Vous êtes sur la page 1sur 42

INSTALLATION INSTRUCTION MANUAL

Document No. 70000734 Version 1.0 Page 1 of 42

Installation Procedure for FLSmidth Spring Mounted


Ring Gears

Scope:

This document covers the installation of all FLSmidth spring mounted ring gears.

References:

All welding procedures shall be in accordance with AWS Section D1.1 or ASME Section 1X.

70001362 Superbolt MT Jackbolt Tightening & Loosening Procedure


70001365 Maintenance Manual for FLSmidth 2 and 4 Segment Ring Gears
70001369 Pinion Alignment Manual

Version Approved Date Description


1.0 J.L.Daubert May 31, 2005 Original Issue
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 2 of 42

Index

1.0 Introduction 4

2.0 General Information 4

3.0 Applicability of Manual 5

4.0 Safety Considerations 5

5.0 Materials to be Gathered 5

6.0 Initial Preparation 6

7.0 Preassembly 7

8.0 Adjustment Chair Preparation 9

9.0 Shell Preparation 13

10.0 On Ground Preparation of Gear 17

11.0 Installing the Gear on the Shell 19

12.0 Assembling the Joint Hardware 22

13.0 Setting Chairs on the Shell 23

14.0 Preparation for Shell Rotation 24

15.0 Installing the Pinion(s) 25

16.0 Checking Gear Runout 26

17.0 Centering and Welding the Spring Mounts 31

18.0 Aligning the Pinion(s) 35

Blank Data Sheets 36


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 3 of 42

List of Tables

Table 1 Adjustment Chair Details

Table 2 Adjustment Chair Elements

Table 3 Axial Runout Example

Table 4 Gear Rim Axial Runout (blank data sheet)

Table 5 Gear Rim Radial Runout (blank data sheet)

List of Figures

Figure 1 Gear with Tangential Spring Mounts

Figure 2 Materials for Adjustment Chairs

Figure 3 Dimensioning Adjustment Chairs

Figure 4 Guideline Layout

Figure 5 Gear Installation Guide Bars

Figure 6 Field Installation of Spring Mount Pins

Figure 7 Gear Segment Hitched for Pick Up from Lay-down Position

Figure 8 Gear Segment at the Shell

Figure 9 Temporary Supports for the First Gear Segment

Figure 10 Gear Joint Alignment

Figure 11 Shell Drive Bars with Bridge Arrangement

Figure 12 Bridge Arrangement Detail

Figure 13 Dial Indicator Stem Position

Figure 14 Dial Indicator Positions

Figure 15 Centering and Welding the Spring Mounts

Figure 16 Centering and Welding the Spring Mounts


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 4 of 42

Figure 17 Work Position and Direction for Welding Gear Spring Mounts

Figure 18 Welding the Spring Mounts

Figure 19 Final Adjustment Chair Dimensions

1.0 Introduction

FLSmidth ring gears are the highest quality gears of this type available. To fully realize
the advantages of this high quality, gears must be installed accurately. The following
procedure has been prepared to detail the steps necessary to obtain an accurate and true
running gear. Read the entire instruction manual prior to commencing work.

1.1 The scope of this document includes the following:

1.1.1 To assemble the gear on the machine so that the segment joints are
properly closed and the gear segments are aligned to each other.

1.1.2 To true the pitch cylinder of the gear with respect to the axis of rotation
so that the eccentricity (radial runout) and axial runout are minimal.

1.1.3 To align the pinion(s) with respect to the gear so that the tooth load
distribution is uniform across the face and to insure that backlash is
correct under operating conditions.

Note: The structure upon which the gear and pinion(s) are mounted must be
sufficiently rigid to maintain good gear/pinion alignment.

