Installation - Ring Gear Installation Manual

RING GEAR INSTALLATION
Manual
For Trunnion and Spring Mounted Ring Gears
PN - 2121224
PRICE $2.00
Installation Manual Falk Ring Gear (Page 2 of 31)
GENERAL INFORMATION
For long life and optimum performance, all gears must be installed properly and aligned accurately. This manual shows how to check alignment and tooth contact during the process of installing ring gears with single helical, double helical, or spur teeth. It is applicable to the installation of both flange mount and spring mount designs and 1, 2 or 4 piece designs. In addition, a section covering the installation of a new pinion with an existing ring gear is included. The steps outlined herein should be studied thoroughly by erectors and mechanics before, and during, the installation of gearing. It should be understood that the values contained in this instruction manual are acceptable limits and that the conscientious erector will strive to improve on these values whenever possible. This will result in optimum gear performance. All dimensions in this manual are in standard English units. Corresponding metric units are shown in parentheses after English values, where appropriate.
Personnel performing installation, procedures, and practices which are included or implied in this manual shall observe the following warnings, cautions and notes. Disregard of these warnings and precautionary information can cause serious injury or loss of life. Warnings, cautions, and notes are used to emphasize important and critical instructions and are used for the following conditions: WARNING: An installation procedure, practice, etc., which, if not correctly followed, could result in personal injury or loss of life. CAUTION: An installation procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment. Cautions also represent crucial procedures of an installation task which must be performed as prescribed before proceeding to ensure validity of subsequent installation steps. NOTE: An installation procedure, condition, etc., which it is essential to highlight. Notes are designated as a Factory recommendation of a specific technique, which may aid the installer in performing an installation task.
TABLE OF CONTENTS General

General Information . . . . . Tools for Installation . . . . . Match Marks . . . . . . . . . Parts Furnished for Assembly of . . . . . . . . . . . . Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 3 4
Installation and Alignment

Step Step Step Step Step Step Step Step 1 2 3 4 5 6 7 8 Check the Axial Runout of the Mounting Flange . . . . . . . . . . . . . . . . . . . . . . Assemble Gear to the Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . Check the Radial Runout of the Gear . . . . . . . . . . . . . . . . . . . . . . . . . . Check the Axial Runout of the Gear Rim Face . . . . . . . . . . . . . . . . . . . . . . Final Flange Bolt Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Final Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dynamic Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6 11 13 15 15 20 20
Appendixes
Appendix Appendix Appendix Appendix I Rim Face Runout Example . . . . . . II Radial Runout Example . . . . . . . III Backlash Calculation Example . . . IV Contact and Backlash Feeler Gauge . . . . . . . . . . . . . . . . . . . . . Measurement . . . . . . . . . . . . . . . Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 23 23 24
Worksheets
Worksheet 1: Mounting Flange Runout (For One Indicator-, Shell Axial Runout Indicator Fixture-, & Three Indicator-Methods). . . . . . . . . . . . . . . . . . . Worksheet 2: Mounting Flange Runout (For Two Indicator-Method) . . . . . . . . . . . Worksheet 3: Radial Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Worksheet 4: Rim Face Runout (For One Indicator-, Shell Axial Runout Indicator Fixture-, and Three Indicator-Methods) . . . . . . . . . . . . . . . . . . . . . . Worksheet 5: Rim Face Runout (For Two Indicator-Method). . . . . . . . . . . . . . . Worksheet 6: Contact and Backlash/Root Clearance . . . . . . . . . . . . . . . . . Worksheet 7: Mesh Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . 26 . . . . . . 27 . . . . . . . . . . . . . . . . . . . . . . . . 28 29 30 31
Rexnord Industries, LLC, 1979, 1999. All Rights Reserved. Litho in U.S.A. Falk, Rexnord, and a good name in industry are registered trademarks. The contents of this manual are subject to change without notice or obligation. Information contained herein should be confirmed before placing orders.
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May 1999 Supersedes 11-97
Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
Falk Ring Gear Installation Manual (Page 3 of 31)
TOOLS FOR INSTALLATION

