------- 29
10.1 ABNORMALLY HIGH TEMPERATURE ................... 29
10.2 LOW OIL PRESSURE................................................... 29
10.3 UNUSUAL OR EXCESSIVE NOISE ........................... 29
10.4 EXCESSIVE VIBRATION............................................ 30
10.5 NO SENSOR READINGS............................................. 30
List of Figures
and Tables
Figure 1 Lifting provisions ...................................................... 7
Figure 2. Axial thermal growth................................................. 8
Figure 3. Mechanical and thermal movement........................... 8
Figure 4. Generator, gear unit, and turbine aligned .................. 9
Figure 5. Tooth contact patterns ............................................. 20
Figure 6. Pressure dam journal bearing .................................. 22
Figure 7. Orientation of pressure dam bearings...................... 26
1.1 SCOPE
The objective of this manual is to give general information on installation, lubrication,
operation, maintenance, disassembly and reassembly of LUFKIN Industries NFVQ2419D
vertical gear units. In addition, there is supplementary information on unit storage, coupling
alignment, oil characteristics, bearing wear, and gear wear. Table 1 provides an overview of
equipment features.
page 2 NFVQ2419D
Table 1. EQUIPMENT DESCRIPTION CHART
Specifications Service Factor Service HP
• AGMA 6011 AGMA 1.67 70,000 HP
• API 613 5th Edition API 1.10 52,200 kW
• GE A-277696
DANGER notices are used to WARNING notices are used CAUTION notices are used to
indicate an imminently to indicate a potentially indicate a potentially
hazardous situation. Failure hazardous situation. Failure hazardous situation. Failure
to comply will result in to comply could result in to comply may result in
death or serious injury to death or serious injury to minor or moderate injury to
personnel. personnel. personnel and/or damage to
equipment.
When manuals are supplied by a vendor for auxiliary or accessory equipment installed by
LUFKIN, they are included in the appendix to this manual. IMPORTANT: Read and observe
all safety warnings and messages in vendor manuals.
LUFKIN does not assume responsibility for proper guarding of shafting and couplings. LUFKIN
may in some cases supply the guards; however, because of the position of the gear in the power
train, the guards must also be attached to other equipment. The user must insure adequate
guarding is provided and used in the power train.
page 4 NFVQ2419D
2.2 SAFETY EQUIPMENT
2.2.1 Wear Proper Safety Equipment
Personnel working with or near heavy equipment should wear safety equipment appropriate to the
area in which they work:
• Safety glasses with side shields
• Appropriate hard soled shoes
• Appropriate head gear (hard hats)
2.2.2 Reduce Danger Of Damage To Hearing
Gears and their connecting equipment may produce noise
CAUTION: levels that are capable of causing hearing loss with long-term,
Use of hearing protection should be unprotected exposure. The use of hearing protection
considered when working near any noisy equipment should be considered whenever working in areas
equipment. containing equipment emitting high noise levels or noise at
frequencies that are bothersome.
2.4 RESUSCITATION
Personnel working with or near high voltage should be familiar with modern methods of
resuscitation. Such information may be obtained from the Bureau of Medicine and Surgery or the
Red Cross.
3.2 STORAGE
The gear is tested at LUFKIN with a break-in oil that contains a rust preventative (Interfilm
Type 1™ by Esgard, Inc.) which will protect the internal parts for at least six months after
shipment. Do not store the gear unit outdoors unless covered. If the inoperative period is
greater than six months, see "Corrosion Protection During Inoperative Periods."
page 6 NFVQ2419D
3.3 LIFTING, HANDLING FOUR LIFTPOINTS
The gear unit should
WARNING: always be moved by
rolling on bars or
Improper lifting techniques could cause
skates, or by lifting it
damage to the gears and/or harm to with properly rated
personnel. slings through the
lifting lugs on the top
of the unit. See the
Installation Plan or
CAUTION: Table 1, “Equipment
Description Chart” for
Do not lift unit by either input or output
shafts. Do not bump the shafts. lifting weights.
Never lift or sharply
strike the shaft
extensions.
Always exercise extreme caution while lifting any
part of a gear unit. The Installation Plan drawing also
provides lifting weights. See Figure 1 for lifting
Figure 1
provision locations.
Figure 1
3.4 FOUNDATION
The unit must be seated on a substantial foundation. The unit is mounted in a base plate
enclosure with tapped holes already in place so that bolts can be used to clamp down the feet
of the gear unit (with the proper shims in place) at all positions. Shim space allows room for
proper positioning of the gear unit for slow speed and high speed coupling alignment. In
making up the shim pack use as few shims as possible so that the pack will not be "soft". The
housing must not be twisted or in a bind as this will adversely affect tooth contact and will
cause bearing edge loading.
CAUTION:
3.5 TRANSPORT BUSHING
During factory assembly and testing and for shipping security,
Torque shaft transport bushing the low speed gear is held in position by a two-piece blue
(blue ring) must be removed prior torque shaft transport bushing on the extension end of the gear
to start-up.
shaft. This ring must be removed prior to start-up. Store the
bushing for later use in alignment or transport.
3.6 ALIGNMENT
3.6.1 General
Securing proper shaft alignment is one of the most important
phases of setting up a gear unit. Any appreciable misalignment
CAUTION: can cause a multitude of gear problems from excess bearing
and gear tooth wear to vibration problems. Uncorrected
Adequate foundation must be provided misalignment can lead to catastrophic failure. Therefore, it is
for proper alignment. essential that thermal growth and shaft operating position in
the bearings be anticipated during shaft alignment and that
good alignment be maintained.
1. Position the equipment on the base as instructed with shims as desired to permit future
equipment replacement if desired.
2. Connect the low speed torque shaft to the generator. Apply torque to the pinion until
the pinion is pulled in operating mesh with the gear.
3. Check dimension between clutch input flange and output ring. This dimension should
be 2.150±0.025 cold.
page 8 NFVQ2419D
4. Move the gearbox or the generator axially until the dimensional requirement is met.
NOTE: High speed shaft coupling “stretch” should be established from the pinion position
established in (3) above.
5. Pull pinion flange toward turbine and verify dimension between clutch input flange and
output ring is less than 2.300.
TURBINE
GENERATOR
Figure 4
page 10 NFVQ2419D
WARNING:
4.4 START-UP PROCEDURE
Activate turning drive and operate at turning drive speed
Coupling guards and inspection covers while ensuring acceptable oil pressure, etc. Start turbine and
must be secured BEFORE start-up. operate at idle speed until temperature is stabilized. Ensure
turning drive has disengaged. Bring up to operating speed and
check for acceptable temperature and vibration.
CAUTION:
Operation of the gear unit with no oil will
result in damage.
4.5. CUSTOMER CHECK AFTER
START-UP
1. Watch the bearings for a sudden high temperature rise which could indicate a bearing
problem.
2. Run gear under full load and speed and check for unusual noise and vibration. Expected
maximum shaft vibration level for the NFVQ2419D is 2.0 mils (0.05 mm) peak-to-peak
displacement. The expected maximum housing velocity is 0.2 in/sec peak (5 mm/sec).
The preliminary settings for warning indicators offered below in “Alarm Switches”
exceed the expected operating levels.
3. Also check oil temperature and bearing temperature. See “Alarm Switches” below for
starting alarm settings. After temperature stabilization, the oil temperature into the gear
unit should generally not be hotter than 140°F (60°C).
4. After unit has run for two hours under load, start turning drive and shut unit down.
Operate turning drive until unit has cooled acceptably. Shut turning drive down. Check
coupling alignment, check and tighten any bolts that may be loose, and check tooth
contact.
5.1 INTRODUCTION
The Scheduled Maintenance instructions in this manual are intended to provide a guide for
minimum operations required to insure years of trouble-free operation. Table 4 gives an
overview of scheduled maintenance.
If major repairs should be needed on this gear unit, it is best to return it to the factory. If time
is not available for factory repairs, LUFKIN has capable field servicemen available who can
go to the job site.
If the customer desires to repair the equipment, the parts list furnished with the gear unit and
the information in this manual should be studied carefully.
Good preventive maintenance habits will prolong the life of the gear unit and will help in
detecting trouble spots before they cause serious damage and long down time.
QUARTERLY ANNUALLY
• analyze oil sample • check bearing clearance
• check endplay
page 12 NFVQ2419D
5.2 DAILY MAINTENANCE
• Check the oil temperature and pressure against previously established norms.
• Check for unusual vibration and noise.
• Check for oil leaks.
Take an oil sample and submit for laboratory analysis. Compare the results to the initial
baseline analysis done when oil was first put into the unit. It is recommended that the oil
be changed in the following cases:
page 14 NFVQ2419D
Disassembly 6
During disassembly, refer to the Installation Plan and
Parts List furnished for the gear unit.
6.1 GENERAL
NOTE: Any work done on equipment during the warranty period without the
written approval of an authorized LUFKIN representative could void the
warranty.
6.1.1 Lock Out/Tag Out Procedure
1. Identify the energy sources used and all control devices.
DANGER: 2. Notify all affected personnel.
3. Turn OFF all operating controls.
When working near rotating elements, be
certain prime mover is turned off and 4. Lock out or tag out all switches and energy controls in
locked out/tagged out. “off” or “safe” positions.
5. Test all operating controls to make sure no power is
getting to equipment.
6. Perform required maintenance.
page 18 NFVQ2419D
Soft blue is usually applied to three or four teeth on the pinion in two places 180° apart.
Clean the teeth thoroughly with solvent, and brush on the blue in a very thin and even layer.
With the gear set centered, hold a drag on the gear and roll the pinion through mesh with the
gear. Rotation direction is not important, but the contact must be checked on the loaded flank,
not the unloaded tooth flank. Observe the blue that transferred from the pinion to the gear.
This is the contact pattern.
Cellophane tape can be used to remove this blue pattern from the gear and save it for
maintenance records: after the check, firmly place a piece of tape on the gear tooth flank,
remove the tape, place it on a clean sheet of white paper, and label it with:
• the date
• name and number of the part the tape was lifted from
• the wing and apex
• which helix (left or right, noting whether wing or apex is leading)
The contact should be checked at three places around the gear (approximately 120˚ apart;)
however, the blue must be reapplied and smoothed on the pinion after each meshing.
7.1.6 Hard Blue Method
Thoroughly clean the area where hard blue is to be applied. The teeth must be absolutely free
of oil, or the blue will not adhere properly and large flakes will chip off, making the contact
check inaccurate.
Apply the blue to an area three or four teeth wide at four places on the gear and at two on the
pinion. Run the unit (usually at full speed.) Running conditions may vary from no load to full
load. The best way is to run the unit at very light load (up to 20%) for two hours or so, and
then shut it down and check the contact. With higher loads the unit should run a shorter time
before checking contact. The trick is to run the unit just long enough to wear the blue off the
areas of higher contact stress. High loads can mask poor contact and give a false reading.
page 20 NFVQ2419D
Abrasion – Type of wear: Removal or displacement of material due to the presence of hard
particles suspended in the lubricant or embedded in the flanks of the mating teeth
(includes scoring).
Bending fatigue– Progressive failure through crack initiation, propagation, and fracture.
Contact fatigue– Cracks and the detachment of material fragments from the gear tooth
surface caused by contact stress (includes pitting, spalling and subcase fatigue.)
Corrosion– Type of wear: Chemical or electrochemical reaction between the surface of a
gear and its environment.
Cracks– Splits caused by bending fatigue, mechanical stress, thermal stress, material flaws, or
improper processing.
Erosion– Type of wear: Loss of material from surface because of relative motion of a high
velocity fluid.
Fracture– A fatigue failure caused by tooth overloading resulting in gear tooth or portion of
tooth breaking off (includes tooth shear.)
Plastic deformation– Deformation caused by stress exceeding the yield strength of the
material (including indentation, cold flow, hot flow, rolling, tooth hammer, rippling,
ridging, burring, root fillet yielding, or tip-to-root interference.)