2.0 General Information

2.1 The ring gear segments may be either steel castings, ductile iron castings or steel
fabrications.

2.2 Adjustment chairs are utilized to achieve the required axial and radial alignment.

2.3 The machined joint surfaces are always full angular, matching the helix angle of
the teeth.

2.4 The segments are match-marked to insure correct assembly.

2.5 The segments are aligned to each other by means of alignment body-bound studs
or alignment tapered studs with matching split taper bore sleeves.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 5 of 42

2.6 These studs must be preloaded by torquing them to the value shown on the
assembly drawing.

2.7 Axial and radial runout and no-load tooth contact patterns are verified for final
installation of the gear set.

3.0 Applicability of Manual

3.1 This manuals primary purpose is to describe the installation of a new FLSmidth
split ring, spring-mounted main gear on a new machine. These descriptions will
also apply for the installation of a new gear on an existing shell as a replacement
for worn or damaged gearing or reversing an existing gear on an existing shell.

4.0 Safety Considerations

4.1 Size, weight and precision finish of FLSmidth Inc. split ring gear segments
require several crane-handling maneuvers between the receiving area and final
installation on the kiln shell.

4.2 In order to minimize potential for personal injury, allow only qualified riggers,
mechanics and crane operators to handle the segments for floor level preparation
and actual placement on the kiln shell.

4.3 After assembly of the gear segments on the kiln shell, the pinion assembly will
be moved into position for meshing of gear and pinion teeth.

4.4 The entire gear and the mating pinion will be exposed and will be potential
bump and pinch danger points until gear and pinion alignment is acceptable.

4.5 Constant alertness during rotation periods is essential for avoiding personal
injury at potential bump and pinch points.

4.6 Industrial cleaning solvents are required for cleaning surfaces coated with
preservative compounds. Use only non-toxic and non-flammable solvents
approved by safety regulatory agencies.

4.7 NEVER USE GASOLINE OR OTHER DANGEROUS FLUIDS FOR


CLEANING GEAR SEGMENTS OR RELATED ASSEMBLY MATERIAL.

5.0 Materials to be Gathered

Erection equipment tools


Trammel bar with scribers
Wrap tape to scribe control lines on shell
Grinder with grinding discs
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 6 of 42

Soft wire brushes


Six heavy duty horses or stacks of timber
Material for chairs (see Section 8)
Material for guide bars (see Section 9)
Material for drive bars (see Section 14)
Rags
Solvents
Files and de-burring stones
Lubricants
Anti-Seize Compound (Molybdenum Disulfide Lubricant)
Hydraulic jack with pump for pushing spring mount pin up from bottom
Heavy gauge baling wire
Wooden chocks
Rubber gloves
Three (3) dial indicators with magnetic bases
Three (3) dial indicator stands made from structural steel
Spring steel strip (1mm x 10mm x 200mm) for radial runout over tooth tips
Paint marker
Fire hose, rubber conveyor belting or similar
Torque wrench
Feeler Gauges
Gear Assembly Drawing
Shim for pinion pillow blocks
Prussian Blue

6.0 Initial Preparation

6.1 Read the original equipment manufacturers installation and operation manual
before rotating the machine.

6.2 Lockout the main motor(s)

6.3 Notify personnel of pending machine rotation. Observe all safety precautions.

6.4 Set up one of the following crane arrangements to provide for control of the
machine and precise positioning required for all assembly and alignment test
work procedures.