WRENCHES Select wrenches to fit all bolts and nuts. MACHINIST LEVEL At least 12 in. (300 mm) long, 18 in. (450 mm) preferred. THICKNESS GAUGES With leaves ranging from 0.0015 in. to 0.200 in. (0,040 mm to 5 mm) thick. CONTACT MARKING MEDIUM A transferable, non-drying medium, typically an oil based dye such as Prussian blue pigment or lamp black. DIAL INDICATORS With 0.001 in. (0,025 mm) graduations and at least a 0.050 in. (1.25 mm) range. Be sure to use a button contact point on indicator. INDICATOR TIP ROCKER SHOES To be used on dial indicator tip when measuring radial runout of ring gears across the top lands of the teeth. OUTSIDE MICROMETER 0 in. to 1 in. (0 mm to 25 mm) TOOL POST HOLDERS Check positions for mounting indicators and provide tool post holders, upright spindles, and several clamps to suit. (Magnetic base indicator holders are usually easier to use.) INDICATOR FIXTURE FOR SHELL AXIAL RUNOUT To be located across the end of the fixed trunnion bearing at the shell axis. This will read out shell float directly. The fixture used must not be affected by elastic deformation of the shell trunnion (e.g. a rigid fixture bolted across the trunnion may buckle during rotation). This may be replaced by two dial indicators properly located on the thrust face of the trunnion bearing. Figure 1 shows a typical shell runout indicator fixture.
DRILL BITS Or a calibrated taper bar with increments from 1/8 in. to 3/8 in. (3 mm to 10 mm) to be used for taking root clearance measurements when setting a new pinion with an existing gear.
MATCH MARKS
Most Falk gears are made in two or more pieces. In these cases, the parts must be assembled with the mating surfaces in the same position as when the teeth were cut. To assure this result, it is necessary to match the identical numbers and letters stamped on one split of each gear section in line with the numbers stamped on its mating section. The location of the match marks is described in Figure 2. The match marks must be aligned for proper assembly of the gear segments. Some gears and pinions are furnished as lapped sets and must operate together. In these cases the pinion will have the same match mark as the gear. Gear identifying numbers are shown in Figure 3. This is a typical example. The sequence and location of the numbers may vary slightly.
ALIGNMENT BOLT CLEARANCE BOLT
17B1 17B1
MATCH MARKS MOUNTING SLOTS DO NOT OVERTIGHTEN BOLTS, ALLOW FOR LONGITUDINAL MOVEMENT OF FIXTURE FINISH MACHINED SURFACE FOR INDICATOR TIP
Figure 2 IDENTIFICATION OF MATCH MARKS ON SPLIT RING GEARS Figure 1 INDICATOR FIXTURE FOR SHELL AXIAL RUNOUT
SHIMS Use stainless steel shims starting at 0.003 in. (0,075 mm) thick and upward for adjusting bearing pedestals. INFRARED THERMOMETER Pyrometer and temperature crayons. TORCH WITH HEATING TIP For clearance bolt pre-stressing. HIGH TEMPERATURE INSULATING GLOVES Two pair DRY LUBRICANT Molybdenum disulfide type for installation of split hardware. LEAD HAMMER For installation of split hardware. LAYOUT DYE For dynamic check of ring gear installation.
Rexnord Industries, LLC, Geared Products, P .O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
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EXAMPLE: A gear manufactured on February 17, 1997, would be match marked in the following way: 17 17
Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B or B
Month A January B February C March D April E May F June G July H August J September K October L November M December
7 7
Year 7 1997 8 1998 9 1999 0 2000 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008
A, B, C, D
Supplementary Letter When a gear consists of more than 2 segments, a supplementary letter will be added to the match marks at each split, and each split shall be given a different letter. Figure 4 ONE ASSEMBLY IS FURNISHED FOR EACH CLEARANCE HOLE OF ALL GEAR SPLITS.
LAST STATION NUMBER CASTING SERIAL NUMBER (FXXXX-A)

X
OUTSIDE DIAMETER (XXX.XXX)
STATION NUMBER 1 (LOCATED AT SPLIT)

1
REFERENCE MARKS (000) IDENTIFYING SURFACE FOR CHECKING RUNOUT (LOCATED AT SPLIT) GEAR DRAWING NUMBER (300000, 400000, 500000)
Figure 5 TWO OF THESE ASSEMBLIES ARE FURNISHED FOR EACH GEAR SPLIT.
000
STEP 1 CHECK THE AXIAL RUNOUT OF THE MOUNTING FLANGE

For flange mount applications, the mounting flange must be checked for axial runout prior to gear installation on the shell. For non-flange mount applications, proceed to Step 2. NOTE: The temperature of the shell should be uniform when checking the mounting flange. For example: a shell with the top surface exposed to the sun for a period of time while the bottom surface is in the shade will give erroneous runout readings.
FALK M.O. NUMBER (X-XXXXXX-XXX-201) STATION NUMBER 2
Figure 3 EXPLANATION OF NUMBERS STAMPED ON RING GEARS
PARTS FURNISHED FOR ASSEMBLY OF GEARS

CLEARANCE BOLTS A clearance bolt assembly consists of: one stud, two heavy nuts, and two jam nuts as shown in Figure 4. ALIGNMENT BOLTS An alignment bolt assembly consists of: one tapered alignment bolt, two jam nuts (one large and one small), one split sleeve (taper bored), two washers (one large and one small), and two standard nuts (one large and one small) as shown in Figure 5. JACKSCREWS Typical jackscrew arrangements are shown in Figure 6. They are used for radial adjustment of the gear during erection by bearing against the outer diameter of the mounting flange or the shell. Jackscrews are generally shipped loose and should be inserted in the appropriate position before the gear is initially bolted to the mounting flange.
FROM INSIDE FROM OUTSIDE. (THIS TYPE MUST BE REMOVED AFTER ASSEMBLY.)
Figure 6 JACKSCREW ARRANGEMENTS
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1.1 MARK FLANGE STATIONS

Count the number of stations that are stamped on the gear rim face as shown in Figure 3. Mark off an equal number of spaces on the mounting flange to correspond with the number of stations on the gear.
When the stem of Indicator A is pointing in the same direction as Indicator F , subtract the values entered in Column 4 from the values entered in Column 5 and enter the difference in Column 6. When the stem of Indicator A is pointing in the opposite direction as Indicator F, add the values in Columns 4 and 5 and enter the sum in Column 6.
1.2 PERFORM AXIAL RUNOUT READINGS

There are four methods available to measure the axial runout of the mounting flange and they are listed below in order of decreasing preference. Select the first method below which is practical to perform at your installation. This will help to achieve the most accurate results possible. CAUTION: It is imperative to follow proper sign convention () when performing the measurements and calculations below. A dropped sign could result in a seriously misaligned gear.
1.2.1.4 Determine The Total Axial Runout

The total runout is the difference between the maximum (most positive) value and the minimum (most negative) runout value determined above. Example: Given the following runout values: {+0.004, +0.009, +0.009, +0.004, -0.004, -0.006, +0.004, 0.000}, the maximum value is +0.009 in., and the minimum value is -0.006 in; the runout equals +0.009 -(-0.006) = 0.015 in. NOTE: With the mounting flange runout data, it is possible to selectively position the gear to the flange and optimize the installed gear rim face runout so that the installed runout duplicates the as-manufactured runout of the ring gear. As-manufactured runouts are included in the inspection documents provided with each ring gear. The mounting flange runout data will also be useful during subsequent steps when analyzing gear rim face runout.
1.2.1 SHELL AXIAL RUNOUT INDICATOR FIXTURE METHOD

This method may be employed if a shell axial runout indicator fixture (See TOOLS FOR INSTALLATION section of this manual for details) is available.
1.2.1.1 Position Indicators

Place one indicator on the side of the mounting flange against which the gear will mount, shown at Position A in Figure 7. The other indicator can be positioned against the shell axial runout indicator fixture, shown at Position F in Figure 7.
1.2.1.5 Proceed to Step 2. 1.2.2 THREE-INDICATOR METHOD

This method may be employed if there is clear access to two positions at 180 apart on the thrust face of the trunnion bearing.

