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Print date 01/14
Global version
Important
CX series
The following information is important in ensuring safety. It must be brought to the attention of personnel involved in the selection of David Brown
power transmission equipment, those responsible for the design of the machinery in which it is to be incorporated and those involved in its installation,
use and maintenance.
1.
1.1.
1.2.
1.3.
1.4.
General information
Introduction
Background
Description
Nameplate
5
5
5
5
2.
2.1.
2.2.
3.
3.1.
3.2.
3.3.
3.4.
3.5.
3.5.1.
3.5.2.
Installation
General
Prior to installation
Fitting couplings and equipment
to the shafts
Foot mount units
Shaft mount units
Procedure
Using a shrink disk
4.
4.1.
4.2.
4.3.
4.4.
4.5.
Lubrication
General
Temperature limitations
Ventilator
Oil level
Approved lubricant
5.
5.1.
5.2.
Start up
Prior to start up
Start up
David Brown power transmission equipment will operate safely provided it is selected, installed, used and maintained properly. As with any power
transmission equipment proper precautions must be taken as indicated in the following paragraphs, to ensure safety.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Fire/explosion
a. Oil mists and vapour are generated within gear units. It is therefore dangerous to use naked light in the proximity of
gearbox
openings, due to the risk of fire or explosion.
b. In the event of fire or serious overheating (over 300C), certain materials (rubber, plastics, etc) may decompose and produce
fumes. Care should be taken to avoid exposure to the fumes, and the remains of burned or overheated plastic/rubber
materials should be handled with rubber gloves.
Guards - rotating shafts and couplings must be guarded to eliminate the possibility of physical contact or entanglement of clothing.
It should be of rigid construction and firmly secured.
Gearbox driven machinery may produce noise levels which are damaging to the hearing with prolonged exposure. Ear defences should
be provided in these circumstances.
Lifting - where provided, only the lifting points or eyebolts should be used for lifting operations (see maintenance and Installation
manuals or general arrangement drawings for lifting positions). Failure to use the lifting points provided may result in personal
injury and/or damage to the product or surrounding equipment. Keep clear of raised equipment.
Lubricants and lubrication
a. Prolonged contact with lubricants can be detrimental to the skin. The manufacturers instruction must be followed
when handling lubricants.
b. The lubrication status of the equipment must be checked before commissioning. Read and carry out all instruction on the
lubricant plate and in the installation and maintenance literature. Heed all warning tags. Failure to do so could result in
mechanical damage and in extreme cases risk of injury.
Electrical equipment - observe hazard warnings on electrical equipment and isolate power before working on the gearbox or associated
equipment in order or prevent the machinery being started.
Installation, maintenance and storage
a. In the event that the equipment is to be held in storage, for a period exceeding six (6) months, prior to installation or commuting,
David Brown must be consulted regarding special preservative requirements. Unless otherwise agreed, equipment
must be stored in a building protected from extremes of temperature and humidity to prevent deterioration.
b. External gearbox components may be supplied with preservative materials applied, in the form of a waxed tape overwrap
or wax film preservative. Gloves should be worn when removing these materials. The former can be removed manually, the latter
using white spirit as a solvent.
CX series
Table of contents
c. Installation must be performed in accordance with the manufacturers instructions and be undertaken by
suitably qualified personnel.
d. Before working on a gearbox or associated equipment, ensure that the load has been removed from the system to eliminate
the possibility of any movement of the machinery and isolate power supply. Where necessary, provide mechanical means to
ensure the machinery cannot move or rotate. Ensure removal of such devices after work is complete.
e. Ensure the proper maintenance of gearboxes in operation. Use only the correct tools and David Brown
approved spares for repair and maintenance. Consult the product maintenance manual before dismantling or performing maintenance
work.
Hot surfaces and lubricants
a. During operation, gear units may become sufficiently hot to cause skin burns. Care must be taken to avoid accidental contact.
b. After extended running the lubricant in gear units and lubrication system may reach temperatures sufficient to cause burns.
Allow equipment to cool before servicing or performing adjustments.