6.4.1 Use one crane for maneuvering with main load line and jib line. Or,

6.4.2 Use two cranes.

6.5 Ensure all bearings are properly lubricated.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 7 of 42

6.6 Ensure all stops have been removed and the machine is free to rotate when
necessary.

6.7 Provide a method to enable rotation of the machine.

7.0 Preassembly

7.1 Gear

7.1.1 Remove rust inhibitor from the gear. Clean and degrease joint surfaces
and spring pin boss surfaces and bores.

7.1.2 Check the joint surfaces, seal diameters and teeth for burrs and upsets. If
found remove by filing or stoning.

7.1.3 Insure that both segments are stamped with the same contract number
and release number.

7.1.4 Note that both segments of the gear are match-marked.

7.1.5 Insure that the gear will be assembled with identical match-marks aligned
to each other.

7.1.6 Verify count of machine bosses and springs.

7.1.7 Preassemble the gear on the ground to ensure proper joint alignment.

7.1.8 Spring Mount Bosses

7.1.8.1 Thoroughly clean

7.1.8.2 Remove burrs and upsets.

7.1.8.3 Coat the spring pin boss bores and machined surfaces with a
light film of anti-seize compound.

7.2 Gear Hardware

7.2.1 Alignment Body-Bound Studs and Alignment Taper Studs

7.2.1.1 Remove upsets by stoning.

7.2.1.2 Check that the nuts run freely on the threads.

7.2.1.3 Lubricate threads with machine oil.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 8 of 42

7.2.1.4 Check taper for upsets.

7.2.2 Regular Studs

7.2.2.1 Check that the nuts run freely on the threads.

7.2.2.2 Lubricate threads with machine oil.

7.2.3 Mechanical Tensioners MT Series, by Superbolt

7.2.3.1 Check that the jackbolts run freely in the threads.

7.2.3.2 Clean the internal threads of the main body and lubricate with
machine oil.

7.2.3.3 Clean and lubricate the internal threads of the jackbolt holes.
Use JL-G Superbolt lubricant. Do NOT use copper bearing
compounds.

7.2.3.4 Clean and lubricate the threads of the jackbolts. Use JL-G
Superbolt lubricant. Do NOT use copper bearing compounds.

7.2.4 Flexnuts (by Superbolt) or Hex Nuts

7.2.4.1 Clean and lubricate the internal threads with machine oil.

7.2.5 Washers

7.2.5.1 Use supplied hardened washers only. Do not substitute.

7.2.5.2 Remove any burrs or upsets.

7.2.6 Tapered Bore Sleeves

7.2.6.1 Check bores and outside diameters for burrs.

7.2.6.2 Remove by filing or stoning.

7.3 Spring Mounts and Spring Mount Hardware

7.3.1 Spring Mounts

7.3.1.1 Rub fork hole and machined surfaces with a light film of anti-
seize compound.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 9 of 42

7.3.2 Spring Pins

7.3.2.1 Thoroughly clean.

7.3.2.2 Remove burrs and upsets.


7.5 Spring Pin Washers

7.5.1 Insure proper fit to spring pin.

7.6 Pinion(s)

7.6.1 Remove the rust inhibitor from the pinion(s).

7.6.2 Check for burrs and upsets, remove by filing or stoning.

8.0 Adjustment Chair Preparation

8.1 A set of properly designed, fabricated and installed adjustment chairs and drive
bars make it possible to use the machines auxiliary drive system for all work
requiring rotation; including tests and alignment adjustments of the gear itself.
See Figures 1 and 2 for reference.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 10 of 42

Figure 1

8.2 Prepare one chair per two spring mounts.

8.2.1 More adjustment chairs may be needed on existing long dry or wet
process machines having five or six supports with full refractory and
chain systems.

8.3 For design of the adjustment chairs, refer to Figure 3 for reference.

8.3.1 Measure the spring mounts or check drawings to verify the proper spring
dimensions for design of the adjustment chairs.

8.4 Fill in final dimensions on Figure 19.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 11 of 42

Figure 2
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 12 of 42

Figure 3

Table 1: Adjustment Chair Details

Value Description

A Radius at inside of gear web minus outside radius of shell at the gear
installation zone

B Width of spring plate at chair installation zone plus 50mm (2) for
clearance, 25mm (1) on each side
C Half of B
D C minus 50mm (2)
F A minus 134.5mm (5-7/16)
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 13 of 42

Table 2: Adjustment Chair Elements

Elements Description (see Figure 2)

Material is C160mm (C6x13lb) channel (or nearest size


currently available).
Do not use wide end of spring mount for planning chair
Main Frame leg spacing dimensions.
Make F of sufficient length to allow clearance for
**
wrench at heavy bolt.
Make B of sufficient length to clear the sides of the
spring mount but not so long as to cause the chair to lose
strength when support legs are too far apart.
Support Plate Material is 25mm (1) thick steel plate.
Gussets Material is 12mm () thick steel plate.

Size is 42mm (1) diameter by 160mm (6) long.