Scuffing– Severe adhesion that causes transfer of metal from one tooth surface to another due
to welding and tearing.
Wear– Change to a gear tooth surface involving the removal or displacement of material,
caused by mechanical, chemical, or electrical action (includes adhesion, abrasion,
polishing, corrosion, fretting corrosion, scaling, cavitation, erosion, electrical
discharge, and rippling.)
page 22 NFVQ2419D
Some wear should be expected, especially on a gear that is stopped and started frequently.
The bearing may be considered operational as long as the measured clearance does not
exceed the design clearance by more than 0.002" (0.050 mm).
NOTE: If shaft vibration is excessive, this clearance increase may not be
acceptable–contact LUFKIN.
8.2.5 Scoring
Scoring, scratching, or marring of the bearing babbitt and/or the journal riding in the bearing
is caused by dirt or metal particles in the oil which passes through the bearing. A little scoring
is not serious, and the bearing may be polished with fine steel wool to remove any rough
edges caused by scoring. Any foreign particles embedded in the babbitt which could score the
journal should be carefully picked out, and that area should then be polished smooth. Scoring
becomes serious when it significantly reduces the bearing area. In this case, the bearing
should be replaced and the gear unit drained and flushed out with a solvent.
page 24 NFVQ2419D
Reassembly 9
9.1 PREPARATION
NOTE: Any work done on equipment during the warranty period without the written
approval of an authorized LUFKIN representative could void the warranty.
NOTE: This procedure assumes that the gear housing is not moved from its foundation/
support and that the original shaft alignment was correct.
1. Clean all the interior surfaces of the housing, the housing cover, and all components
that will be reused. Parting line surfaces must be clean and smooth; use a spray-on paint
and gasket remover fluid and/or carefully scrape the surfaces if necessary. Corroded
spots can be cleaned by using a fine emery cloth, rubbing shafts in a rotary or
circumferential direction. Do not rub shafts in a length-wise direction as it may cause
seal leaks.
2. Check the bearing shells, the parting line, and the housing bores for any burrs or nicks;
remove with a fine file.
3. Put a coat of light oil on all parts to help assembly and to prevent rust during
reassembly.
For the discussion that follows, it is assumed that the entire unit must be reassembled. If the
torque shaft, bearings, or turning gear are already assembled, omit those portions of the
reassembly instructions.
NOTE: Tighten connectors uniformly: when tightening bolts, studs, or screws on
an assembled portion with three or more holes, always partially tighten
connectors equally in a “cross” pattern to avoid torquing, binding, or warping the
section (for example: 1. top left corner, 2. bottom right corner, 3. top right corner,
4. bottom left corner. Repeat to fully tighten.)
page 26 NFVQ2419D
5. Make sure the pinion is level and carefully line it up in mesh with the gear.
6. Carefully set the pinion into its bearings and in mesh with the gear.
7. Check bearing contact as in BEARING INSPECTION, “Bearing Contact and
Correction.”
Note: Because the TOP half of the bearing is the loaded half, first do steps 4-8 with the top
half of the bearing flipped end for end and then positioned in the housing. When contact is
satisfactory, disassemble and reassemble with the bottom half in place.
8. Replace bearing tops.
9. Coat the split line with a small bead of sealer, such as LocTite™ No. 49-31 Plastic
Gasket. Circle all studs to assure sealing of oil; avoid feeder groove areas.
10. Clean and install the cylindrical dowel pins.
5. Measure to ensure low speed shaft has specified axial movement. (Use a pry bar to
move gear from side to side if necessary). Also check that the high speed pinion can
float axially.
6. Install the coupling cover.
7. Reconnect the turning drive and pressurize the Safeset clutch (see Safeset manual for
details).
8. Mount the shaft seals, end plates, and other auxiliary equipment which may have been
disconnected during disassembly.
page 28 NFVQ2419D
Troubleshooting 10
This section provides troubleshooting tips for high speed gears. For detailed information,
refer to the text following. Table 6 at the end of this section provides an overview. If the
problem cannot be remedied through use of this information, contact LUFKIN.
page 30 NFVQ2419D
Table 6. Troubleshooting Tips
Problem Possible Cause Remedy
Abnormally • Housing coated with foreign • Clean outside of housing
High material, preventing heat
Temperature dissipation
• High ambient temperature • Provide adequate ventilation
• Lack of oil to bearings and/or • Check lubrication system
mesh (indicated by low oil
pressure)
Low Oil • Use of lubricant with lower • Use correct viscosity lubricant
Pressure viscosity than required
• Low lubricant viscosity from • See "Abnormally High
high lubricant temperatures Temperature" below
• Clogged oil filter • Replace filter element
• Pump cavitation • Maintain proper oil level in
reservoir
• Air leak in suction line • Check and tighten all pipe
fittings
• Incorrect relief valve setting • Set relief valve correctly
Excessive • Insufficient foundation rigidity • Reinforce foundation
Vibrations • Dynamic instability (critical • Design to attenuate critical
speed) speeds in operating range
• Unbalanced parts • Determine which parts require
balancing and which have
been balanced
• Loose foundation bolting • Tighten bolting
Unusual Noise • Worn parts • Pinpoint noise with mechanic's
stethoscope, replace part
• Coupling misalignment • Realign couplings
Excessive • Worn gearing • Replace worn parts
Noise • Transmission from other • Add sound blanket or
equipment enclosure
No Sensor • No power • Check power supply & repair
Readings or restore
• Faulty gauge or recording • Test gauge or recording
device equipment
• Failed sensor • Replace sensor
• Lead wire braid rubbed • Replace sensor
through; wire contacting metal
GEARS
MODEL GEAR
NO. NFVQ2419D RATIO 1.209:1
SPEC
API 613, 5th
NO. OF
TEETH 81 / 67
GR/PIN
INDUSTRIES, INC.
LUFKIN, TEXAS
page 32 NFVQ2419D
Installation, Operation, and Maintenance page 33
TECHNICAL MANUAL NO. M434
ENGINEERING INC .
INDEX
SAFETY STATEMENTS
F:/doc/tg/tg/in050525
ENGINEERING INC
Safety
The Meaning of Safety Statements
You will find various types of safety information on the following pages
and on the labels attached to the equipment. This section explains the
meaning.
Danger
Danger means that failure to follow the safety statement will result in serious personal injury,
death, or substantial property damage.
Warning
Warning means that failure to follow the safety statement could result in serious personal injury,
death, or substantial property damage.
Caution
Caution means that failure to follow the safety statement may result in minor or moderate
personal injury or property damage.
Notice
Notice means that failure to follow these instructions could cause damage to the equipment or
cause it to operate improperly.
Safety
The following safety statements relate to the installation, operation and
troubleshooting of Koenig Engineering, Inc. Turning Gear Drive
Packages
Notice
Make sure you read and understand the installation procedures in this manual before you attempt
to install, operate, maintain or troubleshoot the equipment.
Warning
The instruction manual should be used for proper installation, operation and maintenance of the
equipment. Improperly installing and maintaining these products can result in serious personal
injury or property damage. Before attempting installation or maintenance, read and understand
this entire manual.
SECTION I
--Page 1--
The TURNING GEAR DRIVE PACKAGE, illustrated on the enclosed assembly drawing, consists
of an electric motor driving through a worm gear reducer connected to an overrunning clutch encased
in an oil tight housing.
The mounting interface, supplied by others, conforms to the bolt circle and spigot diameter of the
TURNING GEAR DRIVE PACKAGE housing. Connection of the TURNING GEAR DRIVE
PACKAGE is made to the high speed shaft of the load gear through a spigot mount on the shaft end.
The high speed shaft end is connected to an SSS (synchro-self-shifting) overrunning clutch for
automatic engagement/disengagement. This clutch is a positive tooth type overrunning clutch which is
self-engaging in the turning mode and overruns whenever the connected shaft exceeds the TURNING
GEAR DRIVE PACKAGE speed. The input flanged hub to the overrunning clutch is mounted on
the output shaft of the worm gear reducer.
The input shaft of the worm gear reducer is to be connected to an electric motor by means of a resilient
coupling.
In the event of power failure or during maintenance procedures, a means for manual turning is
provided through a 1-1/8" hex drive located in fan cover on primary worm gear shaft.
CAUTION
BEFORE ATTEMPTING MANUAL OPERATION,
MAIN A.C. MOTOR BREAKER MUST BE DISCONNECTED AND
TAGGED IN ORDER TO PREVENT ACCIDENTAL INJURY.
Lubrication for the clutch is continuously supplied from the main plant lube oil system through a 1/2"
NPT female pipe connection on the worm gear reducer output shaft cover. Oil is drained from the
clutch housing into the load gear housing for return of the oil to the plant lube oil tank.
Oil for the worm gear reducer is self-contained, refer to instructional booklet for proper lubricant.
F:\DOCUMENT\Turning Gears\TG\050525_M434.doc
--Page 4--
SHIPPING
The TURNING GEAR DRIVE PACKAGE, as depicted per Drawing 05-0525, is shipped partially
assembled. The Input Clutch Hub (Item 1) that connects to the Clutch Input Flange has been mounted
to the Worm Gear Reducer (Item 5) Output Shaft. The clutch housing (Item 2) is mounted to the worm
gear reducer (Item 5) housing and sealed with Dow Corning #732 silicone sealant. The housing (Item
2) should not be removed from the reducer housing as the silicone seal will be broken and the surfaces
must then be thoroughly cleaned and gasket sealer replaced.
2. Check that distance between the high speed gear shaft mounting face and outside mounting surface
of the gear housing is 0.375" nominal.
WARNING
UNDER ALL OPERATING CONDITIONS, THIS DIMENSION MUST REMAIN WITHIN THE
LIMITS OF 0.469" MAXIMUM AND 0.281" MINIMUM.
3. Assemble the clutch output component (Item 4) to the pinion shaft with eight (8) socket head
capscrews (Item 13). Torque to 108 lb-ft and install lockwire. See Figure 1.
F:\DOCUMENT\Turning Gears\TG\050525_M434.doc
--Page 5--
F:\DOCUMENT\Turning Gears\TG\050525_M434.doc
--Page 6--
5. Mount the TURNING GEAR DRIVE PACKAGE, with the clutch housing upper half removed,
to the gear housing mounting suface. Secure with four (4) ¾” hex head cap screws and
lockwashers, and place a temporary support under the worm gear reducer to prevent downward
deflection of the clutch housing lower half. See Figure 3.
6. Perform face and rim alignment checks between the clutch input hub (Item 1) and clutch output
component (Item 4). Readings on the face and rim should not exceed .004” TIR.
7. Remove the TURNING GEAR DRIVE PACKAGE from the gear mating surface and assemble
the clutch input component (Item 4) to the clutch input hub (Item 1) with eight (8) socket head
shoulder screws and locknuts (Items 11 & 12). Torque locknuts to 32 lb-ft. See Figure 4.
8. Clean all horizontal and vertical joints and apply Dow Corning #732 silicone sealant. Then
reassemble the clutch housing upper half to the lower half using the supplied fasteners. See
Figure 5.
10. Apply Dow Corning #732 silicone sealant to the mating face of the clutch housing (Item 2). Pass
the assembled speed reducer, input hub and clutch input component axially into the clutch output
component mounted to the pinion shaft.
NOTICE
THE CLUTCH GEAR TEETH MUST BE IN LINE SO AS TO ACHIEVE MESH WHEN
ASSEMBLING. IF NECESSARY, ROTATE THE TURNING GEAR IN REVERSE
MANUALLY TO ALIGN THE GEAR TEETH. NEVER ROTATE THE TURNING GEAR
FORWARD OR DAMAGE TO THE CLUTCH TEETH MAY RESULT.
