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Manufacturing and
Service Centres
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Approved David Brown


service and repair facility

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Print date 01/14

Revision date 01/14

Global version

Moventas approved service and repair centre


The information contained in this catalogue has been obtained through sources deemed reliable but cannot be guaranteed as to its accuracy. Any information of special interest should be
obtained
through independent verification and consulted with a David Brown representative.
In the interest of continuous development, David Brown reserves the right to alter designs and specifications without prior notice.
David Brown is certified to ISO9001:2008. Your David Brown representative should be consulted prior to product selection and use. 3X terms and conditions apply. Contact your local David
Brown representative for details and to check eligibility.

CX series conveyor drive systems


Installation, operating and maintenance manual

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.

Safety warning symbols

1.
1.1.
1.2.
1.3.
1.4.

General information
Introduction
Background
Description
Nameplate

5
5
5
5

2.
2.1.
2.2.

Handling and storage


Lifting
Storage

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

Electrical hazard Could


result in death or serious injury

EX

Danger (touch hazard)

Damaging situation
Could result in damage to gear unit,
drive assembly or driven equipment

Important notes on explosion


protection

Periodic cleaning necessary

Cleaning

Noise hazard

Hot surface

Hearing protection must be worn

Could result in serious injury

Lifting hazard

3/28

Danger
Could result in death, serious, slight
or minor injuries

Could result in death or serious


injury

Danger of suspended loads

CX series | Installation, operating and maintenance manual

Operation
Noise 22
General safety 22
Initial start up for gear units in a potentially
explosive atmosphere 22

Safety warning symbols

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

CX series | Installation, operating and maintenance manual

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.

Right angle shaft units


These units are offered in to configurations, a two stage (R2) and three stage (R3) bevel-helical.

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.

Three stage right angle (R3)

Two stage right angle (R2)

Parallel shaft unit

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.

Two stage right angle (P2)

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CX series | Installation, operating and maintenance manual

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CX series | Installation, operating and maintenance manual

Handing
The unit handing is determined by facing the unit from the input end of the unit

Handing and rotation

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.

Left handing, clockwise rotation

Right handing, anti clockwise rotation

1.4. Nameplate
Every unit carries a unique
nameplate that contains
vital information.

Red arrow
Blue arrow

6/28

Clockwise (CW ) rotation relative to output


Anti clockwise (ACW ) rotation relative to output

CX series | Installation, operating and maintenance manual

7/28

Type

Unit description

Serial

Unique serial number

Set

Number of unit within serial number

Pi [kW]

Input power

Ni [RPM]

Input speed

Ratio [ /1]

Reduction ratio of unit

Oil Gr

Oil grade

Mass [kg]

Mass of unit only

Year

Year of construction

CX series | Installation, operating and maintenance manual

Handling and storage

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

Lifting point at all corners with shackles only

No welding should be done on the drive.


The drive must not be used as an earthling point for welding, if done so arcing could occur in the bearings or
gear mesh resulting in premature failure.
All CX series units are dispatched without oil, upon installation of the unit fill with the recommended lubricant and to
the correct level.
3.2. Prior to installation

Check gear unit has not been


damaged
Check the gear unit/motor nameplate matches the requirements of the machine the unit is to be
installed into
Thoroughly clean the gearbox mounting surfaces that are to be used and ensure the shafts are free
of paint and anticorrosion agents using a commercially available solvent. Ensure solvent does not
make contact with the oil seals

Drive assembly

The appropriate lifting equipment with sufficient load carrying capacity shall be used at all times.

Unit handing

Lifting point at all corners with shackles only

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.

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CX series | Installation, operating and maintenance manual

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CX series | Installation, operating and maintenance manual

CX series

Installation

Secure unit, or baseplate if fitted to a rigid foundation using heavy duty bolts to ISO grade 8.8 minimum.