Side Bolts
Fine thread.
(Chair)
Utilize for axial adjustment of the gear.
Size is 48mm (2) diameter by 180mm (7) long.
Bottom Bolt Fine thread
Utilize for radial adjustment of the gear.

** Caution: Do not substitute lighter weight material.

9.0 Shell Preparation

9.1 Setting Guideline Layout

9.1.1 The most convenient time for marking the gear location guidelines on the
appropriate shell is at ground level and before the thrust tire is mounted
on the shell adjacent to the gear installation area.

9.1.2 Reference line layout work is easier when thrust tire guidelines scribed
on shell pads are exposed for trammel layout of gear-setting guidelines.
See Figure 4 for reference.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 14 of 42

Figure 4

Where A = Width of the thrust tire at flat side faces

B = Width at ends of the spring mounts

C = Thrust tire centerline to gear centerline

9.1.3 Refer to the machine foundation and drive assembly drawings for the
following:

9.1.3.1 Thrust tire and gear dimensions

9.1.3.2 Spacing dimension between thrust tire and gear centerlines

9.1.3.3 Width at tail-end of spring plates


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 15 of 42

Caution: If gear guard splash bands are used, shell longitudinal welds must be
ground flush with base metal between guidelines, and several centimeters
beyond those lines.

9.1.4 Clean the shell with grinding and wire brush tools.

9.1.4.1 Clean between the guidelines plus 300mm (12) outward past
both lines.

9.1.4.2 Grind down all welds in this zone in preparation for installation
of spring mounts and splash bands, if applicable, on the shell.

9.1.5 Set trammel points for arc layout of reference lines.

9.1.5.1 Use a wrap tape flexible straightedge at peaks of arcs for layout
of circumferential lines.

9.2 Installing Guide Bars

Note: When the gear is picked up by a crane, the gear tends to plumb itself toward a
nearly vertical position. Guide bars enable moving the gear into a position
perpendicular to the slope angle of the shell.

9.2.1 Determine which view of Figure 5 is applicable.

9.2.1.1 View A Flared end of the spring plate is wider than the gear
rim. A spacer is required on the guide bars.

9.2.1.1 Minor allowable fabrication deviations can turn


ends of the springs away from guide lines marked
on the shell.

9.2.1.2 Spacer dimensions must consider differences


between half width of the gear and spring mounts,
plus 13mm () allowance for endplay and/or
tracking discrepancies.

9.2.1.2 View B Gear and spring mounts are the same width. A 13mm
() spacer is needed on the guide bars.

9.2.1.3 View C Arrangement when half of the spring mount width is at


least 13mm () less than half the gear rim width.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 16 of 42

Figure 5

9.2.2 Mark shell top centerline.

9.2.3 Mark four spaces at 45 from each other

9.2.4 Install 4 bars and braces.

9.2.4.1 When the bars are at the downhill side, the suspended gear will
touch the bars below the machine horizontal centerline and the
top of the gear will have to be pulled against the bars above the
horizontal centerline.

9.2.4.2 When the bars are at the uphill side, the suspended gear will
touch the bars above the machine horizontal centerline and the
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 17 of 42

bottom of the gear will have to be pulled against the bars below
the centerline.

9.2.5 Remove bars after the gear has been secured to the machine.

10.0 On Ground Preparation of the Gear

10.1 Place the gear segments on clean timber on the ground.

10.1.1 Position the gear with marks A-A and B-B (and C-C and D-D if
applicable) in position for eventual joint connection work.

10.1.2 Ensure the timbers are high enough to permit installation of the spring
mount pins from below the arrangement.

10.1.3 Pre-assemble the gear with joint hardware to ensure proper joint
alignment.

10.2 Determine the rotation of the machine.

10.2.1 Rotation direction is established as clockwise or counter-clockwise as


seen when looking toward the feed end (uphill) from the firing floor
(discharge end).

10.3 Clearly mark the gear THIS SIDE TOWARD DISCHARGE END with a large
arrow marked to show planned rotation direction.

10.3.1 The springs attached to the gear must PULL the shell in the planned
direction of rotation (see Figure 1 for reference).