NOTICE
TAKE CARE NOT TO REST THE CLUTCH INPUT COMPONENT ON THE CLUTCH
OUTPUT RING AS DAMAGE TO INTERNAL CLUTCH COMPONENTS COULD OCCUR.
NOTICE
IF REMOVING THE TURNING GEAR ASSEMBLY, MANUALLY ENGAGE THE CLUTCH
FIRST. THIS AUTOMATICALLY PUTS THE GEAR TEETH INTO MESH AND PERMITS
SAFE REMOVAL OF THE UNIT.
F:\DOCUMENT\Turning Gears\TG\050525_M434.doc
--Page 7--
Insert and tighten the 3/4" hex head cap screws/lock washers (Items 9 & 11) securing the TURNING
GEAR DRIVE PACKAGE to the mounting interface. See Figure 6.
11. Place a temporary support under the worm gear reducer (Item 5) to prevent downward deflection
when the clutch housing (Item 2) top half is not present.
12. Final alignment checks can be made through the inspection cover (Item 3), or by removing the top
half of the entire clutch housing (Item 2). If removing the top half of the housing, use the jacking
provisions at the horizontal joint.
13. Perform final face and rim alignment checks between the clutch input flange and clutch output
component. Readings on the face and rim should not exceed 0.004" TIR.
14. As a final check, verify the dimension between the clutch input flange and clutch output ring at
2.219" nominal (see drawing 05-0525 for location).
WARNING
UNDER ALL OPERATING CONDITIONS, THIS DIMENSION MUST REMAIN WITHIN THE
LIMITS OF 2.313" MAXIMUM AND 2.125" MINIMUM.
15. Reassemble inspection cover (Item 3) to clutch housing using Dow Corning #732 silicone sealant
on all mating surfaces. See Figure 7.
16. If the top half of the clutch housing was removed, clean all horizontal and vertical joints and apply
Dow Corning #732 silicone sealant prior to reassembling.
17. Connect the oil inlet line from the main lube oil system to the ½" NPT connection on the worm
gear reducer output shaft cover.
18. Fill the worm gear reducer (Item 5) with Mobil SHC 634 lubricant.
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LUBRICATION
1. CLUTCH: The clutch requires a continuous flow of oil, 1.0 gpm at 15-18 psi, at all times. Oil is
supplied to the clutch from the main oil system through a ½" NPT port on the worm gear reducer
output shaft cover.
2. REDUCER: Oil for the reducer is self contained and the recommended lubricant is Mobil SHC
634. Recommended alternate lubricants are listed in the reducer portion of this booklet.
3. MOTOR: The motor bearings are shipped grease-packed. Regreasing procedures are listed in the
motor portion of this booklet.
1. Once the TURNING GEAR DRIVE PACKAGE is installed and prepared for operation, it should
be initially operated manually to ensure that breakaway of the turbine train is possible without
exceeding the torque capability of the Turning Gear.
2. Insert a torque wrench onto the 1-1/8” hex drive on the non-drive end of the worm gear input shaft.
Rotate in the CW direction. Once the SSS clutch is engaged, continue to apply torque through the
Turning Gear until turbine shaft breakaway is achieved.
WARNING
BEFORE ATTEMPTING MANUAL OPERATION, TURNING GEAR MOTOR BREAKER
MUST BE DISCONNECTED AND TAGGED TO PREVENT ACCIDENTAL INJURY
CAUTION
DO NOT EXCEED 450 FT-LB OF TORQUE ON THE MANUAL TURNING ADAPTER OR
DAMAGE TO THE TURNING GEAR COMPONENTS COULD RESULT.
3. Once breakaway is achieved, rotate the manual turning in the CCW direction for approximately 1
turn to fully disengage the clutch.
4. The TURNING GEAR DRIVE PACKAGE is now ready for normal operation.
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1. Disconnect wiring to the electric motor (Item 6). Place a temporary support under the Turning
Gear to prevent downward deflection when the top half of the housing is removed.
2. Remove screws and lock washers (Items 7, 8, 9 & 10) from top half of clutch housing (Item 2) and
remove it from the turning gear using the jacking provisions at the horizontal joint.
3. Remove the output clutch fasteners (Item 13) and compress clutch output component onto the input
component.
4. Disconnect the lube oil supply line, located at the rear of the worm gear reducer (Item 5).
5. Choke a sling around the bottom of the electric motor (Item 6). Attach a lifting device to the
eyebolts on the worm gear reducer (Item 5) and sling on motor.
6. Remove fasteners (Items 9 & 10) holding the lower half of clutch housing (Item 2) to the load gear
and remove the worm gear reducer and electric motor assembly.
1. To reinstall the TURNING GEAR DRIVE PACKAGE, perform the field removal procedure in
reverse.
2. If reinstalling the 1/2" socket head shoulder screws and locknuts for the clutch input component
(Item 11 & 12), torque them to 32 lb-ft.
3. When reinstalling the clutch housing (Item 2) to the worm gear reducer (Item 5) and gear housing,
be sure to clean all mating faces and replace the silicone sealant.
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For all spare parts inquiries and orders refer to Turning Gear serial no. TG#### and contact:
Koenig Engineering, Inc.
410 Eagleview Blvd, Suite 104, Exton, PA 19341
(610) 458-0153 phone, (610)458-0404 fax
www.koenigengr.com webpage, or koenig@koenigengr.com email
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LONG TERM STORAGE INSTRUCTIONS
The unit as it left the factory was prepared for in-transit protection against the elements and is not
intended as protection for long-term storage. In the event the unit cannot be installed and placed into
service, the unit should be removed from the container in which it was shipped, but retaining the wood
skid on which it came to prevent damage. The unit is to be stored in a secure, cool, dry, vibration free
and clean environment limiting its exposure to the elements. Tag unit to show date placed in storage
or decommissioned and current status relating to storage procedure per the following outline.
2. Exposed machined surfaces for coating deterioration and/or rust blush. Renew coating
as required with Dow Corning Metal Protective Coating or equivalent. (See Dow
Corning Protective Coating Specification Sheet in this section.)
3. The Worm Gear Reducer requires approximately 4.7 gallons of oil in the housing for
normal operation. For long term storage, remove breather and completely fill the
Turning Gear with the recommended lubricant immersing the gear completely in oil and
maintaining this level. Replace breather with a solid plug and place breather in a bag
and tag with CAUTION NOTE: "Must Be Drained To Proper Level And Breather
Installed Before Operation". Keep in mind, however, that the oil will expand with
rising ambient temperatures. Tie wire bag and tag to unit. For additional information
refer to Nuttall Gear LLC, Delroyd Worm Gear Division Long Term Storage
Instructions found in this section.
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LONG TERM STORAGE INSTRUCTIONS
1. Maintain the proper level of lubricant in the Worm Gear Reducer using the sight gage to
periodically check the level.
2. Once a month, energize the power plant lube oil system and, while circulating oil, operate
the Turning Gear Unit for a few minutes and every six months operate the unit for two (2)
hours. This can be done with the unit main coupling connected or disconnected from the
main power plant. The power plant operating procedures must be observed when operating
the Turning Gear.
Nuttall Gear LLC, Delroyd Worm Gear Division engineering department provides instructions for long
term storage of the Worm Gear Reducer following in this section.
Refer to Section 2 of Instruction Manual for specified lubrication, feed and drain connections.
F:\DOCUMENT\Turning Gears\TG\050525_M434.doc
ENGINEERING INC
Problems can start to develop through improper standby and storage of new worm gear
reducers awaiting installation or operation. Ambient conditions during long, idle periods
will determine necessary measures.
1. Replace breathers with pipe plugs, wiring the breathers to the unit to prevent loss.
2. Fill the reducer with recommended lubricant to the proper level and operate once a
month for a few minutes, or completely fill the unit, or use desiccants or vapor phase
inhibitors.
3. Cover the reducer with a tarpaulin or plastic cover, leaving openings underneath for
ventilation. A heavy, skidded platform with an internally lined wooden box may also
be required when storage is in highly humid or seaside areas.
4. Periodically drain any accumulated water from the bottom of the oil reservoir and
replace desiccants or vapor phase inhibitors.
Immediate failure of the bearing is not a result, but once the bearing is put in operation
these pit marks act as stress risers. The fatigue life of the bearing can be reduced to a
fraction of the calculated design life.
False brinelling can usually be prevented by filling the reducer with oil to cover the
bearings completely. This maintains a supply of oil at the contact points of the balls or
rollers even under conditions of vibration.
Product Information
Specialty
Coatings Dow Corning ®
Metal Protective Coating
1
Registered trademark of The Dow Chemical
Company.
Note: Caustic cleaners should not STORAGE AND SHELF LIFE WARRANTY INFORMATION
be used to remove Dow Corning Metal When properly stored under – PLEASE READ CAREFULLY
Protective Coating from aluminum normal warehouse conditions, The information contained herein
surfaces. Dow Corning Metal Protective is offered in good faith and is
Coating has a shelf life of 60 months believed to be accurate. However,
Caution from date of manufacture. To obtain because conditions and methods of
Dow Corning Metal Protective uniform mixture, slight stirring after use of our products are beyond our
Coating contains mineral spirits. It storage is recommended before use. control, this information should not
should be used in a well-ventilated be used in substitution for customer’s
area, and the precautions normally PACKAGING tests to ensure that Dow Corning’s
followed when working with this Dow Corning Metal Protective products are safe, effective, and fully
solvent should be implemented. Coating is supplied in 30-lb (13.6- satisfactory for the intended end use.
Solvents used to dilute this material, kg) pails and 375-lb (170-kg)
as well as metal cleaning or alkali drums, net weight. Dow Corning Dow Corning’s sole warranty is
cleaners, should only be used with Metal Protective Coating aerosol is that the product will meet the
adequate ventilation. Follow hand- supplied in 10-oz (284-g) Dow Corning sales specifications in
ling precautions on container labels. containers, net weight. effect at the time of shipment. Your
exclusive remedy for breach of such
USE LIMITATIONS SAFE HANDLING warranty is limited to refund of pur-
Painted surfaces should be well INFORMATION chase price or replacement of any
cured before Dow Corning Metal product shown to be other than as
PRODUCT SAFETY INFORMATION
Protective Coating is applied. If the warranted. Dow Corning specifically
REQUIRED FOR SAFE USE IS NOT
intent is to remove Dow Corning disclaims any other express or
INCLUDED. BEFORE HANDLING,
Metal Protective Coating from the implied warranty of fitness for a
READ PRODUCT AND MATERIAL
painted surface at a later date, only particular purpose or merchantabil-
SAFETY DATA SHEETS AND CON-
one light application should be ity. Unless Dow Corning provides
TAINER LABELS FOR SAFE USE,
made. you with a specific, duly signed
PHYSICAL AND HEALTH HAZARD
endorsement of fitness for use,
INFORMATION. THE MATERIAL
This product is neither tested nor Dow Corning disclaims liability for
SAFETY DATA SHEET IS AVAILABLE
represented as suitable for medical any incidental or consequential
FROM YOUR DOW CORNING REP-
or pharmaceutical uses. damages. Suggestions of use shall
RESENTATIVE, OR DISTRIBUTOR,
not be taken as inducements to
OR BY WRITING TO DOW CORNING
SHIPPING LIMITATIONS infringe any patent.
CUSTOMER SERVICES, OR BY
Liquid – DOT classification: CALLING (517) 496-6000.
flammable liquid.
NOX RUST VCI-lO Oil is a volatile corrosion [1] Since drive clutch and steering clutch assemblies
inhibitive lubricating oil for use in the preservation of are subject to corrosion within their compartments dur-
ferrous metal parts in enclosed ‘systems. ing shipment and storage, this problem was overcome by
fogging three ounces of VCI-i0 to the hydraulic test oil.
After testing, an additional three ounces are added.