Selection and design
a. Where gear units provide holdback facility, ensure that back-up systems are provided if failure of the holdback device would
endanger personnel or result in damage.
b. The driving and driven equipment must be correctly selected to ensure that the complete machinery installation will
perform satisfactorily, avoiding system critical speeds, system torsional vibration, etc.
c. The equipment must not be operated in an environment or at speeds, powers, torques or with any external loads
beyond those for which it was designed.
d. As improvements in design are being made continually the contents of this catalogue are not to be regarded as binding
in detail, and drawings and capacities are subject to alterations without notice.
4
5
5
4
5
5
5
5
5
5
5
4
5
5
5
5
5
4
5
5
5
7.
7.1.
7.2.
7.3.
7.3.4.
7.3.5.
7.4.
7.5.
7.6.
Maintenance
Prior to any maintenance 23
Oil plugs and ventilators 23
Lubrication 23
Periodic inspection 23
Oil changes 24
Sealing 25
Bearings 25
Cleaning 25
4
5
5
5
5
5
5
5
5
8.
Trouble shooting
9.
Risk assessment
Appendix 1
Appendix 2
Errors of angularity
Errors of eccentricity
Notes
4
5
5
EX
Damaging situation
Could result in damage to gear unit,
drive assembly or driven equipment
Cleaning
Noise hazard
Hot surface
Lifting hazard
3/28
Danger
Could result in death, serious, slight
or minor injuries
Operation
Noise 22
General safety 22
Initial start up for gear units in a potentially
explosive atmosphere 22
The above guidance is based on the current state of knowledge and our best assessment of the potential hazards in the operation of the gear units.
Any further information or clarification required may be obtained by contacting David Brown.
2/28
6.
6.1.
6.2.
6.3.
Helpful information
General information
CX series
CX series
General information
1.1. Introduction
1.3. Description
These operating instructions are an integral part of the CX series product supplied and contain important information for
safety, installation, operation and maintenance. These instructions must be accessible and legible to any person operating
or undertaking work on the units at all times.
Offering
The CX series units are offered on both right angled two and three stage configurations along with two stage parallel
stage configuration.
These instructions shall be supplementary to any information contained on the certified arrangement drawing and any
separate instructions for equipment fitted to the gear unit. All units are tested and checked prior to despatch, a great
deal of care is taken in packing and shipping arrangements to ensure that the unit arrives at the customer in the
approved condition.
Any person involved in the installation, maintenance, operation or repair of the product must have read
and understood these operating instructions and must comply with them at all times. David Brown
accepts no responsibility for damage or loss caused by disregard of these instructions.
1.2. Background
The David Brown CX series gear reducers are designed to meet the most arduous of power transmission application needs.
Reliable and efficient in operation, they provide a cost-effective solution to all our customers needs. Designed to David
Browns long established standard of quality, these quiet running units provide exceptional levels of performance,
versatility and life expectancy to meet the demanding requirements of modern industry.
The David Brown story is above all a constant drive for perfection. It starts more than a century ago and tells of
total dedication and commitment to the development of gear technology. The CX series is a part of that story.
The David Brown gear organisation was founded in 1860. It produced the first commercial worm gearbox in 1903 and so
helped to establish a marketplace it has led ever since. The organisation rapidly became a master of its craft. Notable
credits include the introduction of a patented involute helicoidal worm thread form in 1912, followed later by the
development of phosphor bronze materials for worm wheels which have become a standard throughout the industry.
The passage of time has seen constant refinements accumulating expertise and scientific progress but the organisations
pioneering spirit remains unchanged as technological barriers are crossed one after another. The development of the CX
series helical and bevel helical geared units is another example of David Browns superior technical expertise. CX series
gear units are available in inline and right-angle versions in double and triple reduction gear stages having a maximum
power capacity exceeding 12,000 kW.
Designed with global applications in mind, the CX series benefits from the design-for-manufacture philosophy which
ensures optimum product for the application and minimum spares requirements. This, in turn, provides considerable
economies of production whilst maintaining the highest standard of component integrity. Featuring carburised, hardened
and profile ground helical gears, highly efficient and quiet running characteristics are assured. The gear units are available
in a wide range of ratios from 8.4:1 to 47:1.