3.4. Fitting couplings and equipment to the shafts

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

Anchor drive to a secure point by means of the torque arm

Fit guards in accordance with the factory acts

Check motor wiring for correct direction of rotation, this is important when a backstop device is fitted

Fill gear unit with oil as detailed in section 4

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)

CX series | Installation, operating and maintenance manual

Maximum permissible flatness error is for mounting surface is 0.12mm

3.6. Shaft mounted units

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

3.5. Foot mount units

Bolt size

Unit size

430/455

CX series

Installation

11/28

CX series | Installation, operating and maintenance manual

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

Remove shrink disc from gear unit hollow shaft


Clean and degrease locating diameters of gear unit hollow shaft, driven shaft and shrink disc locating diameter
on hollow shaft extension

Draw the gear unit onto the driven shaft

Grease tapered surfaces of outer ring and inner ring with Molykote 321R or similar

Fit shrink disc on gear unit hollow shaft to position

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

Fit protective cover


Note:
When the hollow output shaft is to operate in a vertical position it is essential that the shaft of the driven
machine is provided with a shoulder. When the thrust load is not taken by the shoulder on the driven shaft, a
thrust plate must be fitted.
It is recommended that customers shafts at the non-clamped end of the sleeve should be coated with Molykote
321R or equivalent.

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.

4.2. Temperature limitations


Ensure the lubricant grade stamped on the unit nameplate is suitable for the operational ambient temperature, consult the
table below.
Ambient temperature range
ISO

Lubricant

-5C to 20C (type E)


-30C to 20C (type E)

0C to 35C

20C to 50C

CLP

EP mineral oils (type E)

5E (VG 220)

6E (VG 220)

7E (VG 220)

CLP

Polyalphaolefin based synthetic


with EP additive (type H)

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.).

Removal procedure is similar to the reverse of installation


Note: Do not remove shrink disc locking screws completely
Remove any rust and dirt from gear unit hollow shaft
Withdraw gear unit from driven shaft (see figure 6)

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.

4.5. Approved lubricant


For oils and greases refer to Appendix 1

12/28

CX series | Installation, operating and maintenance manual

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CX series | Installation, operating and maintenance manual

Start up

CX series

5.1. Prior to start up

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

Remove any safety devices that prevent start up of the drive

Start up should only be carried out or supervised by suitably qualified personnel

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).

6.2. General safety


Potential hazards which can be encountered during installation, maintenance and operation of drives
is covered in greater detail in the product safety page at the front of this booklet.
Advice is also given on sensible precautions which need to be taken to avoid injury or damage.

5.2. Start up

CX series

Operation

Start up should only be carried out or supervised by suitably qualified personnel


During initial running it is important to measure the gear units maximum surface temperature when running at
maximum load for three to four hours

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.

6.3. Initial start up for gear units in a potentially explosive atmosphere

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

CX series | Installation, operating and maintenance manual

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CX series | Installation, operating and maintenance manual

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.

De-energise the drive and secure against unintentional switch

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.

7.2. Oil plugs and ventilators

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.

Oil temperature unit operating under load


Type of oil
Environment humidity, dust, etc.
Operating conditions shock, loading, etc.

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

Synthetic oil CLP(HC) Type H

75 or less

17000 hours or 3 years

26000 hours or 3 years

80

12000 hours or 3 years

26000 hours or 3 years

85

8500 hours or 3 years

21000 hours or 3 years

90

6000 hours or 2 years

15000 hours or 3 years

95

4200 hours or 17 months

10500 hours or 3 years

100

3000 hours or 12 months

7500 hours or 2.5 years

105

2100 hours or 8 months

6200 hours or 2 years

110

1500 hours or 6 months

5200 hours or 18 months

CX series | Installation, operating and maintenance manual

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 | Installation, operating and maintenance manual

CX series

Trouble shooting
Problem
Temperature rise at
bearings

Excessive operating
temperature

Change in unit noise

Loud noise in region of


gear unit mounting
Noticeable lubricant
leakage1

Drive does not start or


starts under great effort

Causes

Remedy

Oil level is too low

Check oil level and if required adjust oil level

Oil is over aged

Check when last oil change occurred, change oil if required

Defective bearing

Contact David Brown or bearing manufacturer if bearings not


sourced by David Brown

Oil level in unit is too high

Check oil level and if required adjust oil level

Oil is over aged

Check when last oil change occurred, change oil if required

Oil is very dirty

Change oil

Fan cowl of motor/unit is very dirty

Clean fan cowl and surface of drive

Hold back not running freely

Contact David Brown. Repair, if necessary replace

Damage to gear teeth surface

Contact David Brown. Check gear teeth, if necessary replace


damaged components

Excessive bearing play

Contact David Brown. Adjust bearing play

Defective bearing

Contact David Brown or bearing manufacturer if bearings not


sourced by David Brown

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.