Place one indicator on the side of the mounting flange against which the gear will mount, shown at Position A in Figure 7. The other two indicators can be positioned against the thrust face internal to the trunnion bearing, shown at Positions C & D in Figure 7. The thrust face indicators must be placed 180 apart with both stems pointing in the same direction.
D F A C
1.2.2.2 Collect Runout Data

Rotate the shell one full revolution and record the indicator values for each station on Worksheet 1. The values for the mounting flange indicator (at Position A) can be recorded in Column 5 of the worksheet. The values for the trunnion bearing thrust face indicators (at Positions C & D) can be recorded in Columns 1 & 2 of the worksheet.
Figure 7 SHELL INDICATOR POSITION

Rotate the shell one full revolution and record the indicator values for each station on Worksheet 1: Mounting Flange Runout (For One Indicator-, Shell Axial Runout Indicator Fixture-, and Three Indicator-Methods). The values for the mounting flange indicator (at Position A) can be recorded in Column 5 of the worksheet. The values for the shell axial runout indicator fixture indicator (at Position F) can be recorded in Column 4 of the worksheet. NOTE: Columns 1 through 3 of the worksheet will not be used for this method.
1.2.2.3 Perform Runout Calculations

1.2.2.3.1 Add the values in Columns 1 and 2 and enter the sum in Column 3. 1.2.2.3.2 Divide the values in Column 3 by 2.0 and enter in Column 4. 1.2.2.3.3 Fill in Column 6 according to the instructions given below: When the stem of Indicator A is pointing in the same direction as Indicators C & D, subtract the values entered in Column 4 from the values entered in Column 5 and enter the difference in Column 6. When the stem of Indicator A is pointing in the opposite direction as Indicators C & D, add the values in Columns 4 and 5 and enter the sum in Column 6.

Fill in Column 6 according to the following instructions:
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Follow the procedure described in Step 1.2.1.4.
STEP 2 ASSEMBLE GEAR TO THE SHELL 2.1 CLEAN GEAR

All teeth and the mounting and mating surfaces must be thoroughly cleaned before installation. Bumps and burrs that may have occurred in transit and handling must be removed to insure proper assembly and tooth contact. All machined surfaces of the ring gear are protected with a protective film which can be removed at this time with mineral spirits.
1.2.2.5 Proceed to Step 2. 1.2.3 ONE-INDICATOR METHOD

This method may be employed if the shell is pressed firmly against the thrust face on which it will bear during normal operation. NOTE: This method assumes that there is zero axial runout on the thrust face.
2.2 JACKSCREWS
On ring gears using jackscrews in the bore or counterbore of the mounting flange, place the screws into position BEFORE mounting the gear to the driven equipment, as illustrated in Figure 6. On split gears, determine the correct mating position of the gear halves by observing the stamped match marks previously explained in Figure 2, so that all jackscrews are on the same side of the gear when it is assembled. Follow the instructions below to determine the correct gear mounting procedure for your application: If you have a flange mounted, one-piece gear proceed to Step 2.3. If you have a flange mounted, two-piece gear proceed to Step 2.4. If you have a spring mounted, two-piece gear proceed to Step 2.5. If you have a flange mounted, four-piece gear proceed to Step 2.6. If you have a spring mounted, four-piece gear proceed to Step 2.7.
1.2.3.1 Position Indicator

Place the indicator on the side of the mounting flange against which the gear will mount, shown at Position A in Figure 7.

Rotate the shell one full revolution and record the indicator values at each station in Column 6 of Worksheet 1. Note, Columns 1 through 5 of the worksheet will not be used with this method.

1.2.3.4 Proceed to Step 2. 1.2.4 TWO-INDICATOR METHOD

This method should only be used if it is impractical or impossible to utilize any of the above three methods as there are certain runout patterns which this method cannot detect.

Place one indicator on the side of the mounting flange against which the gear will mount, shown at Position A in Figure 7. The other indicator will be placed on the same face of the mounting flange, 180 from Position A with both stems pointing in the same direction, shown at Position B in Figure 7.
2.3 SOLID GEARS, FLANGE MOUNTDESIGNS

Recheck the mounting flanges on the gear and driven equipment to ensure that any bumps or burrs incurred in handling are removed. Secure the gear to the mounting flange with every fourth bolt. Proceed to Step 3.

Rotate the shell one full revolution and record the indicator values for each station on Worksheet 2: Mounting Flange Runout (Two-Indicator Method). The Indicator A values will be entered in Column 1 and the Indicator B values will be entered in Column 2. Note, use Indicator A as the station reference. For example, if you have a gear with 18 stations, when Indicator A is at Station 1, Indicator B will be at Station 10 (180 apart). Therefore, when Indicator A is at Station 1, stop the gear and record both the Indicator A and the Indicator B readings on the same line (for Station 1) of the worksheet.
2.4 2-PIECE SPLIT GEARS, FLANGE MOUNT DESIGN

2.4.1 MOUNT FIRST GEAR HALF
Position half gear on top 180 of shell. Recheck mounting flanges and remove any burrs incurred in handling. Secure the gear half to the mounting flange with every fourth bolt. Any flange bolts located under the jackscrews should only be tightened finger tight. Rotate the shell so that this gear half is positioned on the bottom with the splits in a horizontal position. WARNING: Provide a means to control the rotation of the unbalanced shell assembly.