These units are offered in a single configuration, a two stage (P2) helical.
The use of high quality materials also provides assurance of long life and reliability in operation in the most
extreme environmental conditions.
4/28
5/28
Handing
The unit handing is determined by facing the unit from the input end of the unit
Left handing
Right handing
Shaft rotation
Shaft rotation is determined by facing the relevant shaft. As the inputshaft rotation is determined from the output
rotation, the rotation must be stated relevant to the output shaft.
1.4. Nameplate
Every unit carries a unique
nameplate that contains
vital information.
Red arrow
Blue arrow
6/28
7/28
Type
Unit description
Serial
Set
Pi [kW]
Input power
Ni [RPM]
Input speed
Ratio [ /1]
Oil Gr
Oil grade
Mass [kg]
Year
Year of construction
CX series
2.1. Lifting
CX series
Installation
3.1. General
Only the lifting points identified below must be used for lifting operations during installation.
The customer shall be responsible for the proper use of articles supplied by the company, particularly the
rotating shafts between their driving and driven members, and their guarding for safety and the
company shall not be responsible for any injury or damage sustained as a result of the improper use of
the articles supplied.
Attention is hereby drawn to the danger of using naked lights in proximity to openings in gearboxes and
gear units supplied by the company, and the company shall not be liable for any claim for injury or damage
arising from any action in contravention of this warning.
Gearbox only
4 off tapped holes with eye bolts only
Drive assembly
The appropriate lifting equipment with sufficient load carrying capacity shall be used at all times.
Unit handing
Rotation
Fan blade
RH
CW
RH
LH
ACW
LH
RH
ACW
LH
LH
CW
RH
Failure to use the lifting points specified could result in death/serious injury and/or damage to
the product and surrounding equipment.
2.2. Storage
Prior to dispatch all units bare metal surfaces (internal and external) are covered with a rust preventative film. This will
provide corrosion protection for a period of 6 months from date of assembly. When the unit is commissioned the first oil
fill dissolves the rust preventative film without any harmful effect to the lubricant.
Parallel shaft units are fitted with radial flow fans which are bi-directional.
David Brown can advise and offer suitable protection for periods greater than 6 months.
8/28
9/28
CX series
Installation
Secure unit, or baseplate if fitted to a rigid foundation using heavy duty bolts to ISO grade 8.8 minimum.
The input or output shaft extension diameter tolerance is to ISO tolerance m6 and the fitted components
should be to ISO tolerance K7
Ensure shaft extensions, bores & keys are cleaned
Items (such as gears, sprockets, couplings etc) should not be hammered onto these shafts since
this would damage the shaft support bearings
The item should be pushed onto the shaft using a screw jack device fitted into the threaded hole
provided in the end of the shaft. See Table 1 below
Items being fitted may be heated to 100C to aid assembly further
M10
46 Nm
M12
85 Nm
M16
200 Nm
M20
350 Nm
M24
610 Nm
M30
1220 Nm
M36
2150 Nm
M42
3460 Nm
R2
Output shaft
M48
5600 Nm
185/210
M16 X 35
M20 X 43
M56
9020 Nm
225/240
M16 X 35
M24 X 52
800
M42 X 80
260/275
M20 X 43
M30 X 63
285/300
M20 X 43
M36 X 74
320/336
M20 X 43
M36 X 74
365/400
M20 X 42
M42 X 81
480/525
M24 X 52
M24 X 52
M56 X 109
560/620
M30 X 72
M30 X 63
M56 X 109
675/720
M30 X 72
M42 X 91
M56 X 109
800
M42 X 80
M42 X 81
M56 X 109
3.6.1. Procedure
The following procedure is recommended for all shaft and foot/shaft mounted units.