Having combined the protective properties of a
preservative oil with those of volatile corrosion
[2] Corrosion of hydraulic cylinders can cause leak-
inhibitors, VCI-l0 Oil makes possible long term age. Protection of cylinders and circulating systems is
protection against rust within what are termed “closed” provided by adding 2% VCI-lO to the hydraulic test oil.
systems or voids. After testing, an additional three ounces are added.
PHYSICAL CHARACTERISTICS [3] To forestall rust which will foul a diesel
(Typical Values, Not Specifications) injection system, one ounce of VCI—l0 per each 7—1/2
Viscosity @ lOO°F. SUS: 210 gallons (1 cubic foot) capacity is fogged into the fuel tanks.
Pour Point: -10°F If tank contains oil or gasoline, one ounce of VCI-l0 is
Flash Point: 300°F added for each gallon present.
Specific Gravity: 0.931
Film Thickness @ 77°F: 0.2 mils [4] To protect crankshaft, bearings, rocker arms
Coverage: 800 sq ft per gal and all surfaces normally lubricated by crankcase oil,
Volatile: 5% 1% VCI-1O, by volume, is added to the crankcase oil.
Accelerated Corrosion Test, Humidity JAN—H-792,
100% RH § 1209F: 300 Hours [5] To protect upper cylinder walls and valves in
Vapor Phase Protection, diesel or gasoline engines, eight ounces of VCI10 are
MIL-P-46002A Procedure: Pass introduced through the air filterand sucked into the
cylinders by turning over the motor with ignition off.
NOX RUST VCI-l0 Oil is intended for use in the pres-
ervation of enclosed systems where the volatile compo- [6] For transmissions, 2% VCI-10 is added to the
nents will provide protection above the oil level. It pro- lubricant.
vides an effective contact preservative oil film. Typical
examples of “closed” systems in which VCI-l0 Oil is The unusual properties of VCI-10 OIL can be used to
used to protect metal from damaging rust include: fuel advantage for winter layaway of farm and road
tanks, storage tanks, cylinders, transmissions, metal building equipment and for summer storage of school
containers, gear housings, clutch compartments, crank buses, snow plows, etc. It may also be fogged into
cases, hydraulic and coolant circu1ating systems. shipping cases to protect unpainted auto and truck body
sections during shipments.
Conventional lubricating or preservative oils slushed
or fogged into such systemswill drain away from the NOX RUST VCI-10 OIL can be used full strength in
vertical metal surfaces in about six months, exposing systems with ferrous metals only. Where non-ferrous
the metal to moisture, condensation and corrosion. While metals are present, VCI-10 must be diluted to 2% or
NOX RUST VCI-l0 OIL also drains away, the vapor- less, depending on the metals present.
izing rust inhibitors evolving from the product spread
throughout the void or system and neutralize the corro-
sion-causing tendency of the moisture present in the
air. VCI-1O OIL, being highly fortified with contact
inhibitors, also protects the metal below the oil level.
WARRANTY: Daubert Chemical Company, Inc. (“Daubert”) warrants all products manufactured by it to
free from defects in material and workmanship. DAUBERT MAKES NO OTHER WARRANTIES
WHETHER EXPRESS OR IMPLIED WITH RESPECT TO SUCH PRODUCTS AND ALL OTHER
WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND
IMPLIED WARRANTIY ARISING FROM A COURSE OF DEALING OR USAGE OF TRADE ARE
DISCLAIMED BY DAUBERT. All claims hereunder must be made in writing within30 days after
receipt of the products at buyer’s plant and prior to further processing the products of combining them
with other materials or products. Daubert’s liability, whether under this warranty of in contract, tort,
negligence or otherwise, is limited to the return of the net purchase price paid for any products proven
defective or at Daubert’s option to repair or replacement of said products upon their return,
transportation prepaid to Daubert. Remedy hereby provided shall be the exclusive and sole remedy of
the buyer. Under no circumstances shall Daubert be liable for consequential or incidental damages. No
Daubert representative or other person is authorized to change this warranty in any way to assume for
Daubert any other liability in connection with the sale or use of its products.
Refer to material safety data sheet for health and safety information.
SECTION II
INSTALLATION, LUBRICATION, OPERATION & MAINTENANCE OF
TOPIC PAGE
Installation 3
Lubrication 3
Operation 5
Long Term Storage 6
Maintenance: 7
Disassembly 7
Reassembly 8
Tooth Contact Instructions 10
Lip Seal Inspection/Discussion 11
Replacement of Mechanical Seal Assembly 11
General Safety Instructions 13
Delroyd Worm Gear Assistance 16
INSTALLATION
Proper installation is essential for efficient, economical operation and long life. The unit is built for
proper operation in the mounting position ordered. Tilted or different mounting positions may require
factory installed lubrication provisions. Avoid heavy hammer blows when mounting couplings as this
may damage the bearings or spring the shafts. When tight fits are used, the coupling half should be
heated in oil to expand the bore. When speed reducers are used as standby equipment, operate them
about once a month. Always store reducers indoors in a clean dry location if possible. Standard shop
preparation will allow storage under the above conditions for up to six months. Longer storage periods,
or outdoor storage requires special preparation at the factory.
LUBRICATION
This turning gear reducer is shipped from the Delroyd Worm Gear factory without oil. Before
operating the reducer, fill to the oil level specified on the reducer outline dimension drawing included
with these instructions. Be sure to allow time for the oil to fill all parts of the reducer housing and to
reach a stable level. For extreme temperature changes Delroyd Worm Gear recommends MOBIL SHC
634 synthetic oil for use in this reducer. This oil allows use at ambient temperatures of -30 to 140°F (-
34 to 54° C) and is an ISO 460 grade PAO base synthetic oil. The improved thermal and oxidation
stability of this oil means that oil change intervals can be extended to every 8500 hours or more if an oil
analysis determines that contamination or oxidation has not occurred. Alternative petroleum base
lubricants listed below may be used.
If ambient temperatures below 15°F are expected, a winter lubricant must be selected, since the above
AGMA lubricants will solidify and the motion of the gears will channel the solidified oil until no
lubricant is present at the gear mesh. The lubricant should be changed back to the heavier oils when the
minimum ambient temperature goes above 15°F.
FOR AMBIENT TEMPERATURE OF AGMA LUBRICANT
0°F 6 EP
-10°F 5 EP
-20°F 4 EP
-30°F 3 EP
Due to the nature of worm gear sliding and rolling action, the above lubricants must be used for worm
gearing. Suppliers of industrial lubricants, not service stations, should be contacted to supply suitable
lubricants to meet the above AGMA specifications.
AGMA 8 Comp. - compounded cylinder oil with acidless tallow additives. Approximately 150 SSU
viscosity @ 210°F.
AGMA 7 Comp. - compounded cylinder oil with acidless tallow additives. Approximately 135 SSU
viscosity @ 210°F.
AGMA 6 EP - mild EP oil containing lead napthanate additives. Approx. 120 SSU viscosity @ 210°F.
AGMA 5 EP - mild EP oil containing lead napthanate additives. Approx. 100 SSU viscosity @ 210°F.
AGMA 4 EP - mild EP oil containing lead napthanate additives. Approx. 75 SSU viscosity @ 210°F.
AGMA 3 EP - mild EP oil containing lead napthanate additives. Approx. 53 SSU viscosity @ 210°F.
The following lubricants should never be used for this type reducer:
4. EP oils. Some suppliers may suggest oils with “inactive” sulfur-phosphorous additives instead of
the cylinder oils specified here. We do not recommend their use, except in cold weather operation
as described above.
Between oil changes:
Check oil level periodically when unit is stopped and add oil if necessary. Check that the breather is
not clogged. Units in intermittent service, indoors or outdoors, should be checked for water
contaminated lubricant on a monthly schedule as follows:
1. With reducer off, first let the gear box cool to ambient temperature.
2. Loosen bottom drain plug and drain some lubricant into a small container.
3. Examine for water or discolored (creamy appearing) lubricant. If present, drain until
uncontaminated oil flows out.
If the unit will be idle for any extended time, particularly out-of-doors, rusting of the bearings, gears,
and other internal parts must be prevented. We suggest filling the complete reducer with oil which
contains a soluble vapor-phase corrosion inhibitor, (such as SHELL VSI circulation oil). Replace the
breather with proper size pipe plug, attach breather to unit for future reinstallation. When the unit is
returned to service, drain oil and refill with recommended lubricant to proper level. Install breather.
If the unit is equipped with grease lubricated upper bearing then the grease lubricant will need to be
maintained. Bearings are packed with NLGI Grade 2 lithium based grease at the factory before
shipping. When servicing greased bearings make sure that the fittings are clean and unplugged. Using a
manual grease gun, pump 10 to 15 strokes into the grease fitting once per year for normal service. If the
reducer is run continuously 24 hrs/day for 6 months or more then we recommend greasing the bearings
once every 6 months. We do not recommend using a pneumatic or automatic powered grease gun since
high pressure could damage the shaft seal and/or grease retainer.
OPERATION
Make certain that the reducer is filled with oil before starting, see lubrication instructions. Although
the unit has been tested under no-load at the factory, it takes additional hours of running to attain the
highest efficiency. If necessary, full load can be applied immediately, but it is better for the ultimate life
of the gear to operate the unit initially at one-half load for 20-30 hours and three-quarters load for 20-30
hours, if possible. During the first few minutes of operation, the reducer efficiency will be low due to
churning of heavy cold oil. On this initial run, oil temperatures will stabilize at a higher level, efficiency
will be lower, and gear noise will be greater than after the gear run-in. Successful operation of worm
gearing depends on the ability of the bronze gear to conform to the hardened steel worm. Some initial
wear and/or pitting is therefore necessary on the gear tooth to allow the contact to spread across the full
face of the gear.
Once through the run-in period, the oil temperature rise, noise level, wear and pitting will stabilize and
your Delroyd Worm Gear reducer will be operating at peak efficiency. At this point, the oil temperature
in the gear box if operated continuously should stabilize at a maximum of 100°F above the surrounding
air temperature when transmitting catalog thermal rating. For example, if the air temperature is 70°F,
the oil temperature below the oil level may be 150-160°F, so the unit could be very hot to the touch but
still be operating normally. Therefore, to minimize maintenance problems, it is important during
operation to:
2. Shield reducer from external sources of heat such as furnaces or other machinery.
3. Prevent direct exposure to sunlight unless unit is painted with reflective paints.
5. If the unit is supplied with a fan, keep fan operating and fan inlet unobstructed.
6. Keep outside surfaces of the gear box housing free of dust and dirt if possible.
Keeping operating oil temperatures as low as possible will also aid in preventing excessive seal
replacements.
Lip type oil seals are used on both shafts. The high speed shaft seal has a dust excluding second lip.
During initial operation, these seals may heat the shaft considerably and tend to leak slightly until the
sealing lip is run-in and properly seated on the shaft. Even after run-in, some seepage of oil through the
seal is necessary for proper lubrication of the lip.
If the unit is subjected to chemicals or abrasives not compatible with the seal, it is important to
provide guards where possible to prevent accumulations at the seal area. To prevent oil leakage, the
breather should be checked periodically to be sure it is not clogged and producing internal pressure
build-up.
Problems can start to develop through improper standby and storage of new worm gear reducers
awaiting installation or operation. Ambient conditions during long, idle periods will determine
necessary measures.
1. Replace breathers with pipe plugs, wiring the breathers to the unit to prevent loss.
2. Fill the reducer with recommended lubricant to the proper level and operate once a month for a
few minutes, or completely fill the unit, or use desiccants or vapor phase inhibitors.
3. Cover the reducer with a tarpaulin or plastic cover, leaving openings underneath for ventilation.
A heavy, skidded platform with an internally lined wooden box may also be required when storage is
in high humidity or seaside areas.
4. Periodically drain any accumulated water from the bottom of the oil reservoir and replace any
desiccants or vapor phase inhibitors.