1.2.4.3.1 Subtract the corresponding Indicator B reading from the Indicator A reading for each station and enter these values in Column 3. 1.2.4.3.2 Divide the values in Column 3 by 2 to obtain the runout for each station and enter in Column 4.
2.4.2 CHECK CLEARANCE BOLT ASSEMBLY

Insert a clearance bolt from the top of the split into the clearance holes, located nearest the outside diameter of the gear half. If the bolts will pass completely through the holes, proceed with mounting the other gear half.

1.2.4.5 Proceed to Step 2.
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If the bolts will not pass completely through the holes because of interference at the inside rim diameter of the gear, as illustrated in Figure 8, all clearance bolts will have to be inserted into this half as far as they will go before the other gear half can be assembled.
Figure 9 ALIGNMENT SLEEVE ORIENTATION
2.4.4.2 Install Alignment Bolts

INTERFERENCE
Insert the small end of the tapered alignment bolt into the flanged end of the sleeve so the large end of the taper is towards the flanged end of the sleeve when the bolt is installed. Tap the alignment bolt down until it seats in the sleeve. Use a lead hammer or block of hard wood to avoid damage to the threads. If the bolt is not driven into the taper, the stud will turn when tightening the nut which could damage the stud or sleeve. Install the remaining sleeves and alignment bolts following the same procedure.
2.4.4.3 Draw Alignment Bolts Securely Into Sleeves

Figure 8 CLEARANCE BOLT INTERFERENCE
CAUTION: Do not damage clearance bolt threads during assembly.
Place a washer over the smaller end of each alignment bolt and turn on a standard nut. Torque the alignment bolts to 25% of the values listed in Table 1 using the cross bolt tightening technique.
2.4.3 MOUNT SECOND GEAR HALF

Make a final check for bumps and burrs on the mounting flange and mating surfaces of both gear halves. Bring the second half of the gear into position. Assemble so that the stamped match marks all appear at the same split. Secure the gear half against the mounting flange with every fourth bolt. These bolts should be snug enough to insure metal-to-metal contact, but not so tight that this gear half cannot be shifted slightly. Any bolts located under the jackscrews should only be tightened finger tight. Position the internal bores of the alignment holes in the splits as accurately as possible by shifting the top half of the gear using the jackscrews, screw jacks, or hydraulic jacks. CAUTION: Confirm proper alignment of the alignment holes by sight and feel. Improper alignment of the alignment holes before installation of the taper sleeves could result in severe damage to the sleeves and alignment bolts. The alignment bolt assembly is not designed to pull the split into alignment. This must be done manually. The alignment bolts are only designed to maintain proper alignment of the gear split.
TABLE 1 Alignment Bolt Torque Values

Thread Size (Small End) 1 1- 1- 1- 2 2- 2- 2-
H Lubricate with SAE 20 oil.
Torque H (lb-ft) 380 700 1,230 2,000 2,600 3,700 5,100 7,100 (Nm) 515 950 1 670 2 710 3 525 5 015 6 915 9 625
2.4.4.4 Check Split Alignment

With a small parallel and feeler gauge, check the alignment of the rim faces. See Figure 10. They should align themselves within approximately 0.003 in. (0,076 mm). If offset is excessive, remove the sleeves and check for damage or disparities and verify proper alignment hole alignment. When the alignment is acceptable, torque the small nut on the end of the alignment bolts to the full torque values listed in Table 1.
2.4.4 INSTALL SLEEVES AND ALIGNMENT BOLTS

ALL ALIGNMENT BOLTS MUST BE INSTALLED BEFORE ANY OF THE CLEARANCE BOLTS ARE TORQUED.
2.4.4.1 Coat and Insert Sleeve

Coat the internal and external surfaces of the split sleeve with a dry lubricant such as molybdenum disulfide and insert into an alignment hole (normally located closest to the ring gear bore) with the sleeve flange toward the gear half with the counterbore stamped TOP. The word TOP may not exist if the split is only counterbored from one side. In this case, the alignment sleeve should be inserted with the sleeve flange on the counterbored side. The alignment sleeve splits should be staggered from split to split as shown in Figure 9. Seat the flange portion of the alignment sleeve against this counterbore. Do not force sleeves into hole.
2.4.4.5 Complete Alignment Bolt Hardware Installation

Install the large end washer and turn on the large end standard nut. Tighten with a wrench to prevent loosening. This nut protects the threads during operation and aids in removal of the alignment bolt in the future. CAUTION: Over tightening of this nut will unseat the alignment bolt from the sleeve. Use an indicator to check for longitudinal displacement of the large end of the tapered alignment bolt. If necessary, loosen the standard nut to relieve any displacement of the large end. Install jam nuts on both ends and tighten to prevent loosening in operation.
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.005" (0,127mm) MAXIMUM GAP AT TOOTH ROOT .0015" (0,038mm) MAXIMUM GAP
MAXIMUM RIM FACE STEP AT SPLIT .003 (0,076mm
SECTION A-A
Figure 10 SPLIT INSPECTION
2.4.5 INSTALL CLEARANCE BOLTS After the clearance bolts have been inserted, adjust the top and bottom standard nuts so that equal portions of the bolt extend above and below the split. Using the cross bolt tightening technique, tighten all clearance bolts as high as necessary so that the split joint is tight to the values shown in Figure 10, being careful not to exceed the torque values shown in Table 2. If the split openings exceed the values shown in Figure 10, recheck the splits for bumps, burrs and foreign objects.
Figure 11 HEAT CLEARANCE BOLT
TABLE 2 Clearance Bolt Tightening Torque