Clean shaft extensions, driven machine shaft, gear unit bore and ventilator when fitted
Locate in position, ensuring it is as close as possible to the bearing on the driven machine
Secure unit onto the shaft. For units using a shrink device refer to section 3.5.2
Fit torque arm to the drive as indicated on the relevant general arrangement drawing
Note: Unless specified otherwise, the torque arm will be supplied loose
Check motor wiring for correct direction of rotation, this is important when a backstop device is fitted
Ensure the base foundation mounting surface is flat1, vibration absorbing and torsionally rigid
Note: Units on baseplates should if possible be mounted on the same bedplate as the prime mover
The gear unit must be installed in the specified mounting position. The maximum deviation from the
designated mounting position is 3 (unless gear unit is suitably modified and approved for non standard
mounting positions)
Align unit (see Appendix 1)
Working principle
The shrink disc consists of a locking collar, a tapered inner ring and locking screws. By tightening the
locking screws, the locking collar and tapered inner ring are pulled together, exerting radial forces on
the inner ring, thus creating a positive friction connection between hollow shaft and driven shaft (See
Figure
4). As the tapered surfaces of locking collar and inner ring are lubricated with Molykote 321R or similar and
the taper angle is not self locking, locking collar will not seize on the inner ring and can be released easily
when removal is necessary. When the shrink disc is clamped in position the high contact pressures
between tapered surfaces and screw heads and their seatings ensure hermetic sealing and eliminate the
possibility of fretting corrosion.
Note:
It is important to ensure when aligning unit on baseplate that all machined mounting points are supported
over their full area. If steel packings are used, these should be placed either side of the foundation bolt as
close as possible
During final bolting ensure the unit or baseplate is not distorted as this would cause strains in the gear
case resulting in errors of alignment of shafts and gearing
Check all mounting points are fully supported and adjust if necessary using steel packings
Torque tighten bolts to torque specified in table overleaf
10/28
Tightening torque
R3 and P2
Bolt size
Unit size
430/455
CX series
Installation
11/28
Installation
CX series
Installation
4.1. General
Shrink discs are supplied with shaft mounted units. The following procedures should be followed when fitting
or removing units from the driven shaft.
Release locking screws gradually and in succession. Initially a quarter of a turn on each screw will avoid tilting
and
jamming, do not remove locking bolts completely
Grease tapered surfaces of outer ring and inner ring with Molykote 321R or similar
Tighten all locking screws gradually and in succession. Do not tighten in a diametrically opposite sequence.
Several passes are required until all screws are tightened until the inner and outer ring faces are in line and
the torque figures Ta shown in Table 3 are achieved
All CX units are dispatched and shipped without oil. Prior to start up the client shall fill the unit with the
sufficient grade and quantity of oil.
Lubricant
0C to 35C
20C to 50C
CLP
5E (VG 220)
6E (VG 220)
7E (VG 220)
CLP
5H (VG 220)
5H (VG 220)
6H (VG 220)
4.3. Ventilator
Clean and secure the ventilator in the correct location for the required mounting position.
4.4. Oil level
Removal
CX series
Lubrication
The unit should be filled to the level marked on the dipstick or any other level indicator fitted (sight glass etc.).
Where possible run the unit without load for a short time to circulate the lubricant thoroughly, then stop the unit and recheck the oil level after allowing the unit to stand for 10 minutes and if necessary top up to the correct mark on the
dipstick or any other level indicator fitted (sight glass etc.).
Note:
Warning do not overfill as excess may cause overheating and leakage
Shrink disc should be removed and cleaned thoroughly, and Molykote 321R or similar applied to the
tapered surfaces of inner ring and locking collar before re-use.
Check and re-fit all plugs & tighten to correct torque figure see notes in maintenance section. Clean
away any oil spillage from the surface of the gear unit and driven machinery.
Note:
Protective covers are supplied with all shrink discs. Assembly or removal kits and thrust plates are not provided.