Occasionally an idle reducer undergoes severe vibration from adjacent operating machinery. Even if
the bearings are subjected to only partial load, vibrations can exclude residual oil or grease from under
bearing rollers or balls and result in false Brinelling.
Immediate failure of the bearing is not a result, but once the bearing is put in operation these pit
marks act as stress risers. The fatigue life of the bearing can be reduced to a fraction of the calculated
design life.
False brinelling can usually be prevented by filling the reducer with oil to cover the bearings
completely. This maintains a supply of oil at the contact points of the balls or rollers even under
conditions of vibration.
MAINTENANCE
If the reducer is to be over-hauled, refer to the outline dimension drawing, parts list, and parts
drawing included with these instructions. The model, serial #, and ratio should be obtained from the
reducer nameplate and the necessary spare parts ordered from the factory.
NOTE: When assembling and disassembling the reducer be sure to refer to the corresponding
drawings included with this instruction manual. Numbers in parenthesis reference the part
on the assembly drawing. Due to the special nature of the reducer, the assembly drawing
may differ slightly from the actual reducer.
Place the reducer at the work site in an upside down position from it’s normal mounting position.
Worm under gear. After match marking, remove bolts and two gear shaft covers and large top cover.
Refer to parts drawings included with these instructions. Lift out the bronze wormgear assembly with its
shaft and two bearings. If necessary remove backstop clutch assembly as shown on partial assembly
drawing. Next , remove the adjacent thrust bearing retainer. By tapping on the end of the worm shaft
inside the motor adapter, push the worm shaft along its axis until its bearings are loose enough so that it
can be removed from the housing. The worm bearings can then be pressed off the worm from the
housing. The worm bearings can then be pressed off the worm shaft. Similarly, the low speed shaft
bearings can be pressed off the shaft. The bronze worm gear is a heavy press fit on the shaft and a
hydraulic press should be used as follows:
The reassembly procedure used affects the life expectancy of all rotating parts as well as the
quietness of operation. The important procedures are the establishment of the correct axial bearing end
play on the worm shafts and gear shaft, with proper contact between worms and gears. Be sure to
thoroughly clean all mating surfaces before reinstallation.
1. Install all new bearings/inner races onto the shafts with the proper shims/grease retainers/spacers
with the same configuration as when disassembled. Be sure bearings are fully seated against
corresponding shoulders. Bearings can be heated in 280° oil bath or bearing heater and pressed on.
WARNING: Make sure the thrust bearing is installed with the proper cone and cup arrangement. The
cone and cup marked with an etched “A” should be paired together as well as the cone
and cup without an etched “A”. Failure to do so will result in improper end play.
2. Coat worm threads with soft Prussian Blue and install into housing from side opposite the
coupling extension. Be sure to gently guide the bearings into their bores. Make sure the bearings
are fully seated against their shoulders.
3. Install bulge cover (6) with gasket onto housing. Do not use silicone sealant on this gasket and
cover.
4. Drop gear shaft assembly (gear shaft, gear, spacers, and bearings into upper housing half.
5. Install covers onto upper half of housing using the same shims from disassembly and only three
bolts at this time.
6. The end play of the output shaft should now be checked and set. To do this place dial indicator
on the housing at a location where the tip of the indicator can contact the end of the output shaft.
Push on the end of the output shaft while rotating back and forth slightly to seat the bearings in that
direction. Now set the indicator reading to zero. Without disturbing the indicator pull and rotate
slightly back and forth the shaft. The maximum indicator reading is the end play. Add or delete
shims from either side until the end play is .001" to .002".
7. Rotate the bronze gear until the contact pattern can be seen. Referring to the page in these
instructions titled “Tooth Contact Instructions” adjust until the proper contact is obtained. The
contact is adjusted by adding or removing shims from under the covers. The total amount of
combined shims on both sides must remain the same in order to maintain the proper end play.
Therefore adding .005" shims on one side would require deleting .005" shims on the opposite side.
This would shift the contact pattern to the side the shims were deleted from. Shim sizes are as
follows:
If using new gearing follow the “Tooth Contact Instructions” by setting up for “leaving side contact”
relative to the direction of rotation. If however the existing gearing is being used the contact should
be set to show a full sweep across the face with a “entering side” gap for oil flow.
8. Remove covers being sure to save shims and record their position.
9. Place silicone sealant on mating surface of upper housing half and install lower half onto upper
half. Install bolts and flip unit over to its normal mounted position.
10. Reinstall covers placing silicone sealant onto mating surfaces as well as around each bolt circle
and around the inside diameter of the shims.
11. Insert primary worm shaft bearings (42) completely into bores. Install bulge cover onto housing
with .032" thick shims (26) as a starting point.
12. The end play of the primary worm shaft must now be checked. To do this place a dial indicator
onto the housing in a convenient location so that the tip of the indicator contacts the input end of the
worm shaft. Slightly push and rotate the worm shaft back and forth from the input end, being careful
not to touch the dial indicator. Now set the indicator display to zero. Slightly pull and rotate the
worm shaft back and forth being careful not to touch the indicator. The maximum indicator reading
is the end play. Adding shims will increase the end play and deleting shims will decrease the end
play by the amount added or deleted. Adjust end play until indicator reads .003" to .007".
13. The next step is to install the shaft seals. Before doing so the shaft surfaces where the seals will
rub should be carefully inspected for damage. If the shaft is even lightly scratched where the seal lip
rubs, a “Speedi-Sleeve” should be purchased and installed. Obtain the size “Speedi-Sleeve” suitable
for use with the seal numbers given in the parts list. If the shaft is only slightly grooved, a new seal
can be recessed in its cover by 1/16" to 1/8" so that the seal lip will rub on an undamaged part of the
shaft. Before putting the seal on the shaft, apply friction or “Scotch” tape over the full length of the
keyway. The lip should be coated with a small amount of grease before assembly on the shaft. The
metal outside diameter of the seal is a press fit in its cover but, before it is started in its bore, RTV
silicone sealant should be applied around the circumference to prevent leakage. Using a suitable
size pipe or tubing against the seal, the seal may be pressed or driven into position. Be careful to
keep seal square with shaft and avoid striking seal directly since surface could be bent or damaged.
14. Install low speed shaft seal into cover bore being careful not to rub against key slot..
15. Install worm shaft seal being careful not to rub against key slot.
18. Install backstop assembly per partial assembly drawing and outline drawing. Be careful to orient
backstop clutch to allow rotation as shown on outline drawing.
19. Install motor adapter and coupling. Set coupling to dimension as shown on outline drawing.
20. Fill reducer with proper lubricant to level shown on outline drawing before running.
Worm gears are produced to allow for deflection and provide an entry gap on the “entering side” of
the gear tooth. In order to obtain this condition the tooth contact should be set up so that there is
“leaving side” contact on the driving face of the gear tooth as shown in Figure 1.
Figure 1
The contact should be checked after the worm and gear have been installed with Prussian Blue
coating on the worm threads. Turn worm shaft by hand and observe contact pattern on gear teeth.
Interchanging secondary gear shaft shims from one end to the other will shift position of contact and
move gear to right or left of worm (entering or leaving side) as required. Shims should not be added or
deleted after axial end play is established, but may be shifted from one side to the other.
Primary gear contact is adjusted by adding or deleting shims located at primary gear hub on
secondary worm shaft and at other end of secondary worm shaft.
With the contact on the “leaving side” of the gear tooth, as the worm deflects under load, contact
moves toward the center of gear but still maintains some gap for lubricant to enter on the “entering
side”.
When assembling a worm gear which operates in both directions of rotation, it is necessary to
consider both driving faces of gear teeth and aim at contact as shown in Figure 2. Note that both faces
of gear teeth have a “leaving side” contact relative to the corresponding direction of rotation.
Figure 2
Lip Seal Inspection/Discussion
The careful inspection of lip seals on your worm gear reducer can help to identify problems within the
unit. Following are some examples of problems that can be identified by careful inspection of lip seals.
1. Changes in pressure will effect the way the lip seal seats onto the shaft.
a. Externally applied pressure will lift the lip off of the shaft slightly, allowing inward leakage of
oil from one side to the other. If the oil is clean, no damage will occur. A drop in pressure will
allow the garter spring and lip to return to normal position. Lip seals typically do not resist
external pressure.
b. Internal pressure (from inside the reducer) will push the lip down tighter onto the shaft. Higher
internal pressure will typically result in the entire seal sliding outward. In extreme cases, the
seal can slide completely out of the bore in the cover that it was pressed into.
2. If improperly installed, the seal can get caught while attempting to slide it over a shoulder or
chamfer on the shaft. If the lip is turned under, this is a sign that the seal was installed improperly
and not a result of high pressure. The seal will leak under these conditions and must be replaced.
Visible inspection of the outboard side of a good seal should show the outer lip very close to or
touching the shaft uniformly and evenly all the way around. A turned under lip will usually bulge
out, lifting the outer lip locally part of the way around the shaft.
For all units refer to the generic Mechanical Seal Assembly Drawing included in this manual. The
following procedure should be used as a guide to replace the mechanical seal assembly on the closed
end of the output shaft of your worm gear reducer:
1. Drain the oil from the reducer to a level below the output shaft bearings.
3. Remove the fasteners, lock washers, and seal plate from the reducer. The mechanical seal is pressed
into the seal plate and comes off with the seal plate when it is removed. Inspect the area of the
reducer around the now exposed end of the output shaft to insure that no pieces of the mechanical
seal have remained on the shaft, or fallen into the reducer. If so, remove them.
4. Remove the shims between the seal plate and the bearing retainer. If the shims are not damaged
during disassembly they may be re-used. If the shims are damaged, remove any remnants from the
bearing retainer and make a note of the stack-up. Shims are color coded for size. The shim that is
blue on one side is 0.005” thick and the shim that is silver on both sides is 0.007” thick.
5. Clean the mating surfaces of the new seal plate and bearing retainer. Replace the shim pack with
reused or new shims. Using a depth micrometer, verify the “Working Length At Assembly”
dimension indicated on the reducer Outline drawing. Adjust the shims to achieve the proper
dimension with a tolerance of ± 0.003”. Apply a small bead of RTV sealant to the seal plate at the
inside corner just inside the bolt circle. Slide the replacement seal plate assembly with seal straight
inwards over the studs and against the shims. Tighten the nuts evenly all around. Once the seal is in
place, look through the oil supply port and verify that the seal is seated evenly against its locating
shoulder. This can be done by looking all the way around the end of the output shaft and making
sure the seal is even all the way around. Replace the plumbing and refill the reducer with oil to the
proper level.
WARNING: INSTALL, OPERATE AND MAINTAIN Delroyd Worm Gear EQUIPMENT ONLY
IN ACCORDANCE WITH THE FOLLOWING INSTRUCTIONS, AND Delroyd Worm Gear
CATALOGS AND INSTRUCTION BOOKS. FAILURE TO OBSERVE THIS WARNING
COULD RESULT IN SEVERE BODILY INJURY AND PROPERTY DAMAGE. CONTACT
Delroyd Worm Gear TO GET CATALOGS AND INSTRUCTION BOOKS.
All catalog information, warning tags, these instructions, all special or general instruction manuals, parts
lists, maintenance instructions, and drawings must be kept with the reducer.
Selection Responsibility
1. Delroyd Worm Gear customers are responsible for selecting the proper reducers.
2. Delroyd Worm Gear customers must select reducers that can be used in accordance with Delroyd
Worm Gear criteria concerning transmitted horsepower, speed, applied external loads, applied axial
thrust loads and applicable service factors. Use of Delroyd Worm Gear reducers must conform to all
such criteria.
3. Customers requesting recommendations from Delroyd Worm Gear concerning reducer selection
must provide accurate and complete information concerning all operation variables that may be
encountered in the proposed reducer application. Such variables include but are not limited to loads,
speeds, shock, ambient temperature and published Delroyd Worm Gear service factors.