Warning: If at anytime after the gear is in place on the shell, it is noted that the gear
was installed with springs in compression (pushing the kiln shell for
rotation), the gear with springs and chairs still attached, must be removed,
reversed, reinstalled and then realigned and welded at the spring mounts.

10.4 Verify that the curved end of the spring mounts fit on the shell when set for
rotation direction.

10.5 Install the spring mount pins.

10.5.1 Tack weld one of the washers to the end of the pin as per the appropriate
assembly drawing. Make sure the washer is square to the pin axis.

10.5.2 Fit the fork plates of the spring mounts onto the gear boss.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 18 of 42

10.5.3 Lubricate machined surfaces of the pin with anti-seize compound. Insert
the end of the pin from the bottom in the assembled spring and gear boss.
See Figure 6 for reference.

Figure 6

10.5.4 Weld the remaining washer to the pin per the appropriate assembly
drawing.

10.5.5 Washers should be snug against the spring mount fork plates.

10.6 Install all the chairs.

10.6.1 Set all the chairs in appropriate positions on the gear web in spaces
between the springs. Locate chair at narrow zone for spring, but avoid
interference points.

10.6.2 Tighten the side bolts to hold the chairs in place.

10.7 Tie back the spring mounts.

10.7.1 Swing the tail ends of the spring mounts as far as possible toward the
gear web plate.

10.7.2 Tie the spring mounts against the web with lengths of soft heavy-gauge
baling wire or an acceptable substitute to secure the arrangement for
crane handling maneuvers.

Warning: Verify that the direction of the spring mounts is correct for the
eventual direction of rotation of the machine when mounted on the
shell.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 19 of 42

Note: When installing a new gear on an existing shell or reversing an existing gear on
an existing shell, the gear must be indexed, such that the spring mounts are
positioned in an area of the shell which has not been previously welded to.

11.0 Installing the Gear on the Shell

11.1 Chock the machine.

11.2 Lift the first gear segment. Protect the gear during lifting by padding wire ropes
with rubber conveyor belts, fire hose or similar. See Figure 7 for an example.

Figure 7

11.2.1 The main load line, Line A, is hitched at a position for holding the
projecting spring mount off the ground when moving from the lay-down
position to the ends-down position for transfer to the shell.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 20 of 42

11.2.2 The jib, or second crane, Line B, is needed for stability of the unbalanced
load of the gear segment until the segment is in a safe position for being
handled by the main load line.

11.3 Let Line B out so that all the gear weight rests on the main load line and looks
like Figure 8. (The line may need to be relocated to enable rolling the segment
around and under the shell.)

Figure 8
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 21 of 42

11.4 Continue crane maneuvers until the first gear segment has been rolled under the
shell and then moved to the predetermined support and assembly position.

11.5 Temporarily support the first gear segment in a balanced position at the bottom
of the gear with a timber-plus-jacks arrangement. See Figure 9 for reference.

Figure 9

11.6 Secure the ends of the gear segment in the ends up condition.

11.6.1 Ends of the gear segment can be secured by welding locking bars to the
shell at both sides of the machine and at the uphill and downhill sides of
the gear segment.

11.6.2 The segment may also be secured by a wire rope lashing arrangement
shown in Figure 9.

11.7 Lift the second gear segment. Protect the gear during lifting by padding wire
ropes with rubber conveyor belt, fire hose or similar.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 22 of 42

11.7.1 The jib, or second crane, Line B from Figure 7, is hitched at a position
for holding the projecting spring mount off the ground when moving
from the lay-down position to the ends-down position for transfer to the
shell.

11.7.2 The main load line, Line A from Figure 7, is in position for moving the
segment from the lay-down to an ends-down position and transfer to the
shell after releasing the jib, or second crane.

11.8 Move the segment to place.

11.8.1 Pre-install 2 regular studs, one on either end, in the second segment to
aid in placing the segment.

11.8.2 Steady the incoming segment at both joints while the segment is being
lowered.

11.8.3 If possible, do not release the crane until after the fully assembled gear is
in place at pre-marked guidelines and is secure on the chairs.