12/28
13/28
Start up
CX series
6.1. Noise
Ensure the unit is filled with the appropriate oil level and grade and the the breather is securely fitted and clear of
debris
If fitted ensure the holdback allows for free rotation in the desired direction of rotation
Perform an uncoupled spin test of the motor to ensure the motor is correctly wired
Ensure drive and relating components are aligned correctly, refer to Appendix 2
Ensure all safety devices are in place and secure (i.e. guards). Ensure the guards do not catch or touch any
rotating components, this is an ignition source
The range Series CX 185 - 400 product satisfies a noise (sound pressure level) of 85 dB(A) or less when
measured at 1 metre from the unit surface. Units larger than 480 may exceed this level consult
application engineering.
Measurements taken in accordance with BS 7676 Pt1 : 1993 (ISO 8579-1 : 1993).
5.2. Start up
CX series
Operation
This must be read and understood prior to carrying out any work whatsoever!
Any deviation from normal operating conditions such as excessive noise, temperature,
vibration or power consumption suggests a malfunction, inform maintenance personnel
immediately.
EX
During initial running in it is important to measure the gear unit maximum surface temperature when
run under maximum load after approximately 3 hours operation.
The maximum surface temperature must not exceed 110C for temperature class T3 & T4 and 80C for T5. If
this temperature is exceeded, shut down immediately and contact application engineering.
14/28
15/28
CX series
Maintenance
7.1. Prior to any maintenance
on
Initial fill of oil should be changed in a new gear unit after 1000 hours operation or six
months, whichever is the soonest.
pressure build up
Wait until the unit has cooled down. Danger of skin burns &
Figures quoted are for oil temperatures when the unit has attained normal running temperature when
operating under load. These figures are based on normal running but where conditions are particularly severe
it may be necessary to change the oil more frequently.
When changing lubricant, if same lubricant is not used then unit must be flushed out and filled with one type
of lubricant.
CX series
Maintenance
Prior to removing plugs, ensure that the unit has cooled sufficiently so that oil will not burn
Place a container under the oil drain plug to be removed
Note: it is recommended that the oil should be slightly warm, (40-50C) when drained. (Cooler oil will be more difficult to
drain correctly)
Top ups or refills should be done through the ventilator position or the inspection cover
Remember to refit all plugs and torque tighten to Table M1 below
Gear unit
Plug size
Tightening torque
CX185 - 275
1/2 BSP
102 Nm
CX 285 - 400
1 BSP
203 Nm
CX 430 - 620
1 1/2 BSP
305 Nm
CX 675 - 800
2 BSP
400 Nm
Warning
Do not mix synthetic and mineral lubricants.
Do not overfill the unit as this can cause leakage and overheating.
EX
For units installed in potentially explosive atmosphere it is essential to ensure that the oil is changed on
or before the renewal period specified in Table 4.
7.4. Sealing
7.3. Lubrication
7.3.4. Periodic inspection
All CX series units are equipped with a grease purged labyrinth per shaft extension. These points are to
be greased every 720 hours of operation or 30 days, whichever is soonest. For approved greases refer
to Appendix 1.
For units fitted with dipstick or other level indicating device, check the oil level every 720 hours or 1 month
whichever is sooner and if necessary top up with the recommended type of lubricant.
7.3.5. Oil changes
On all sizes regular oil changes are essential and the following factors should be used to determine the frequency
at which these are carried out.
7.5. Bearings
All CX series units are equipped with a grease purged labyrinth per shaft extension. These points are to
be greased every 720 hours of operation or 30 days, whichever is soonest. For approved greases refer
to Appendix 1.
At elevated temperatures the effective life of the oil is very much reduced. This is most pronounced with oils
containing fatty and EP additives. To prevent damage to the unit through lubricant breakdown the oil should
be renewed as detailed in Table M2.
Temperature C
16/28
EX
Bearings should be replaced every 5 years for units marked with the icon on the left. Alternatively they
should be replaced in accordance with the agreed specification.
Oil type
Mineral oil CLP(CC) Type E
75 or less
80
85
90
95
100
105
110
7.6. Cleaning
With the drive stationary, periodically clean any dirt or dust from the gear unit and the electric motor cooling
fins and fan guard to aid cooling. Ensure build up of dirt or dust does not exceed 5mm.