External loading on input and/or output too high

Correct loading to nominal data

SIL rating

Gear unit mounting has loosened

Tighten bolts/ nuts at recommended tightening torques. Replace


damaged bolts/nuts

NO SIL

No damage to unit

0+

Minor incident with limited damage to unit

Minor incident with significant damage to unit

Serious accident with limited damage to unit

Serious accidents with significant damage to unit

Serious accidents with severe damage to unit

4+

Disastrous accidents

Wrong mounting position/oil level

Correct mounting position. Check oil level

Inadequate sealing of housing cover or joints

Contact David Brown. Seal again

Radial shaft seal defective

Contact David Brown. Replace oil seal

Lubricant viscosity incorrect

Fill unit with correct lubricant

Oil level is too high in the gear unit

Check oil level. If required adjust

External loading on output too high

Correct loading to nominal data

Motor brake not released

Check connections of brake. If required rectify

Drive works against holdback

Contact David Brown. Change direction of rotation of the motor or


holdback. Check the holdback

Drop in speed or torque

Belt tension too low/high on belt drives

Correct belt tension

Play on input and output


too high

Elastic element on coupling worn

Replace element

Positive connection worn out due to overload

Hazard

Contact David Brown

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

Stop unit. Report to


David Brown

Seizure of unit

N/A

Isolate unit. Report to


David Brown

See page/contamination of water

Ensure that saw dust is available to


contain spillage

Ensure that spillages are dealt with


immediately

Personnel slips on oil

Ensure that signs visible indicating


slippery area

Report to David Brown

Bearing damage

Damage to gear teeth, couplings


and gear case

Regular visual inspection of bearings

Isolate unit. Report to David Brown

Seizure of unit

Damage to gear teeth, couplings &


gear case. Shearing of shafts

N/A

Isolate unit. Report to David Brown

Broken gear teeth

Catastrophic failure of gear unit

Regular visual inspection of gear


teeth condition

Stop unit. Report to


David Brown

Lubrication oil feed


failure

Damage to bearings, gear teeth


and shafts

Monitor inlet and outlet oil pressures

Stop unit. Report to


David Brown

Overheating

Carefully monitor bearing and oil


temperatures

Stop unit. Report to


David Brown

Seizure of unit

Ensure that only specified oil grades


and types are used in unit

Stop unit. Report to


David Brown

Failure of bearings

Carefully monitor bearing and oil


temperatures

Stop unit. Report to David Brown

Fire

Carefully monitor bearing and oil


temperatures

Follow emergency fire procedures.


Isolate unit. Report to David Brown

Scolding/burns to unprotected skin

Ensure that personal protective


equipment is supplied

Stop unit and report to


David Brown

CX series | Installation, operating and maintenance manual

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 | Installation, operating and maintenance manual

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

Overheating, damage to case,


shafts and gear teeth

Regular visual inspection of bearings

Isolate Unit. Report to David Brown

Broken teeth

Ensure that unit is operated to


David Brown indicated specifications

Stop unit. Report to David Brown

Overload of unit

Blockage of
lubrication pipes

Twist of gear case

Lack of lubrication, pitting of gear


teeth. Bearing damage

Ensure that no foreign objects are


allowed in/near unit

Stop unit. Drain oil, and flush


lubrication pipes. Report to
David Brown

Report to David Brown

Excessive vibration, bearing


overheating and misalignment

Misalignment

Twist on case and shafts, and


damage to couplings

Report to David Brown

Rust/corrosion

Seizure of unit, bearing failure and


pitting of gear teeth

Ensure that unit is correctly stored/


lubricated

Report to David Brown

Damage to base and surroundings

N/A

Isolate area. Report to David Brown


immediately

N/A

Follow emergency procedures.


Isolate unit and report to
David Brown

Contact with
rotating parts
Incorrect
installation of unit

19

Shock loading

Electrical shock

Seizure of input
drive

Multiple loss of limbs/deaths

Loss of limbs/death

24

25

Follow emergency medical


procedures and notify emergency
medical services

4
1

3
5

Carl Bechem GmbH

Castrol International

Loss of limbs/fingers

Ensure that during operation there is


no access to the inside of the unit

Follow emergency medical


procedures and notify emergency
medical services

Destruction of unit

Ensure that sufficient protection is in


place for the unit

Seek advice from David Brown,


before restarting unit

Damage to gear teeth and shafts

N/A

Stop unit. Conduct visual inspection


of unit. Report to David Brown
immediately

Excessive vibration, bearing


overheating and misalignment

Ensure that case is mounted


according to David Brown
specifications, that all alignments
are checked and in accordance with
David Brown specifications

Report to David Brown

N/A

Isolate unit. Report to David Brown

Notify David Brown

Noise pollution

Ensure that vibration spectrum is


within David Brown specifications

Notify David Brown

Damage to
couplings

injury to surrounding personnel/


death

Regular inspection of couplings and


coupling fitting

Follow emergency procedures.