12.0 Assembling the Joint Hardware

12.1 If alignment tapered studs are used, perform the following:

12.1.1 Coat the inner diameter and the outer diameter of the tapered sleeves
with an anti-seize compound.

12.1.2 Insert the tapered sleeves into the alignment holes. Be sure that the head
of the sleeve is seated in the counterbore.

12.1.3 Assemble the alignment tapered studs.

12.1.4 Torque the Mechanical Tensioner jackbolts per the gear assembly
drawing and instruction 70001362.

12.2 If alignment body-bound studs are used, perform the following:

12.2.1 Coat the body-bound stud with anti-seize compound.

12.2.2 Assemble the alignment body-bound studs.

12.2.3 Torque the Mechanical Tensioner jackbolts per instruction 70001362 to


the value listed on the gear assembly drawing.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 23 of 42

12.3 Regular studs

12.3.1 Assemble the regular studs

12.3.2 Torque the Mechanical Tensioner jackbolts per instruction 70001362 to


the value on the gear assembly drawing.

Caution: Insure that a 0.04mm (0.0015) feeler gauge will not enter the
assembled joint.

12.4 Inspect the alignment of the gear joints. Axial and radial steps at the joints
should be less than 0.05mm (0.002). See Figure 10.

Figure 10

13.0 Setting Chairs on the Shell

13.1 Back out the adjustment chair side bolts far enough to allow for setting the chairs
in relation to the guide lines.

13.2 Weld the support leg channels to the shell with a 5mm (3/16) size fillet weld.
Seal weld all flush butt joints.

Caution: Protect bolt and nut threads.

13.3 Tighten the adjustment chair side bolts alternately and gradually to move the
gear into the best possible position relative to the surface of the shell.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 24 of 42

13.4 Tighten the bottom bolt of the adjustment chairs enough to support the gear
when the crane is released.

14.0 Preparation for Shell Rotation

14.1 Place the drive bar(s) about 25mm (1) from the legs of the chairs to allow for
adjustment of the gear and such that there is adequate clearance for welding the
spring mounts to the shell upon final alignment.

Note: A single drive bar is usually adequate for a new gear on a new machine, but
when a gear is being reversed, or a new gear is replacing a worn gear on an
older kiln, it may be necessary to place a drive bar at each chair in order to
handle the internal refractory and coating load at the start of rotation.

14.2 Tack weld in place.

14.3 Install the bridge arrangement(s) as shown in Figure 11 and Figure 12.

Figure 11
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 25 of 42

DRIVE BAR

BRIDGE LEG

DRIVE BAR

BRIDGE LEG

DRIVE BAR

BRIDGE LEG

Figure 12

14.4 Install bridge arrangement side bolts and top bolts tight against the bar(s) for
rotation of the gear for runout test work.

14.5 Weld the bridge legs to the kiln shell.

Note: Drive bars and plate hold-down arrangements are not limited to items shown in
Figure 12, but it is important that an alternate arrangement will not be in a
position to interfere with eventual welding at the sides and trailing ends of the
plates.

15.0 Installing the Pinion(s)

15.1 Setting up the pinion(s)

15.1.1 See instruction 70001369 for pinion installation procedure.

15.1.2 Apply lubricant to the pinion before turning the machine.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 26 of 42

16.0 Checking Gear Runout

Warning: Gear runout tests are not valid if the shell is, in any way, affected by any
source of heat, including sunshine.

16.1 Check the axial runout on the gear rim end face or the proof surface if one exists.

16.1.1 Set dial indicator A on the surface to be aligned.

16.1.2 Set dial indicator B on the same surface, at 180 apart from dial
indicator A; with the dial indicator stems pointing in the same
direction. Dial indicator stems must be perpendicular to the surface
being aligned. See Figures 13 and 14 for proper dial indicator
position.