Bolt Diameter (Inches) 2.25 2.50 2.75 3.00 3.25 3.50
H Lubricate with SAE 20 oil.
Torque H (lb-ft) 6,200 8,500 10,500 14,000 18,000 23,000 (Nm) 8 405 11 525 14 235 18 980 24 405 31 185
CAUTION: When heating the bolt, care must be taken to HEAT THE BOLT EVENLY. The torch must be moved constantly. Clearance bolts are heat treated and any reduction in hardness caused by overheating will reduce the tensile strength of the bolt. Care must be taken to keep heat away from the gear. After proper heating, QUICKLY slip the clearance bolt into the hole and turn a nut on the bottom threads (Figure 12). Seat the nut with a wrench and sledge. Turn on the top and bottom jam nuts and tighten with a wrench and sledge. The time to install the nuts after heating should not exceed one minute. It is recommended that the installer practice this procedure without heat to ensure that the time limit is not exceeded during the installation. Install the remaining clearance bolts in the same manner. After all bolts have been installed, the splits must be feeler tight as shown in Figure 10.
2.4.6 CLEARANCE BOLT TORQUING PROCEDURE

Torque the clearance bolts to the values listed in Table 2. If it is not possible to torque the bolts to these values, perform the bolt prestressing procedure as follows: Remove one bolt completely or withdraw as shown in Figure 11 if it cannot be removed completely. Heat the unthreaded center portion of the bolt with an acetylene or propane torch until the center portion of the bolt is uniformly heated to 400F (222C) above the ambient temperature. Use a heating tip on the torch, and hold the tip no closer than 1 in. (40 mm) from the bolt. Check the temperature every three or four minutes with a surface pyrometer or temperature crayon. Approximately 20 minutes is required for proper heating.
Figure 12 TIGHTEN NUTS
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NOTE: In some instances, the gear split hardware will utilize alternate tensioning devices. In this case the above instructions should be replaced by the proper tightening technique for the specific product installed on the gear. Refer to the contract instruction manual or gear drawing for details on installation of these products.
2.5.2 LAYOUT GEAR LOCATION ON SHELL

To aid in installation it is typical to scribe layout lines on the shell indicating the location of the ring gear in the cold position. Cold is considered at 70F (21C). Allow for expansion or contraction for warmer or cooler temperatures during this process.
2.4.7 PROCEED TO STEP 3.
2.5.3 POSITION FIRST GEAR HALF

Maneuver the first gear half under the shell so the split flanges are horizontal and the gear half is as close to the shell as practical. It is important to note that the shell will be on an incline while the gear will be vertical at this stage. Do not attempt to incline the gear so that it is perpendicular to the shell at this time. It should remain vertical during the assembly of the gear halves. Place a support and jack arrangement under the first gear half to support it.
2.5 TWO-PIECE SPLIT GEARS, SPRING MOUNT DESIGN

2.5.1 PRE-ASSEMBLY OF GEAR SEGMENTS
While the gear segments are on the ground and unassembled, install the springs and support/adjustment chairs per the shell manufacturers specifications. See Figure 13 for a typical support chair assembly. The chairs should be installed as close to the gear as possible to allow maximum clearance when assembling the gear halves to the shell. Ensure that the springs are installed so that they will be under tension during normal operation of the shell and that the spring ends are oriented properly for attachment to the shell. Also, tie off hinged springs so that they are fully retracted towards the gear.
KILN GEAR WITH HINGED SPRINGS

Insert a clearance bolt from the top of the split into the clearance holes, located nearest the outside diameter of the gear half. If the bolts will pass completely through the holes, proceed with mounting the other gear half. If the bolts will not pass completely through the holes because of interference at the inside rim diameter of the gear, as illustrated in Figure 8, all clearance bolts will have to be inserted into this half as far as they will go before the other gear half can be assembled. CAUTION: Do not damage the clearance bolt threads during assembly.
2.5.5 POSITION SECOND GEAR HALF

Examine the split flanges at this time and verify that all surfaces are clean and free from defects before proceeding. The second gear half may now be lowered on top of the first gear half.
SPRING
2.5.6 INSTALL SPLIT HARDWARE

Install the split hardware as described in Steps 2.4.4 through 2.4.6. Once the split hardware is installed, the gear can be lifted slightly by a crane and the supports under the first half can be removed.
KILN SHELL
2.5.7 ALIGN GEAR WITH SHELL AXIS

Up to this point the gear has been positioned vertically. It is now necessary to angle the gear so that the gear axis is parallel to the shell axis. Typically this can be accomplished through the use of rigging and/or guide bars. Follow the shell manufacturers instructions for alignment of the gear with the shell axis.
AXIAL ADJUSTMENT BOLTS
2.5.8 ATTACH SUPPORT CHAIRS TO SHELL

TYPICAL GEAR CHAIR FOR TEMPORARY DUTY
FOR GEAR RADIAL ADJUSTMENTS
The gear can now be positioned so the chairs are aligned axially and in the proper radial position. Once this is verified, the chairs can be lowered and secured to the shell. Firmly adjust all alignment bolts on all chairs to align the gear to the shell as accurately as possible. If the springs include provisions for bolting at the interface to the shell, the bolts may be installed at this time. Once all chairs and alignment bolts are secured, the crane supports can be removed from the gear. See Figure 14 for a typical gear/spring/chair mounting arrangement.
Figure 13 TYPICAL SUPPORT CHAIR FOR A KILN SPRING GEAR
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assembly of the mating sections. Also, inspect the mating faces to ensure that they are free of any bumps, burrs, etc. incurred in transit and handling.