Isolate unit and report to
David Brown

Power spike/surge

Damage to gear unit and input


motor

Ensure sufficient surge protection


within control system

Isolate unit. Report to David Brown

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)

RPM borate EP lubricant

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)

Engen Petroleum Limited

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)

Renolin CLPF super

Klberoil GEM1

220 (-5)

320 (-5)

460 (-5)

Kuwait Petroleum International

Q8 goya

220 (-16)

320 (-13)

460 (-10)

Lubrication Engineers Inc.

Almasol vari-purpose gear

607 (-18)

605 (-13)

608 (-10)

630 (-13)

632 (-13)

634 (-1)

220 (-19)

320 (-13)

460 (-7)

Optimal lwerke GmbH

2
2

Mobil gear XMP

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)

Molub-alloy gear oil

90 (-18)

690 (-16)

140 (-13)

Tribol 1100

220 (-20)

320 (-18)

460 (-16)

Saudi Arabian Lubr. Oil Co.

Texaco Limited
Total
Tribol GmbH

21/28

Mobil gear 600 series

Pertamina (Indonesia)

Sasol Oil (Pty) Limited

Klber Lubrication

Mobil Oil Company Limited

CX series | Installation, operating and maintenance manual

Ambient temperature range C


-5 to 20

Powergear

7E

220 (-13)

Shell Oils

20/28

Remus

6E

220 (-16)

Omega Manufacturing Division Omega 690


3

See notes
page 19

Gear comp EP (USA ver)

Lubricant range

5E

Gear comp EP (Eastern ver)

Chevron International Oil Company Limited

Excessive noise

Caltex

Ensure that personal protective


equipment is supplied

Supplier

Report to David Brown

Damage to gear teeth

Grade numbers

Batoyle Freedom Group

Ensure that unit is correctly installed


by David Brown service technicians

Catastrophic failure of gear unit

Damage to hearing
23

Ensure that access to moving parts,


while unit is in operation, is limited/
or denied

Type E - Mineral oil containing industrial EP additives. These have a high load carrying capacity.

BP Oil International Limited

Ensure that during installation all


alignments meet David Brown
specifications

Catastrophic failure
of unit

Approved lubrication

Boxer Services/Millers Oils

Report to David Brown

Failure of driven
equipment

22

Stop unit. Report to David Brown

Lack of lubrication, pitting of gear


teeth. Bearing damage

Excessive vibration

Contact with
meshing parts

21

Ensure that unit is operated to


David Brown indicated specifications

Ensure that the vibration spectrum


of the unit is within David Brown
specifications

18

20

Twist on Case

Ensure that case is mounted


according to David Brown
specifications, that all alignments
are checked and in accordance with
David Brown specifications

CX series

Appendix 1

Omala
Omala F
Meropa
Meropa WM

CX series | Installation, operating and maintenance manual

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

Ambient temperature range C


-30 to 35 2

0 to 50

Batoyle freedom

Group titan

220 (-31)

320 (-28)

Boxer services/millers oils

Silkgear

220 (-35)

320 (-35)

BP oil international limited


Caltex
Carl bechem GmbH
Castrol international

Enersyn EPX

Pinnacle EP

Alphasyn EP

220 (-38)

320 (-35)

220 (-37)

320 (-31)

220 (-31)

320 (-28)

Chevron international oil co

Tegra

220 (-46)

320 (-33)

Esso/exxon

Spartan Synthetic EP

220 (-46)

320 (-43)

Renogear SG

220 (-32)

320 (-30)

Renolin unisyn CLP

220 (-37)

320 (-34)

220 (-30) 3

20 (-25)
320 (-19)

Fuchs lubricants
Klber lubrication

Klbersynth GEM4

Kuwait petroleum international

Q8 El greco

220 (-22)

Lubrication engineers inc.