17/28
CX series
Trouble shooting
Problem
Temperature rise at
bearings
Excessive operating
temperature
Causes
Remedy
Defective bearing
Change oil
Defective bearing
To ensure the safe operation of any David Brown gearing product the following risk
assessment must be taken into account. The risks and hazards identified must be mitigated or
if possible designed out of the system.
Risk analysis and mitigation for David Brown gear units
The following table displays the risks/hazards associated with the use/operation of our gear units, the recommended
risk mitigation and response action associated with these risks.
The SIL (Safety Integrity Level) rating indicates the level of safety management that should be assigned to specified risk.
The SIL matrix displayed on the following page indicates the relationship between the probability and severity of the
risks associated with the use of our units.
The table below shows the definitions attached to each SIL Rating.
SIL rating
NO SIL
No damage to unit
0+
4+
Disastrous accidents
Replace element
Hazard
Nameplate data
Type and extent of problem
Time and circumstance of the problem
Possible cause
19/28
Mitigation
Action/response
Probability
Severity
Sil rating
Damage to bearings
N/A
Seizure of unit
N/A
Bearing damage
Seizure of unit
N/A
Overheating
Seizure of unit
Failure of bearings
Fire
Definition
18/28
Potential effects
Oil leak
It is normal for a small amount of grease to seep out from the labyrinth during a 24 hour period
When contacting our sales office please have the following information available.
CX series
Risk assessment
Use of Incorrect
lubrication oil
Oil leak
CX series
Risk assessment
10
11
12
13
14
15
16
17
Hazard
Potential Effects
Mitigation
Action/response
Probability
Severity
Sil rating
Failure of bearings
Broken teeth
Overload of unit
Blockage of
lubrication pipes
Misalignment
Rust/corrosion
N/A
N/A
Contact with
rotating parts
Incorrect
installation of unit
19
Shock loading
Electrical shock
Seizure of input
drive
Loss of limbs/death
24
25
4
1
3
5
Castrol International
Loss of limbs/fingers
Destruction of unit
N/A
N/A
Noise pollution
Damage to
couplings
Power spike/surge
3
3
3
0 to 35
20 to 50
220 (-2)
320 (-2)
460 (-2)
Indus
220 (-10)
320 (-10)
460 (-10)
Energol GR-XF
c, e
220 (-16)
320 (-13)
460 (-1)
Energol GR-XP
220 (-15)
320 (-10)
460 (-7)
Meropa
220 (-4)
320 (-4)
460 (-4)
20 (-7)
320 (-4)
460 (-7)
Berugear GS BM
220 (-20)
320 (-13)
460 (-10)
Staroil G
220 (-13)
320 (-13)
460 (-10)
Alpha max
c, e
220 (-19)
320 (-13)
460 (-10)
Alpha SP
220 (-16)
320 (-16)
460 (-1)
320 (-13)
460 (-10)
320 (-13)
460 (-13)
Ultra gear
220 (-10)
320 (-7)
460 (-7)
Eko-Elda Abee
Eko gearlub
220 (-13)
320 (-10)
460 (-1)
Gengear
220 (-15)
320 (-12)
460 (-3)
Esso/Exxon
Spartan EP
220 (-12)
320 (-12)
460 (-4)
P/Gear (-16)
M460 (-4)
Fuchs Lubricants
Renogear V
220EP (-13)
320EP (-4)
460EP (-4)
Renogear WE
220 (-7)
320 (-4)
400 (-4)
6 (-13)
8 (-10)
10 (-10)
Klberoil GEM1
220 (-5)
320 (-5)
460 (-5)
Q8 goya
220 (-16)
320 (-13)
460 (-10)
607 (-18)
605 (-13)
608 (-10)
630 (-13)
632 (-13)
634 (-1)
220 (-19)
320 (-13)
460 (-7)
2
2
Omega 690
85w/140 (-15)
Optigear BM
220 (-11)
320 (-10)
460 (-7)
Optigear
220 (-18)
320 (-9)
460 (-7)
Masri
220 (-4)
320 (-4)
460 (-7)
Petro-Canada
Ultima EP
220 (-22)
320 (-16)
460 (-10)