SPRING MOUNT
KILN SHELL
ADJUSTMENT CHAIR
Insert a clearance bolt from the top of the split into the clearance holes, located nearest the outside diameter of the gear. If the bolts will pass completely through the holes, proceed with mounting the other gear section. If the bolts will not pass completely through the holes because of interference at the inside rim diameter of the gear, as illustrated in Figure 8, all clearance bolts will have to be inserted into the split as far as they will go before the other gear section can be assembled.
2.6.3 LIFT QUARTER GEAR SECTION PER FIGURE 15.
ROTATION
Figure 14 TYPICAL SPRING MOUNT ARRANGEMENT
2.5.9 PERFORM RADIAL RUNOUT INSPECTION

Follow the radial runout procedure described in Steps 3.2 through 3.5.
2.5.10 Perform Axial Runout Inspection

Follow the axial runout inspection procedure described in Steps 4.1 through 4.3.4.
2.5.11 Adjust Gear Alignment

Based on the axial and radial runout readings obtained above, adjust the chair alignment screws to minimize the installed radial runout (see Column 3 of Worksheet 3) and rim face runout (see Column 8 of Worksheet 4 or Column 6 of Worksheet 5) values. Check the runout values after adjustment and verify that all values are within the acceptable limits. If not, re-adjust the chair alignment screws and repeat.
Figure 15 LIFTING QUARTER SECTION GEAR
Place the two mating gear quarters on rigid parallel supports. Check the match marks to verify proper assembly of mating sections. NOTE: The difference in the split gap from one edge of the face to the other will indicate the accuracy with which one section is parallel to the other. Adjust the position of the gear segments on parallels to bring the alignment holes into close proximity to each other.
2.5.12 Attach Springs to Shell

The springs may now be attached to the shell per the shell manufacturers instructions.
2.6.4
Insert the clearance bolts at the split if they are not already in place. Use the wrench provided to turn the clearance bolts and bring the two sections of the gear into contact. Pay particular attention to the alignment of the alignment holes. The clearance bolts should not be secured at this time. They should only be used to bring the two sections into contact and tightened enough to insure that the splits will close per Figure 10. Some jacking will be required to align the internal bores of the alignment holes in the splits. Confirm alignment by sight and feel. These alignment holes must be lined up accurately before the split alignment sleeves are inserted.
2.5.13 Check Installation

After the springs are attached to the shell, the alignment bolts on the chairs may be backed off so they are no longer in contact with the gear. Check the axial and radial runout to verify that they are within acceptable limits. If the runout values are acceptable, the support chairs may be removed.
2.5.14 Proceed to Step 6.
2.6 FOUR-PIECE SPLIT GEARS, FLANGE MOUNT DESIGN

2.6.1 PRE-ASSEMBLY OF GEARS FURNISHED IN FOUR SECTIONS
The gear quarter-sections must be pre-assembled to form two half-gear sections prior to mounting on the shell. Before proceeding, check the section match marks to ensure proper
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2.6.5
Insert the alignment and clearance bolts following the procedure described in Steps 2.4.4 & 2.4.5.
2.6.6
Repeat the above procedure for the other two mating quarter-sections so the result is two mating gear halves.
STEP 3 CHECK THE RADIAL RUNOUT OF THE GEAR 3.1 PRELIMINARY RADIAL RUNOUT ALIGNMENT
Measure and record the gap between the mounting flange outside diameter and the counterbore of the gear at each station. Use the jackscrews to adjust and even out the gap for the entire circumference of the gear. In some cases it may be necessary to use steel blocks or wedges to adjust the gap spacing between jackscrew pairs.
2.6.7
Proceed with mounting the gear halves on the shell following the procedure described in Steps 2.4.1 through 2.4.5.
2.6.8 CHECK ALIGNMENT

Rotate the shell 90 so the splits that were preassembled are horizontal. The rim face step at the horizontal split should not exceed 0.003 in. (0,076 mm) as shown in Figure 10.
3.2 DETERMINE THE ALLOWABLE INSTALLED RADIAL RUNOUT

There are two considerations when evaluating radial runout of installed ring gears. The first is the total installed radial runout and the second is the change in installed runout from station to station. Allowable total installed radial runout is shown in Table 3. The allowable radial runout between stations is determined by multiplying the allowable installed radial runout by the MF factor given in Table 4. The allowable station-to-station runout applies to a positive or negative difference. That is, if the station-to-station allowable runout is calculated to be .0014 in., station-to-station runout values of -.0014 in. to +.0014 in. would be considered acceptable. It is critical to verify that the installed ring gear satisfies both of these criteria to ensure proper operation of, and maximum life for, the gear set. See Appendix II for an example of a completed radial runout worksheet. Allowable Runout Calculation Example: A gear for a trunnion mounted shell has an outside diameter of 288 in. and has 18 stations. The allowable installed rim face runout, from Table 3, is .021 in. The allowable rim face runout between stations is determined by multiplying this value by the MF factor of .171 from Table 4 or .021 in. x .171 = .0036 in.
2.6.9 CHECK SPLIT TIGHTNESS

If horizontal splits are tight per Figure 10, proceed with the Clearance Bolt Torquing Procedure as described in Step 2.4.6. If the above alignment and split tightness does not meet stated requirements, proceed as follows: Relax the clearance bolts for the two preassembled splits. Relax the alignment bolts for the two preassembled splits. Check the sleeves and alignment studs for damage and for proper hole alignment. Correct the alignment as required. CAUTION: Only inspect one alignment bolt at a time. All other clearance and alignment bolts should remain in place to properly support the gear. Reassemble and retighten the alignment and clearance bolts as described in Steps 2.4.4 through 2.4.6.
2.6.10
Rotate the shell 90 and tighten the clearance bolts of the remaining two splits using the Clearance Bolt Torquing Procedure as described in Step 2.4.6.
3.3 PERFORM RADIAL RUNOUT READINGS