YES NO

Figure 13
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 27 of 42

Dial indicator
measuring axial
runout

Dial indicator
measuring axial
runout

Dial indicator measuring


radial runout placed near
the pinion

Figure 14

16.1.3 Rotate the machine to bring gear station number 1 in line with dial
indicator A

16.1.4 Zero both dial indicator A and B.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 28 of 42

16.1.5 Record station number, dial indicator A reading, and dial indicator
B reading in Table 4.

16.1.6 Rotate the machine so that the next station is aligned with dial
indicator A.

16.1.7 Record station number, dial indicator A reading and dial indicator
B reading in Table 4.

16.1.8 Continue this procedure through one complete revolution.

16.1.9 Repeat readings at station number 1.

16.1.10 Compare the first axial runout reading of station number 1 with the
second reading.

16.1.10.1 If the value in column 5 is outside the range of


0.05mm to -0.05mm (0.002 to -0.002) dial indicator
A or B may have been inadvertently disturbed.

16.1.10.2 Accordingly, discard all readings and repeat process.

16.1.11 See Table 3 for an example.

16.1.11.1 Axial runout is the algebraic difference between the


maximum and the minimum values in column 5.

16.1.11.2 The values in column 5 relate to the station numbers


associated with column 1.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 29 of 42

Table 3: Example Axial Runout

DTI A DTI B Column 2 Add Take half


Station Station
Reading Reading with signs Column of
Number Number
(0.001) (0.001) reversed 1& 3 Column 4
Column 1 Column 2 Column 3 Column 4 Column 5
1 0 4 0 0 0 0
2 -6 5 -2 +2 -4 -2
3 +4 6 +2 -2 +2 +1
4 +9 1 -4 +4 +13 +6.5
5 +2 2 -6 +6 +8 +4
6 -6 3 +3 -3 -8 -4

1 -6 4 -5 +5 -1 0.5

Does second reading of Column 5 at Station Number 1 result in a value outside the
range of -0.05mm to 0.05mm (-0.002 to 0.002)?

No (Accept)
Maximum Plus +0.0065
Maximum Minus -0.004
Total Axial Runout 0.0105
Allowable Axial Runout 12ft * 0.001 = 0.012 (Accept)

16.1.12 Obtain the allowable axial runout from the gear assembly drawing or
calculate the allowable axial runout per the following specification.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 30 of 42

Specification: Allowable Axial Runout


Use whichever is greater of the following
Metric English
0.083mm/m of Pitch Diameter 0.001/ft of Pitch Diameter
OR OR
0.254mm 0.010

Warning: Allowable axial and radial runouts are for the condition after welding
spring mounts to the shell, and with all adjustment bolts and drive bars
released for runout tests. Runout test results should be less than allowable
prior to the start of the spring mount tack welding and finish welding
procedures to allow for possible effects of weld stress reactions at spring
mount bosses and pivot pins.

16.2 Check the radial runout over the tooth tips. Dial indicator stems must be
perpendicular to the surface being aligned. See Figures 13 and 14 for proper dial
indicator position.

16.2.1 Record the data in Table 5.

16.2.2 Obtain the allowable radial runout from the gear assembly drawing or
calculate the allowable radial runout per the following specification.

Specification: Allowable Radial Runout


Use whichever is greater of the following
Metric English
0.125mm/m of Pitch Diameter 0.0015/ft of Pitch Diameter
OR OR
0.380mm 0.015

16.3 Continue alignment procedures until axial and radial alignment are within
acceptable limits.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 31 of 42

17.0 Centering and Welding the Spring Mounts

17.1 Secure one spring mount at a time. See Figure 15 for reference.

17.2 Spring mounts which are not fixed to the shell by bridge arrangements should be
welded first.

17.3 Move the spring mount toward A and mark the side of the plate.

17.4 Move the spring mount toward B and mark the side of the plate.

17.5 Mark midway between A-B lines for aligning the edge of the spring mount.

17.6 Starting at the tangent line, place 2 tack welds at both sides of the spring mount.
See Figure 16 for reference.

Note: Welds must start at the spring tangent line and move toward the tail end of the
spring mount plate(s) for beads at both sides of all the spring mounts.