Reducer compatibility with the drive system
1. When selecting a reducer, the customer must analyze the motor, reducer, driven machine, and all
connecting parts for compatibility, critical speeds, torsional or other vibrations and other applicable
forces during all modes of operation.
2. The customer should request Delroyd Worm Gear assistance in selecting a reducer if conditions
such as overloads during starting, momentary peak or stalling loads, high inertia starting or stopping
systems, reversing direction of rotation, over running operation, corrosive or dusty atmospheres or
ambient temperatures under 20°F or over 100°F might be encountered.
3. When selecting a motor for a Delroyd Worm Gear reducer, NEMA (National Electrical
Manufacturers Association) Standards Publication MG2 d(Safety standards for construction & guide
for selection, installation and use of fractional and integral horsepower motors and generators) must
be obtained and studied. Electrical and other motor hazards should be considered. In all instances
the motor manufacturer’s instructions should be followed carefully. Such instructions must be
obtained from the motor manufacturer directly or through Delroyd Worm Gear.
1. Examine the equipment for damage and corrosion. Report any discrepancy to the shipper, and to
Delroyd Worm Gear for replacement or repair.
2. Examine the reducer nameplate and motor nameplate (if a motor is supplied) to be sure the
proper equipment had been received.
3. Do not remove these nameplates. They are provided to identify the model number, size and
serial number so that Delroyd Worm Gear can supply the proper spare or replacement parts to you or
any subsequent owner. The information on the nameplates also enables the user to check
manufacturer’s publications for instructions concerning proper application, installation, operation,
and maintenance of reducers and motors.
4. Study and retain all warning tags, instruction, parts lists and parts drawings received with the
shipment or sent separately.
Installation
1. Follow Delroyd Worm Gear installation instructions and the instructions of the motor
manufacturer.
2. Provide proper OSHA conforming safety guards for couplings, exposed rotating shafts, belts and
chains on your Delroyd Worm Gear reducer.
3. Lifting eyebolts or other lifting devices supplied with the reducer are designed for raising the
reducer only. They should not be used to lift the reducer plus other components, and should be
removed after installing the reducer.
4. All Delroyd Worm Gear reducers are shipped without oil. Add oil to proper oil level before
starting. Allow sufficient time for the oil to fill all parts of the reservoir and recheck the level.
1. Disconnect the reducer from its driving motor and check motor rotation. Reverse motor rotation
if necessary and reconnect the reducer.
2. Rotate the motor and reducer by hand to be sure all components turn freely.
Fan precautions
Most Delroyd Worm Gear reducers are equipped with a fan for cooling the reducer. This fan is guarded,
but must have inlet and outlet air openings to provide the necessary air movement. To avoid severe
bodily injury or property damage:
1. Do not remove the fan guard or insert fingers or other objects into the air openings when the
reducer is operating.
2. Shut down and lock out the motor driving the reducer before the fan or fan guard is removed or
in any way adjusted.
Inspections
As with all mechanical equipment, a program of regular inspection is important to prolong equipment
life and to safeguard people and property.
1. Periodic inspection of the reducer must be made every 2,000 hours of operation or every six
months, whichever comes first.
2. The above inspection must also be conducted after each time the reducer has been subjected to
any overload, or stall condition or loss of lubricant.
3. Reducer parts that are damaged or worn, or the presence of contaminants (such as water, dirt,
bronze or steel particles) in drainage oil could indicate impending failure. An increase in noise, a
drastic increase in backlash, an increase in motor HP required, or other erratic behavior of the
reducer could indicate impending failure.
4. If any of the above conditions are observed, the reducer should be immediately taken out of
service until the cause of the condition is determined and corrections made.
Maintenance of Delroyd Worm Gear reducers
1. Care should be exercised when draining oil during lubricant replacement. Oil temperatures of
180°F to 200°F can normally be expected and severe burns could result if oil contacts personnel or
their clothing.
2. Before beginning removal or disassembly of any part of your Delroyd Worm Gear reducer for
maintenance or inspection, lock out the driving motor control panel to prevent inadvertent starting
and disconnect the driven load.
3. Repairs can be done by Delroyd Worm Gear using factory stocked or manufactured parts if the
reducer can be returned to our plant in Niagara Falls, NY. If repairs are done elsewhere, all
instruction book adjustments must be followed and Delroyd Worm Gear manufactured parts must be
used.
SECTION III
DriveIT Low Voltage Motors for Hazardous Areas
Manual for M3000 Range
Manual d’installation,
d’exploitation et de
maintenance FR 31
.......................................................................
Asennus-, käyttö- ja
kunnossapito-opas FI 88
.......................................................................
Installation, operation and maintenance manual
List of Contents
1. General 3
2. Installation 4
3. Operating 9
4. Maintenance 9
5. Environmental Requirements 13
Check all rating plate data, especially voltage, winding Windings drenched in seawater normally need to be
connection (star or delta), category, type of protection rewound.
and temperature marking. The type of bearing is speci-
fied on the rating plate of all motors except the smallest Direct-on-line or star/delta starting
frame sizes. The terminal box on standard single speed motors
normally contains six winding terminals and at least one
Remove transport locking if employed. Turn shaft by earth terminal.
hand to check free rotation.
For two-speed and special motors, the supply connec-
Do not exceed permissible loading values of bearings tion must follow the instructions inside the terminal box.
stated in the product catalogues.
Earthing must be carried out according to local regula-
Motors equipped with roller bearings: tions before the machine is connected to the supply
Running the motor with no radial force applied to the voltage.
shaft may damage the roller bearing.
The voltage and connection are stamped on the rating
Motors equipped with angular contact bearing: plate.
Running the motor with no axial force applied in the right
direction to the shaft may damage the angular contact Direct-on-line starting (DOL):
bearing. Y or D winding connections may be used.
E.g. 690 VY, 400 VD indicates Y-connection for 690 V
The type of bearing is specified on the rating plate. and D-connection for 400 V.
Lifting eyebolts must be tightened before lifting. If When fitted in a vertical position with the shaft pointing
needed the position of the eyebolt can be adjusted using downwards, the motor must have a protective cover
suitable washers as spacers. against falling objects and fluid.
Ensure that proper lifting equipment is used and that the Ensure that the motor protection corresponds to the
sizes of the hooks are suitable for the lifting lugs. environment and weather conditions; e.g. make sure that
water cannot enter the terminal box.
Care must be taken not to damage auxiliary equipment
and cables attached to the motor. The earth terminal on the frame has to be connected to
PE (protective earth) with a cable as shown in Table 3 of
Machine weights EN 50014.
The total machine weight can vary within the same
frame size (center height) depending on different output, The cable connection between the network and motor
mounting arrangement and added features. terminals must fulfil the requirements stated in the
country standards for installation or in the standard EN
The following table shows estimated maximum weights 60204-1 according to the rated current indicated on the
for machines in their basic versions as a function of rating plate.
frame material.
Motors are intended for fixed installation only. In other
The actual weight of all ABB’s motors, except the cases ensure only certified cable glands for increased
smallest frame sizes is shown on the rating plate. safety and flameproof motors are used. For non-spark-
ing motors, cable glands should comply with EN 50014.
The IP-class of the cable gland should be at least same
as the motor protection.
NOTE!
Cables should be mechanically protected and
clamped close to terminal box to fulfil requirements
of EN 50014 and local installation standards (e.g.
NFC 15100).
Approved connectors must be used to connect the The cable gland must be of an approved design. The
auxiliary elements. Thermistor relays, like other type and dimensions of the cable gland must conform to
switches and relays, must be placed outside the explo- the type and section of the cable. The degree of protec-
sion hazard zone. tion and diameter are specified in the documents relat-
ing to the cable gland.
Non-sparking & increased safety motors
Standard motors have the terminal box fitted on the top Please ensure that assembly of the terminal connection
and cable entry possibilities on both sides. A full de- is carried out precisely in the order that is set out in the
scription is contained in the product catalogues. assembly plan, which is found inside the terminal box.
Unused cable entries must be closed with appropriate The creepage distance and clearance must be conform
(certified for EEx e) plugs and with same IP protection to EN 50019.
as stamped on the rating plate.
The seals of the terminal box must be placed correctly
Flameproof motors in the slots provided, to ensure complete air tightness. A
There are two different types of protection for the leak could lead to penetration of dust or water, creating
terminal box: a risk of flashover to live elements.
In case of balancing without key, the shaft is marked Ex-motors in IEC frame size 280-400 shall be equipped
with a BLUE tape, with the text “Balanced without key”. with insulation bearings in N-end (non-drive end). The
insulation method is indicated on the motor rating plate,
Special instructions for motors with a e.g. “INSULATED BEARING IN N-END”.
frequency converter
Connection
In frequency converter applications, motor frame exter-
ABB motors with protection types EEx d, EEx de, EEx e
nal earthing must be used for equalising the potential
(on request) and Ex nA/Ex N or EEx nA are certified for
between the motor frame and the driven machine,
use with variable speed drives.
unless the two machines are mounted on the same
metallic base. See manual “Grounding and cabling of the
The use of a motor with a frequency converter must be
drive system” (3AFY61201998).
studied in advance. Check that the motor fulfils the
specifications. The maximum loadability (T = f(N)) of the
When the motor and the gearbox are mounted on a
motor, rotational speed area, frequency and the type or
common steel fundament, no potential equalisation is
characteristics of the converter are shown by an addi-
required.
tional rating plate or by a test report delivered with the
motor.
Potential equalisation
Winding and bearing insulation of a motor in variable
speed drive use and the filters of the drive must be
chosen according to the instruction “Selection rules for V1 Plate/strip Cables/wires
VSD applications/Insulation” (3GZF500930-2) and U1 W1
PE
“Instructions for selection of Ex-motors for VSD” 3~M
0.75 mm > 150 mm
(3GZF500930-4).
70 mm 2
min 50 mm
Flameproof motors EEx d(e) operating with a frequency Driven machinery
Use WARNING
Standards relating to connection and use of
WARNING electrical apparatus in hazardous areas must be
Disconnect and lock out before working on the taken into consideration. Only fully trained
motor or the driven equipment. Ensure no explo- personnel competent with these standards must
sive atmosphere is present while the work is in handle this type of apparatus.
progress.
Depending on the nature of the work in question,
The motors are designed for the following environ- disconnect and lock out before working on motor or
mental conditions: driven equipment. Ensure no explosive gas or dust
is present while work is in progress.
Normal ambient temperature limits are -20°C to +40°C.
Maximum altitude 1000 m above sea level.
General inspection
1. Inspect the motor at regular intervals. The fre-
If these limits are exceeded, all motor data and con-
quency of checks depends on the humidity level of
struction data must be checked to equalise the surface the ambient air, and on the local weather condi-
temperature with the temperature class according to the tions. This can initially be determined experimen-
ignition temperature of any gases or dust. Please tally and must then be strictly adhered to.
contact ABB for further information. 2. Keep the motor clean and ensure free ventilation
airflow. If the motor is used in a dusty environment,
Particular attention must be paid to corrosive atmos- the ventilation system must be regularly checked
pheres when using flameproof motors; ensure that the and cleaned. For DIP motors respect the environ-
paint protection is suitable for the ambient conditions as ment specifications stated in standard
corrosion can damage the explosion-proof enclosure. EN 50281-1-2.
3. Check the condition of shaft seals (e.g. V-ring or
radial seal) and replace if necessary.
Safety considerations
For DIP motors the shaft seals should be changed
The motor is intended for installation and use by quali- at least once a year depending of environment
fied personnel, familiar with health and safety require- conditions as mentioned above (1).
ments and national legislation. 4. Check the condition of connections and mounting
and assembly bolts.
Safety equipment necessary for the prevention of 5. Check the bearing condition by listening for any
accidents at the installation and operating site must be unusual noise, vibration measurement, bearing
provided in accordance with local regulations. temperature, inspection of spent grease or SPM
bearing monitoring.