Rocol
Sapphire hi-torque
220 (-13)
320 (-13)
460 (-13)
Cobalt
220 (-4)
320 (-1)
460 (-4)
Hemat
220 (-10)
320 (-7) 4
60 (-4)
Gear lube EP
EP220 (-1)
EP320 (0)
EP460 (0)
220 (-4)
320 (-4)
460 (-4)
220 (-13)
320 (-10)
460 (-4)
220 (-16)
320 (-16)
460 (-10)
220 (-19)
320 (-16) 4
60 (-11)
Carter EP
220 (-7)
320 (-7)
460 (-4)
CarterVP/CS
220 (-16)
320 (-13)
460 (-7)
90 (-18)
690 (-16)
140 (-13)
Tribol 1100
220 (-20)
320 (-18)
460 (-16)
Texaco Limited
Total
Tribol GmbH
21/28
Pertamina (Indonesia)
Klber Lubrication
Powergear
7E
220 (-13)
Shell Oils
20/28
Remus
6E
220 (-16)
See notes
page 19
Lubricant range
5E
Excessive noise
Caltex
Supplier
Grade numbers
Damage to hearing
23
Type E - Mineral oil containing industrial EP additives. These have a high load carrying capacity.
Catastrophic failure
of unit
Approved lubrication
Failure of driven
equipment
22
Excessive vibration
Contact with
meshing parts
21
18
20
Twist on Case
CX series
Appendix 1
Omala
Omala F
Meropa
Meropa WM
CX series
Appendix 1
CX series
Appendix 1
Type H - Polyalphaolefin based synthetic lubricants with anti-wear or EP additives. These have a medium to high
load carrying capacity.
Danger
Numbers in brackets indicate the minimum pour point temperature of the specified oil in C. The unit must not be
run below this temperature
Grade numbers
Supplier
Lubricant range
See notes
page 19
5H
6H
0 to 50
Batoyle freedom
Group titan
220 (-31)
320 (-28)
Silkgear
220 (-35)
320 (-35)
Enersyn EPX
Pinnacle EP
Alphasyn EP
220 (-38)
320 (-35)
220 (-37)
320 (-31)
220 (-31)
320 (-28)
Tegra
220 (-46)
320 (-33)
Esso/exxon
Spartan Synthetic EP
220 (-46)
320 (-43)
Renogear SG
220 (-32)
320 (-30)
220 (-37)
320 (-34)
220 (-30) 3
20 (-25)
320 (-19)
Fuchs lubricants
Klber lubrication
Klbersynth GEM4
Q8 El greco
220 (-22)
9920 (-40)
220 (-40)
320 (-37)
220 (-40)
320 (-33)
220 (-31)
320 (-31)
Notes:
220 (-43)
320 (-37)
Shell oils
Omala HD
220 (-43)
320 (-40)
220 (-43)
320 (-43)
20 (-43)
320 (-40)
Total
Pinnacle WM
Carter EP/HT
c2
220 (-34)
320 (-31)
Tribol GmbH
Tribol 1510
220 (-36)
320 (-33)
To
-30
130
Multifak EP
120
LMX grease
-40
150
-30
110
-10
120
Fuchs lubricants
Renolit EP
-25
100
Klber lubrication
Klberlub BE 41-542
-20
140
Mobilgrease XHP
-15
150
Mobilith SHC
-20
180
Omega 85
-40
230
Longtime PD
-45
140
Albida RL
-20
150
Alvania EP B
-20
120
Nerita HV
-30
130
-30
140
Texaco limited
Above
Spheerol AP
Shell oils
Petro-Canada
Spheerol EPL
Optigear synthetic A
Pinnacle EP
Energrease LS-EP
Castrol international
Texaco limited
320 (-43)
Alphasyn T
e
Lubricant range
320 (-28)
220 (-43)
Berusynth GP
Supplier
Notes:
22/28
These lubricants have been tested for micro-pitting (FZG Type C), test results are available
These lubricants contain additives which may adversely affect silvered or white metal components; consult oil supplier
Minimum operating temperatures of these lubricants are based on worst case values, lower operating temperatures
may be available, please check with local stockist
23/28
CX series
Appendix 2
Appendix 2
CX series
Shaft/coupling alignment
Errors of eccentricity
These occur when the centre lines of shafts do not intersect (Fig.2). Where the misalignment is in the vertical plane, it can
be corrected by altering the height of the motor by means of packing shims placed under the motor feet.