17.6.1 Work in a flat position on top of the shell for simultaneous welding at
both sides of the spring mount(s). See position A of Figure 17 for
reference.

17.6.2 If necessary, it is possible for up-vertical deposit of weld as shown in


position B of Figure 17.

17.6.3 Down-vertical or overhead welding as shown in position C is not


acceptable. Welding from tail end of the spring mount plate will affect
gear alignment with stress load variations at pivot pins.

17.7 Secure the spring mount 180 from the first, then a spring mount 90 from the
first, followed by a spring mount 180 from the third spring mount.

17.8 Repeat steps 17.3 through 17.6 for the balance of the spring mounts.

17.9 For spring mounts with drivers, release pressure at the top bridge bolt and side
bolts.

17.10 Follow steps 17.3 through 17.6.

17.11 Tighten the top bridge bolt.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 32 of 42

Figure 15

17.12 Continue with rotation, as needed, to finish the root weld and then follow with
finish welds at the specified fillet size. See Figure 18 for reference. Follow the
guidelines outlined in step 17.7. Never apply more than two weld passes at a
time until the full weld size is achieved.

17.13 If the weld toe at the tangent point is not smooth, grind it.

17.14 Check the axial runout again and compare it with the values obtained prior to
welding the spring mounts.

17.15 Check the radial runout again and compare it with the values obtained prior to
welding the spring mounts.
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 33 of 42

Figure 16
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 34 of 42

Figure 17
INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 35 of 42

Figure 18

18.0 Aligning the Pinion(s)

18.1 See instruction 70001369 for pinion alignment procedure.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 36 of 42

Customer Name
Serial Number
Machine Size
Prepared By
Fabricated By
Date

Sheet 1 of

Figure 19: Final Adjustment Chair Dimensions


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 37 of 42

Customer Name
Serial Number
Machine Size
Date

Sheet 1 of

Table 4: Gear Rim Axial Runout

DTI A DTI B Column 2 Add Take half


Station Station
Reading Reading with signs Columns of
Number Number
(0.001) (0.001) reversed 1&3 Column 4
Column 1 Column 2 Column 3 Column 4 Column 5

This is the first page.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 38 of 42

Sheet of

Table 4: Gear Rim Axial Runout (continued)

DTI A DTI B Column 2 Add Take half


Station Station
Reading Reading with signs Columns of
Number Number
(0.001) (0.001) reversed 1&3 Column 4
Column 1 Column 2 Column 3 Column 4 Column 5

Copy this page for any number of intermediate pages.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 39 of 42

Sheet of

Table 4: Gear Rim Axial Runout (continued)

DTI A DTI B Column 2 Add Take half


Station Station
Reading Reading with signs Columns of
Number Number
(0.001) (0.001) reversed 1&3 Column 4
Column 1 Column 2 Column 3 Column 4 Column 5

Does second reading of Column 5 at station number 1 result in a value outside the range
-0.05mm to 0.05mm (-0.002 to 0.002)?

(Accept / Reject)

Maximum Plus

Maximum Minus

Total Axial Runout

(Accept / Reject)

This is the last page.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 40 of 42

Customer Name
Serial Number
Machine Size
Date

Sheet 1 of

Table 5: Gear Rim Radial Runout

Station Number DTI Reading ( )


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

This is the first page.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 41 of 42

Sheet of

Table 5: Gear Rim Radial Runout (continued)

Station Number DTI Reading ( )

Copy this page for any number of intermediate pages.


INSTALLATION INSTRUCTION MANUAL
.

Document No. 70000734 Version 1.0 Page 42 of 42

Sheet of

Table 5: Gear Rim Radial Runout (continued)

Station Number DTI Reading ( )

Does a comparison of the first and second reading of runout at station 1 result in a value outside
the range of -0.05mm to 0.05mm (-0.002 to 0.002)?

(Accept / Reject)

Maximum Plus

Maximum Minus

Total Radial Runout

(Accept / Reject)

This is the last page.