WARNING
Small motors with supply current directly switched When signs of wear are noticed, dismantle the motor,
by thermally sensitive switches can start automati- check the parts and replace if necessary. When bear-
cally. ings are changed on DIP motors, replacement bearings
must be of the same type as those originally fitted. The
shaft seals have to be replaced with seals of same
Points to observe quality and characteristics as the original ones when
1. Do not step on the motor. changing bearings.
2. The temperature of the outer casing of the motor
may be hot to the touch during normal operation. For flameproof motors, periodically turn the knurled
3. Some special motor applications require special head of the drain plug, if equipped, in order to prevent
instructions (e.g. using frequency converter sup- jamming. This operation must be done when the motor
plies).
is at standstill. The frequency of checks depends on the
4. Lifting lugs must only be used for lifting the motor
itself. They must not be used to lift the motor when humidity level of the ambient air, and on the local
it is attached to other equipment. weather conditions. This can initially be determined
experimentally and must then be strictly adhered to.
Lubrication information plate and general lubrica- When 2-pole motors are automatically regreased, the
tion advice note about lubricant recommendations for 2-pole motors
in the chapter on Lubricants should be followed.
If the machine is fitted with a lubrication information
plate, follow the given values.
The following grease can be used: Rewinding should always be carried out by qualified
EEx approved repair shops.
• FAG L69 (polyurea base)
• Klüber Klüber quiet BH 72-102 (polyurea base) When re-assembling end shield or terminal box to the
• SKF LGHP2 (polyurea base) frame, check that the spigots are clean of paint and dirt
with only a thin layer of grease. In the case of DIP
If other lubricants are used, check with the manufacturer
motors, when re-assembling the endshields on the
that the qualities correspond to those of the above
frame special sealing grease or sealing compound
mentioned lubricants, or if the compatibility of the
should be reapplied to the spigots. This should be the
lubricant is uncertain, contact your local ABB Sales
same as originally applied to the motor for enclosure
Office.
protection.
Frequency converter drives
Bearings
Higher speed operation, e.g. in frequency converter
Special care should be taken with the bearings.
applications, or lower speed with heavy load will require
These must be removed using pullers and fitted by
shorter lubrication intervals. Consult your local ABB
heating or using special tools for the purpose.
Sales Office in such cases.
Bearing replacement is described in detail in a separate
Typically a doubling of speed will require a reduction of
instruction leaflet available from ABB Sales Office.
lubrication intervals to approx. 40 % of values tabulated
above.
Any indication placed on the motor, such as labels, must
be followed.
WARNING
The designed maximum speed of the motor must
NOTE!
not be exceeded. Any repair by the end user, unless expressly
approved by the manufacturer, releases the manu-
Suitability of bearings for high-speed operations must be facturer from his responsibility to conformity.
checked.
Noise levels
Most of ABB’s motors have a sound pressure level not
exceeding 82 dB(A) (± 3 dB) at 50 Hz AC.
Additional information:
Product code:
3 G B A 3 1 2 2 1 0 - A D A
Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1.3
1.2
1.1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4
P2/Pn
Jmotor (kgm2) 0.19 Voltage (V) 100% 400 Voltage (V) 400V(100%)
Jload (kgm2) Tstart/TN 3.1 Tstart/TN 3.1
Speed (r/min) 1476 Starting time (s) Run-up time (s)
TN (Nm) 120 Speed (r/min) Speed (r/min)
Tload (Nm) Is/In 8.3 Is/In 8.3
Nbr. of consecutive starts Tmax/Tn 3.6 Tmax/Tn 3.6
5 10
4.5 9
4 8
3.5 7
3 6
Ts/Tn
Is/In
2.5 5
2 4
1.5 3
1 2
0.5 1
0 0
0 250 500 750 1000 1250 1500 1750
Speed (r/min)
Replaced by:
Date: 14.03.2001 Approved by: L.Järf
Customer Reference:
ABB Oy
Koenig Engineering Inc
Instruction Manual M434
SECTION IV
SSS clutches
SIZE 44T SSS CLUTCH FOR
TURNING GEAR DRIVE
C O N T E N T S
PAGE
Section 1. INTRODUCTION 1
Section 2. CONSTRUCTION 2
Section 3. OPERATION 2
Section 4. INSTALLATION 4
Section 5. MAINTENANCE 7
I N D E X Sheet No. 1
Page
Section 1. INTRODUCTION 1
Section 2. CONSTRUCTION 2
Section 3. OPERATION 2
Section 4. INSTALLATION 4
4.1. Identification 4
4.2. Alignment 4
4.3. Installation 5
4.4. Lubrication 5
Section 5. MAINTENANCE 7
5.2. Examination 8
5.3. Assembly 9
Page
Section 1. INTRODUCTION
- 1 -
Section 2. CONSTRUCTION
The design of the Size 44T SSS turning gear clutch is shown
on Drawing No. SM.17557. It comprises three main assemblies.....
Section 3. OPERATION
The SSS clutch is designed for a maximum input speed from the
turning gear drive of 220 rpm which must not be exceeded. For
input speeds above 220 rpm, SSS must be consulted.
- 2 -
occurs, the pawls (6) contact the ratchet teeth on the heli-
cal sliding component (2) thus precisely aligning the clutch
teeth.
When the speed of the input drive to the SSS Clutch equals
that of the rotating output, the pawls (6) contact the
ratchet teeth on the helical sliding component (2) and the
clutch engages as described in Section 3.1.
- 3 -
Section 4. INSTALLATION
4.1. Identification
DIRECTION OF
INPUT
ROTATION
4.2. Alignment
- 4 -
4.3. Installation
NOTE For transit, the output clutch ring has been reversed, placed
on the helical splines of the input shaft and bolted, with
RED packing pieces under the switch ring face, to the input
shaft flange face with two bolts which are also painted RED.
Before installation, remove the output clutch ring from the
input shaft.
1. Having removed the output clutch ring (3) from the input
shaft (1), align numbered holes in the flange of the output
clutch ring (3) with the flange of driven machine, and bolt
flanges together.
4.4. Lubrication
- 5 -
Oil from the machinery lubricating system should be supplied
to the clutch at the minimum flow rate of 1 US gallon/minute
as stated on Drawing No. SM.17557, passing into the clutch
through a central oilway in the input shaft (1) as shown on
the drawing.
Diagram 1.
Rotate dial indicator stylus -
See section 4.2.1 of this manual
- 6 -
Section 5. MAINTENANCE
The SSS clutch requires very little maintenance and need only
be fully inspected during each major overhaul of the main
machinery.
AAAAAA
5.1.2 Splined connections:
AAAAAA
Two external splines
and one internal
spline are marked X X X
with an 'X' and an
arrow to form an in-
terlocking row of
three 'X's' thus....
- 7 -
5.2. Examination
5.2.2. Remove four socket cap screws (11) and stop cap (4). Withdraw
the helical sliding component (2) from the shaft, noting
match marks between splines for correct re-assembly.
5.2.3 Before removing the pawls (6) from the output clutch ring
(3), the load exerted by the pawl springs (7) should be
checked. The spring are correctly set if a radial load, of
115 grammes (4.0 ozs) applied at each pawl tip, will just
fully depress the pawls.
5.2.4 Remove two socket set screws (12) and separate the pawl pivot
pins (8), pawls (6) and pawl springs (7) from the output
clutch ring (3).
5.2.5 Examine the pivot pins and bore of the pawls for signs of
excessive wear and/or fretting. The pawl tips and the ratchet
teeth on the helical sliding component with which they en-
gage, should be examined for signs of chipping. Renew parts
as necessary. The pawl springs (7) should be replaced when-
ever the pawls are replaced, or independently if wear or
distortion dictates.
5.2.6 Examine all ratchet teeth, clutch teeth and helical splines,
sliding surfaces and end faces for signs of excessive wear or
chipping.
- 8 -
5.3. Assembly
- 9 -
Section 6. PARTS LIST
1. Input Shaft 1
4. Stop Cap 1
5. NOT USED -
6. Pawl 2
7. Pawl Spring 2
8. Pawl Pin 2
- 10 -
Section 7. RECOMMENDED SPARES
7.1.1. Name and item number of the part required. This may be ob-
tained by referring to the Drawing No. SM.17557 and the Parts
List on page 10 of this Manual.
Quantity
Item No. Description Per Clutch
6. Pawl 2
7. Pawl Spring 2
8. Pawl Pin 2
- 11 -
SAFESET COUPLING
SERIAL NUMBER CROSS REFERENCE
Customer: LUFKIN
Coupling Type: SR- CB 350
Coupling #: 11520925, 11520927
Drawing #: 29435
Customer P/O#: 106/216151
Sales Order#: S017168
CONTENTS
IMPORTANT INFORMATION
When the pre-set torque is exceeded, the Safeset coupling slips and the top
of the shear tube is sheared off by the shear ring, releasing the oil pressure in
the coupling. This happens within a few milliseconds. After release the
coupling will run freely on the shaft.
Due to its design it has a limited ability to take up other types of loads, as
bending torque and radial loads. This must be take into account when
installing the Safeset coupling.
The combination must not lead to reaction forces such as loads or bending
torque on the Safeset coupling.
If the drive line where the SAFESET coupling is installed is not continuously
supervised a monitoring system discovering the release of the SAFESET
coupling must be installed.
This system will prevent that the SAFESET coupling rotates freely during a
longer period of time.
Transport locking
CAUTION!
Coupling is pressurised to
20-35 MPa for transport only!
Loosen the sheartube ½ turn until the oil is evacuated into the pump.
Safety regulations
• When the SAFESET coupling releases, parts from the shear tube
and oil are thrown out of the coupling at very high pressure.
Smaller couplings are delivered with a protection band. If the
coupling lacks protection band, a plate cover must be installed
around the coupling. Min. plate thickness 1.5 mm.
3. Push the coupling onto the shaft. Assemble the plate, item 19, with the screws, item
20.
4. After mounting of Safeset check that the coupling easily can be rotated.
(Note! Unscrew the shear tube to avoid damage when testing).
5. To limit the heat generation in the coupling after a release, a release indicator should
be installed and used to stop the power supply to the coupling after a release.
Important!
To avoid personal injury, a protection device must be installed to prevent shear tube parts
and oil to be thrown out with very high pressure when the SAFESET® releases.
1. Unscrew the screws, item 20 from the plate, item 19, and remove the plate.
2. Assemble a hydraulic pump (max. pressure 100 MPa) into the centre thread of the
shaft (thread G1/4").
3. Mount a pulling device in the screw holes (M16 (6x60°)) on the housing, item 15. Pull
with the device and at the same time inject oil into the shaft connection (injecting oil
makes it easier to disassemble the sleeve).
Important!! Use Mobil SHC 624 oil as lubrication oil, otherwise the transmittable torque will
change!!!
Oil drain:
1. Depressurise the SAFESET® , see pressure lowering instruction, and remove all
sheartubes.
3. Unscrew the downward lubrication plug first, and then unscrew the horizontal
lubrication plug.
Refill / check:
1. Depressurise the SAFESET® and remove all sheartubes (if not already done).
2. Rotate the SAFESET® so that one port is in an upward position, 10° from vertical.
10°
Lubrication port
SAFESET®
Lubrication port
4. Fill Mobil SHC 624 oil slowly into the upward port with the lubrication injector until a
clear flow of oil emerges from the other port. Note: if the oil that emerges is
contaminated, a complete change of oil is recommended.
5. Allow the SAFESET® to sit in this position for 15 minutes to allow the oil to distribute
inside the coupling.
45° 45°
7. Allow the SAFESET® to sit in this position for 15 minutes allowing the oil to drain from
the coupling until oil stops coming out from the lubrication ports.
A calibration diagram is enclosed every coupling. The coupling has a number right next to
the filling connection which corresponds to the calibration diagram. In this diagram the
necessary pressure for required torque limit can be read.