For coupling alignment see appropriate manufacturers installation and maintenance manual
Whilst no general rule can be laid down for permissible errors in lining up, it is recommended that, for
example couplings, faces and the peripheries are true to within 0,1mm total indicator reading
Alignment in accordance with the following procedure should ensure vibration levels meeting ISO 10816 Part 1
Errors of alignment are either of angularity (Fig.1) or eccentricity (Fig.2) or a combination of both
When the error is in the horizontal plane, correction may be made by moving the unit transversely until set in the
required position.
Radial runout may be checked using a dial test indicator mounted on one side of the coupling and measured on the
outer diameter of the other half. To measure and record eccentricity of the coupling diameter, both coupling halves
should be locked together using coupling pins or other flexible element and then both halves of the coupling should be
rotated together and readings taken at four positions as shown in Fig.4.
Errors of angularity
Angularity errors should be corrected before any attempt is made to eliminate errors of eccentricity. The procedure is
shown in Fig.3, using a dial test indicator or a thickness gauge in conjunction with feeler gauges. Readings should be
taken in positions 1, 2, 3 and 4 with any axial float in bearings in the coupled shaft taken up. Adjust the motor by
shimming for vertical errors. or move the unit on its foundation or baseplate for horizontal errors.
In lining up elements involving rigid couplings it is important that no attempt is made to correct errors of
alignment or eccentricity greater than those above by tightening of the coupling bolts. ( This applies when
the system is cold or at operating temperature). The result is misalignment and the setting up of undue
stresses in the shaft, coupling and bearings. This will be revealed by the springing apart of the coupling
faces if the bolts are slackened off. A check on the angularity of a pre-assembled job, after bolting down,
can be obtained in the case of rigid couplings by slackening off the coupling bolts, when any misalignment
will cause the coupling faces to spring apart. This check may not, however, reveal any strains due to
eccentricity owing to the constant restraint imposed by the spigot.
24/28
Effect of temperature
If there is a substantial difference between the running temperature of the gear casing and the adjacent machinery,
differences in heights may be appreciable. The co-efficient of linear expansion for cast iron is 0.000011 per unit length per
C.
For a 500mm centre height and a difference in temperature of 30 between the gearcase and the driven or driving
machine the error in alignment, if correct when cold, will be 0,165mm.
Such operating conditions can produce, particularly in large and close coupled units, very heavy additional bearing
loads and it is recommended that allowance be made such that the alignment will be correct under normal working
temperatures.
25/28
CX series
Action
complete
Y/N
Date
CX series
Signature
Action
complete
Y/N
Date
Signature
Visual inspection check for transit damage e.g. bruising, paint damage,
loose items
Run under 25% load for 30mins and increase at 25% intervals each
30mins until 100%
Check that all holding down bolts are secure and torqued to
recommended level on motor, gearbox and brakes
Check retaining bolts on guards, brake power packs and all other
externally mounted equipment
Check all cover bolts and jacking/adjusting screws are correctly tightened
Check high speed coupling and brake disc bolts for correct torque
If brake test is carried out check disc temperature after successive stops
Check for free rotation of gearbox rotate a minimum one full revolution
of output shaft and watch for signs of jamming
After running
Check all mounting bolts
Check gearbox, high speed coupling and holdback for oil and grease
leaks
Ensure all oil dams and troughs are primed with oil and replace
inspection cover
Remove inspection cover and check and record tooth mesh contact
pattern
No load running
Note: Checks done on gearbox should be replicated on the motor and brake power pack where appropriate.
26/28
27/28