Mount a dial indicator so that it can be set against one of the four machined surfaces shown in Figure 16. Place the indicator squarely to the machined surfaces at one of the stations stamped on the gear face. When utilizing the indicator positions shown on sketches A or B, be sure to use the side of the gear that has been stamped (000). Rotate the gear slowly and record the indicator reading for each station at the corresponding station number in Column 1 of Worksheet 3: Radial Runout. After one complete revolution, the indicator must read within +.002 in. (+0,050 mm) of the initial reading at the starting station. If not, repeat this step. CAUTION: It is imperative to follow proper sign convention () when performing the measurements and calculations below. A dropped sign could result in a seriously misaligned gear.
2.6.11 Proceed to Step 3.
2.7 FOUR-PIECE SPLIT GEARS, SPRING MOUNT DESIGN

2.7.1
Begin by assembling two of the four gear segments into a half gear segment as described in Steps 2.6.1 through 2.6.4. Verify that the match marks are aligned correctly.
2.7.2
Tighten alignment and clearance bolts as described in Steps 2.4.4 through 2.4.6.
2.7.3
Repeat Sections 2.7.1 & 2.7.2 above so that there are two assembled half gear sections.
2.7.4
Assemble the two gear halves to the shell as described in Step 2.5.1 through 2.5.14.
3.4 DETERMINE THE INSTALLED RADIAL RUNOUT

For an ideal installation, the measured ring gear radial runout values should duplicate the values of the gear at the time of manufacture. These as-manufactured values are included in the inspection documents provided for each gear. Enter the as-manufactured values in Column 2 of Worksheet 3. Next, calculate the installed radial runout by subtracting the values in Column 2 from the values in Column 1 and enter the difference in Column 3 of the worksheet.
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5 6
TABLE 3 Ring Gear Allowable Installed Radial Runout

Trunnion Mounted Shells and Outside Roller Mounted Shells with Shell Diameter Speed > 6 rpm of Gear (in) (in) (mm) 108 120 132 144 156 168 180 192 204 216 228 240 252 264 276 288 300 312 324 336 348 360 372 384 396 408 420 432 444 456 468 480 492 504 516 528 540 552 .008 .009 .010 .011 .011 .012 .013 .014 .015 .016 .017 .018 .018 .019 .020 .021 .022 .023 .024 .025 .026 .026 .027 .028 .029 .030 .031 .032 .033 .033 .034 .035 .036 .037 .038 .039 .040 .040 0,203 0,229 0,254 0,279 0,279 0,305 0,330 0,356 0,381 0,406 0,432 0,457 0,457 0,483 0,508 0,533 0,559 0,584 0,610 0,635 0,660 0,660 0,686 0,711 0,737 0,762 0,787 0,813 0,838 0,838 0,864 0,889 0,914 0,940 0,965 0,991 1,016 1,016 Roller Mounted Shells With Shell Speed < 6 rpm (in) .018 .020 .022 .024 .026 .028 .030 .032 .034 .036 .038 .040 .042 .044 .046 .048 .050 .052 .054 .056 .058 .060 .062 .064 .066 .068 .070 .072 .074 .076 .078 .080 .082 .084 .086 .088 .090 .092 (mm) 0,457 0,508 0,559 0,610 0,660 0,711 0,762 0,813 0,864 0,914 0,965 1,016 1,067 1,118 1,168 1,219 1,270 1,321 1,372 1,422 1,473 1,524 1,575 1,626 1,676 1,727 1,778 1,829 1,880 1,930 1,981 2,032 2,083 2,134 2,184 2,235 2,286 2,337
(D) OVER TEETH
(A) ON SEAL RING
(B) ON COUNTER BORE
(C)
ON GAP
Figure 16 PLACEMENT OF INDICATORS
NOTE: If this procedure is being used to install an existing gear, the as-manufactured runout values may not be available. Contact the Factory to obtain the as-manufactured values if they are not available on site. In the event that the Factory no longer has the records for your installation, enter zeros in Column 2 of Worksheet 3. The total installed radial runout can now be determined by subtracting the lowest installed radial runout value from the highest installed radial runout value. Verify that this value is below the allowable limit.
3.5 DETERMINE STATION-TO-STATION RUNOUT

The station-to-station runout can be calculated and entered into Column 4 of the worksheet. Starting at Station No. 2 in Column 4, enter the difference between the installed runout of Station No. 1 (shown in Column 3) minus the installed runout of Station No. 2. Repeat this for the remaining stations. Review the station-to-station values in Column 4 and verify that they are all within the allowable station-to-station limit.
TABLE 4 MF Factor
No. of Stations 8 10 12 14 16 18 20 22
1
MF H .353 .293 .250 .217 .191 .171 .154 .141
No. of Stations 24 26 28 30 32 34 36 ...
MF H .129 .120 .111 .104 .098 .092 .087 ...
3.6 PERFORM FINAL RADIAL ALIGNMENT

Review the total installed runout values and the station-to-station runout values and verify that they are all within the allowable limits. If either the total installed runout or station-to-station runouts exceed the allowable, correction can be made by recentering the gear. Use jackscrews, hydraulic jacks or screw jacks. Adjust the gear to minimize the installed runout values in Column 3 and repeat the radial runout inspection procedure. If the error cannot be corrected, check for restrictions (e.g. body bound bolts).
H The above values for MF can be calculated by the following equation: MF =
/2 sin (360/# stations)
3.7 PRE-TIGHTEN FLANGE BOLTS