2. Fasten new shear tubes until they reach the bottom. The end of the shear tube is then
formed to fit the valve seat at the bottom of the hole. Then tighten the shear tubes with
care (tightening torque 30-35 Nm). This makes the coupling absolutely leak proof.
3. Unscrew the shear tube next to the filling connection 1/2 turn.
4. Remove the protection plug, item 2. Screw the quick connection into the G1/4" thread.
5. Connect the hose and pump oil into the coupling until the manometer on the pump
shows the correct pressure (see calibration diagram on page 10).
6. Tighten the shear tube at the filling connection carefully (30-35 Nm).
8. Remove the quick connection and reset the protection plug into the connection hole.
2. Connect the pump to the quick connection. Check if there is enough room in the pump
to evacuate the oil from the SAFESET®.
ATEX information
This SAFESET® coupling is classified for use in potentially explosive atmospheres
according to the EU Directive 94/9/EC of March 1994 (ATEX). The classification is:
II 3G c g T3
II 3G c g T3
SAFESET®
Calibration diagram / Kalibrierdiagramm
Coupling type / Kupplung type Order / Bestell Nr. Coupling No / Kupplung Nr.
Setting / Einstellung
T= kNm
P= MPa
Torque (x10³ lb-in)
0 500 1000 1500 2000 2500 3000 3500 4000
90
12
80
70
10
60
Pressure / Druck (MPa)
50
6
40
30
4
20
2
10
0 0
0 50 100 150 200 250 300 350 400 450 500
Torque / Drehmoment (kNm)
SAFESET®
Calibration diagram / Kalibrierdiagramm
Coupling type / Kupplung type Order / Bestell Nr. Coupling No / Kupplung Nr.
Setting / Einstellung
T= kNm
P= MPa
Torque (x10³ lb-in)
0 500 1000 1500 2000 2500 3000 3500 4000
90
12
80
70
10
60
Pressure / Druck (MPa)
50
6
40
30
4
20
2
10
0 0
0 50 100 150 200 250 300 350 400 450 500
Torque / Drehmoment (kNm)
Customer: LUFKIN
Coupling Type: SR- CB 350
Coupling #: 11520926,
11520929 - 11520933
Drawing #: 29435
Customer P/O#: 106/216151
Sales Order#: S017168
CONTENTS
IMPORTANT INFORMATION
When the pre-set torque is exceeded, the Safeset coupling slips and the top
of the shear tube is sheared off by the shear ring, releasing the oil pressure in
the coupling. This happens within a few milliseconds. After release the
coupling will run freely on the shaft.
Due to its design it has a limited ability to take up other types of loads, as
bending torque and radial loads. This must be take into account when
installing the Safeset coupling.
The combination must not lead to reaction forces such as loads or bending
torque on the Safeset coupling.
If the drive line where the SAFESET coupling is installed is not continuously
supervised a monitoring system discovering the release of the SAFESET
coupling must be installed.
This system will prevent that the SAFESET coupling rotates freely during a
longer period of time.
Transport locking
CAUTION!
Coupling is pressurised to
20-35 MPa for transport only!
Loosen the sheartube ½ turn until the oil is evacuated into the pump.
Safety regulations
• When the SAFESET coupling releases, parts from the shear tube
and oil are thrown out of the coupling at very high pressure.
Smaller couplings are delivered with a protection band. If the
coupling lacks protection band, a plate cover must be installed
around the coupling. Min. plate thickness 1.5 mm.
3. Push the coupling onto the shaft. Assemble the plate, item 19, with the screws, item
20.
4. After mounting of Safeset check that the coupling easily can be rotated.
(Note! Unscrew the shear tube to avoid damage when testing).
5. To limit the heat generation in the coupling after a release, a release indicator should
be installed and used to stop the power supply to the coupling after a release.
Important!
To avoid personal injury, a protection device must be installed to prevent shear tube parts
and oil to be thrown out with very high pressure when the SAFESET® releases.
1. Unscrew the screws, item 20 from the plate, item 19, and remove the plate.
2. Assemble a hydraulic pump (max. pressure 100 MPa) into the centre thread of the
shaft (thread G1/4").
3. Mount a pulling device in the screw holes (M16 (6x60°)) on the housing, item 15. Pull
with the device and at the same time inject oil into the shaft connection (injecting oil
makes it easier to disassemble the sleeve).
Important!! Use Mobil SHC 624 oil as lubrication oil, otherwise the transmittable torque will
change!!!
Oil drain:
1. Depressurise the SAFESET® , see pressure lowering instruction, and remove all
sheartubes.
3. Unscrew the downward lubrication plug first, and then unscrew the horizontal
lubrication plug.
Refill / check:
1. Depressurise the SAFESET® and remove all sheartubes (if not already done).
2. Rotate the SAFESET® so that one port is in an upward position, 10° from vertical.
10°
Lubrication port
SAFESET®
Lubrication port
4. Fill Mobil SHC 624 oil slowly into the upward port with the lubrication injector until a
clear flow of oil emerges from the other port. Note: if the oil that emerges is
contaminated, a complete change of oil is recommended.
5. Allow the SAFESET® to sit in this position for 15 minutes to allow the oil to distribute
inside the coupling.
45° 45°
7. Allow the SAFESET® to sit in this position for 15 minutes allowing the oil to drain from
the coupling until oil stops coming out from the lubrication ports.
A calibration diagram is enclosed every coupling. The coupling has a number right next to
the filling connection which corresponds to the calibration diagram. In this diagram the
necessary pressure for required torque limit can be read.
2. Fasten new shear tubes until they reach the bottom. The end of the shear tube is then
formed to fit the valve seat at the bottom of the hole. Then tighten the shear tubes with
care (tightening torque 30-35 Nm). This makes the coupling absolutely leak proof.
3. Unscrew the shear tube next to the filling connection 1/2 turn.
4. Remove the protection plug, item 2. Screw the quick connection into the G1/4" thread.
5. Connect the hose and pump oil into the coupling until the manometer on the pump
shows the correct pressure (see calibration diagram on page 10).
6. Tighten the shear tube at the filling connection carefully (30-35 Nm).
8. Remove the quick connection and reset the protection plug into the connection hole.
2. Connect the pump to the quick connection. Check if there is enough room in the pump
to evacuate the oil from the SAFESET®.
ATEX information
This SAFESET® coupling is classified for use in potentially explosive atmospheres
according to the EU Directive 94/9/EC of March 1994 (ATEX). The classification is:
II 3G c g T3
II 3G c g T3
SAFESET®
Calibration diagram / Kalibrierdiagramm
Coupling type / Kupplung type Order / Bestell Nr. Coupling No / Kupplung Nr.
Setting / Einstellung
T= kNm
P= MPa
Torque (x10³ lb-in)
0 500 1000 1500 2000 2500 3000 3500 4000
90
12
80
70
10
60
Pressure / Druck (MPa)
50
6
40
30
4
20
2
10
0 0
0 50 100 150 200 250 300 350 400 450 500
Torque / Drehmoment (kNm)
Customer: LUFKIN
Coupling Type: SR- CB 350
Coupling #: 11521894 - 11521897
Drawing #: 29435
Customer P/O#: 106/216151
Sales Order#: S017168
CONTENTS
IMPORTANT INFORMATION
When the pre-set torque is exceeded, the Safeset coupling slips and the top
of the shear tube is sheared off by the shear ring, releasing the oil pressure in
the coupling. This happens within a few milliseconds. After release the
coupling will run freely on the shaft.
Due to its design it has a limited ability to take up other types of loads, as
bending torque and radial loads. This must be take into account when
installing the Safeset coupling.
The combination must not lead to reaction forces such as loads or bending
torque on the Safeset coupling.
If the drive line where the SAFESET coupling is installed is not continuously
supervised a monitoring system discovering the release of the SAFESET
coupling must be installed.
This system will prevent that the SAFESET coupling rotates freely during a
longer period of time.
Transport locking
CAUTION!
Coupling is pressurised to
20-35 MPa for transport only!
Loosen the sheartube ½ turn until the oil is evacuated into the pump.
Safety regulations
• When the SAFESET coupling releases, parts from the shear tube
and oil are thrown out of the coupling at very high pressure.
Smaller couplings are delivered with a protection band. If the
coupling lacks protection band, a plate cover must be installed
around the coupling. Min. plate thickness 1.5 mm.
3. Push the coupling onto the shaft. Assemble the plate, item 19, with the screws, item
20.
4. After mounting of Safeset check that the coupling easily can be rotated.
(Note! Unscrew the shear tube to avoid damage when testing).
5. To limit the heat generation in the coupling after a release, a release indicator should
be installed and used to stop the power supply to the coupling after a release.
Important!
To avoid personal injury, a protection device must be installed to prevent shear tube parts
and oil to be thrown out with very high pressure when the SAFESET® releases.
1. Unscrew the screws, item 20 from the plate, item 19, and remove the plate.
2. Assemble a hydraulic pump (max. pressure 100 MPa) into the centre thread of the
shaft (thread G1/4").
3. Mount a pulling device in the screw holes (M16 (6x60°)) on the housing, item 15. Pull
with the device and at the same time inject oil into the shaft connection (injecting oil
makes it easier to disassemble the sleeve).
Important!! Use Mobil SHC 624 oil as lubrication oil, otherwise the transmittable torque will
change!!!
Oil drain:
1. Depressurise the SAFESET® , see pressure lowering instruction, and remove all
sheartubes.
3. Unscrew the downward lubrication plug first, and then unscrew the horizontal
lubrication plug.
Refill / check:
1. Depressurise the SAFESET® and remove all sheartubes (if not already done).
2. Rotate the SAFESET® so that one port is in an upward position, 10° from vertical.
10°
Lubrication port
SAFESET®
Lubrication port
4. Fill Mobil SHC 624 oil slowly into the upward port with the lubrication injector until a
clear flow of oil emerges from the other port. Note: if the oil that emerges is
contaminated, a complete change of oil is recommended.
5. Allow the SAFESET® to sit in this position for 15 minutes to allow the oil to distribute
inside the coupling.
45° 45°
7. Allow the SAFESET® to sit in this position for 15 minutes allowing the oil to drain from
the coupling until oil stops coming out from the lubrication ports.
A calibration diagram is enclosed every coupling. The coupling has a number right next to
the filling connection which corresponds to the calibration diagram. In this diagram the
necessary pressure for required torque limit can be read.
2. Fasten new shear tubes until they reach the bottom. The end of the shear tube is then
formed to fit the valve seat at the bottom of the hole. Then tighten the shear tubes with
care (tightening torque 30-35 Nm). This makes the coupling absolutely leak proof.
3. Unscrew the shear tube next to the filling connection 1/2 turn.
4. Remove the protection plug, item 2. Screw the quick connection into the G1/4" thread.
5. Connect the hose and pump oil into the coupling until the manometer on the pump
shows the correct pressure (see calibration diagram on page 10).
6. Tighten the shear tube at the filling connection carefully (30-35 Nm).
8. Remove the quick connection and reset the protection plug into the connection hole.
2. Connect the pump to the quick connection. Check if there is enough room in the pump
to evacuate the oil from the SAFESET®.
ATEX information
This SAFESET® coupling is classified for use in potentially explosive atmospheres
according to the EU Directive 94/9/EC of March 1994 (ATEX). The classification is:
II 3G c g T3
II 3G c g T3
SAFESET®
Calibration diagram / Kalibrierdiagramm
Coupling type / Kupplung type Order / Bestell Nr. Coupling No / Kupplung Nr.
Setting / Einstellung
T= kNm
P= MPa
Torque (x10³ lb-in)
0 500 1000 1500 2000 2500 3000 3500 4000
90
12
80
70
10
60
Pressure / Druck (MPa)
50
6
40
30
4
20
2
10
0 0
0 50 100 150 200 250 300 350 400 450 500
Torque / Drehmoment (kNm)