Synolec gear lubricant

9920 (-40)

Mobil gear SHC

220 (-40)

320 (-37)

220 (-40)

320 (-33)

220 (-31)

Mobil oil company limited

Mobil gear XMP

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 manufacturing division

Omega 85

-40

230

Optimol lwerke GmbH

Longtime PD

-45

140

Albida RL

-20

150

Alvania EP B

-20

120

Nerita HV

-30

130

Multifak all purpose EP

-30

140

Texaco limited

Super gear fluid

Above

Spheerol AP

Shell oils

Petro-Canada

Allowable operating temperature range C

Spheerol EPL

Mobil oil company limited

Optigear synthetic A

Pinnacle EP

Energrease LS-EP

Castrol international

Optimal lwerke GmbH

Texaco limited

BP oil international limited


Caltex multifak

320 (-43)

Alphasyn T
e

Lubricant range

320 (-28)
220 (-43)

Berusynth GP

Supplier

All above greases are NLGI grade 2


Refer to our application engineers if the unit is operating in an ambient temperature outside the range of -10C to 50C

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

CX series | Installation, operating and maintenance manual

23/28

CX series | Installation, operating and maintenance manual

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

CX series | Installation, operating and maintenance manual

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 | Installation, operating and maintenance manual

CX series

Commissioning check sheets


Pre- commission checks

Action
complete
Y/N

Date

CX series

Commissioning check sheets


After running

Signature

Action
complete
Y/N

Date

Signature

After running check all mounting bolts incl jacking/adjustment screws

Visual inspection check for transit damage e.g. bruising, paint damage,
loose items

Check brake disc and high speed coupling bolts

Check all name plates to confirm correct equipment supplied

Check low speed coupling bolts

Check pre-delivery inspection and testing reports are completed and


signed off

Check gearbox for oil and grease leaks


Check brake power pack settings

Check correct handing for installation

Let oil settle for 15mins and recheck oil level

Check motor DOR

Running under load

Check holdback DOR and indicating directional arrows are correct

Run under 25% load for 30mins and increase at 25% intervals each
30mins until 100%

Check fan blade handing against DOR


Check for fouling of drive components against supporting structure

Record gearbox temperatures at sump, bearings and ambient, min


interval 15mins

Check that all holding down bolts are secure and torqued to
recommended level on motor, gearbox and brakes

Run for min 3hrs or until temperatures stabilised

Check retaining bolts on guards, brake power packs and all other
externally mounted equipment

Monitor gearbox vibration levels of gearcase and bearings, min interval


15mins

Check all cover bolts and jacking/adjusting screws are correctly tightened

Monitor drive assembly vibrations, min interval 15mins

Check all couplings are properly connected and aligned

Monitor gearbox and drive sound levels, min interval 15mins

Check low speed coupling bolts for correct torque

Monitor holdback, check vibration and noise plus temperature

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 torque pad is not restricted for sideways movement and


restraining bolts are correctly installed

Check reducer split line bolts

Check operation and adjustment of brake assembly

Check alignment of drive and couplings

Check any instrumentation e.g. RTDs, vibration monitors etc are


functioning correctly

Check jacking / adjusting screws are correctly aligned and tightened


Check torque pad retaining bolts

Check high speed coupling is correctly lubricated

Check brake disc and high speed coupling bolts

Check non-contact seals for grease expulsion

Check low speed coupling bolts

Check grease lines are secure and free from leakage

Check gearbox, high speed coupling and holdback for oil and grease
leaks

Check breathers for contamination


Remove inspection cover and fill gearbox with recommended oil to level
on dipstick

Check brake power pack settings


Let oil settle for 15mins and recheck oil level

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

Check lubrication pipe valves for correct operation

Check breather element

Check security of guard doors

No load running

Note: Checks done on gearbox should be replicated on the motor and brake power pack where appropriate.

Record gearbox temperatures at sump, bearings and ambient, min


interval 15mins
Run for min 3hrs or until temperatures stabilised
Monitor gearbox vibration levels of gearcase and bearings, min interval
15mins
Monitor drive assembly vibrations, min interval 15mins
Monitor gearbox and drive sound levels, min interval 15mins
Monitor holdback, check vibration and noise plus temperature
If brake test is carried out check disc temperature after successive stops

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CX series | Installation, operating and maintenance manual

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CX series | Installation, operating and maintenance manual

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