When the radial runout values are within the allowable limits, install all remaining flange bolts and torque to 50% of the shell manufacturers specifications. All jackscrews can be removed at this time. If it is not possible to remove the jackscrews, back-off the jackscrews and stake to prevent movement during operation. CAUTION: Jackscrews can cause distortion of the gear rim and must be removed (if non-captive) or backed-off (if captive) prior to final runout checks.
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STEP 4 CHECK THE AXIAL RUNOUT OF THE GEAR RIM FACE 4.1 ESTABLISH ALLOWABLE RIM FACE RUNOUT
There are two considerations when evaluating rim face runout of installed ring gears. The first is the total installed runout of the rim face and the second is the change in installed runout from station to station. Allowable total installed rim face runout is shown in Table 5. The allowable rim face runout between stations is determined by multiplying the allowable installed rim face runout by the MF factor given in Table 4. The allowable station-to-station runout applies to a positive or negative difference. That is, if the station-to-station allowable runout is calculated to be .0014 in., station-to-station runout values of -0.0014 in. to +.0014 in. would be considered acceptable. It is critical to verify that the installed ring gear is within both of these limits to ensure proper operation of, and maximum life for, the gear set.
EXAMPLE: A gear for a trunnion mounted shell has an outside diameter of 288 in. and has 18 stations. The allowable installed rim face runout, from Table 5, is .014 in. The allowable rim face runout between stations is determined by multiplying this value by the MF factor of .171 from Table 4 or .014 in. x .171 = .0024 in.
4.2 PERFORM AXIAL RUNOUT READINGS

Rim face runout of the gear should be checked, recorded, and calculated using the same procedure as used for checking the mounting flange runout given in Step 1. The only difference will be that instead of placing Indicators A or B against the mounting flange, these indicators must be placed against the 000 face of the mounted ring gear. Ideally, the rim face runout should duplicate the values of the gear at the time of manufacture. The as-manufactured values are included in the inspection documents provided for each gear. There are four methods available to measure the axial runout of the rim face and they are listed below in order of decreasing preference. Select the first method below which is practical to perform at your installation. This will help to achieve the most accurate results possible. CAUTION: It is imperative to follow proper sign convention () when performing the measurements and calculations below. A dropped sign could result in a seriously misaligned gear.
Table 5: Allowable Installed Rim Face Runout

Trunnion Mounted Shells & Roller Mounted Shells with Shell Outside Roller Mounted Shells with Shell Speed < 6 rpm Diameter Speed > 6 rpm of Gear (in.) (in) (mm) (in) (mm) 108 120 132 144 156 168 180 192 204 216 228 240 252 264 276 288 300 312 324 336 348 360 372 384 396 408 420 432 444 456 468 480 492 504 516 528 540 552 .005 .006 .007 .007 .008 .008 .009 .010 .010 .011 .011 .012 .013 .013 .014 .014 .015 .016 .016 .017 .017 .018 .019 .019 .020 .020 .021 .022 .022 .023 .023 .024 .025 .025 .026 .026 .027 .028 0,127 0,152 0,178 0,178 0,203 0,203 0,229 0,254 0,254 0,279 0,279 0,305 0,330 0,330 0,356 0,356 0,381 0,406 0,406 0,432 0,432 0,457 0,483 0,483 0,508 0,508 0,533 0,559 0,559 0,584 0,584 0,610 0,635 0,635 0,660 0,660 0,686 0,711 .011 .012 .013 .014 .016 .017 .018 .019 .020 .022 .023 .024 .025 .026 .028 .029 .030 .031 .032 .034 .035 .036 .037 .038 .040 .041 .042 .043 .044 .046 .047 .048 .049 .050 .052 .053 .054 .055 0,279 0,305 0,330 0,356 0,406 0,432 0,457 0,483 0,508 0,559 0,584 0,610 0,635 0,660 0,711 0,737 0,762 0,787 0,813 0,864 0,889 0,914 0,940 0,965 1,016 1,041 1,067 1,092 1,118 1,168 1,194 1,219 1,245 1,270 1,321 1,346 1,372 1,397
4.2.1 SHELL AXIAL RUNOUT INDICATOR FIXTURE METHOD

This method may be employed if a shell axial runout indicator fixture (See the TOOLS FOR INSTALLATION section of this manual for details) is available.

Place one indicator against the 000 rim face, shown at Position A in Figure 17. The other indicator can be positioned against the shell axial runout indicator fixture, shown at Position F in Figure 17.
D F A C
Figure 17 INDICATOR PLACEMENT
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Rotate the shell one full revolution and record the indicator values for each station on Worksheet 4: Rim Face Runout (for One Indicator-, Shell Axial Runout Indicator Fixture-, and Three Indicator-Methods). The values for the mounting flange indicator (at Position A) can be recorded in Column 5 of the worksheet. The values for the shell axial runout indicator fixture indicator (at Position F) can be recorded in Column 4 of the worksheet. NOTE: Columns 1 through 3 of the worksheet will not be used for this method.
4.2.4 TWO-INDICATOR METHOD

This method should only be used if it is impractical or impossible to utilize any of the above three methods as there are certain occurrences of shell float which this method cannot detect.

Place one indicator against the 000 rim face, shown at Position A in Figure 17. The other indicator will be placed on the same face of the mounting flange, 180 from Position A with both stems pointing in the same direction, shown at Position B in Figure 17.
4.2.1.3 Compute Runout

Complete the runout computation as described in Step 1.2.1.3.

Rotate the shell one full revolution and record the indicator values for each station on Worksheet 5: Rim Face Runout (Two-Indicator Method). The Indicator A values will be entered in Column 1 and the Indicator B values will be entered in Column 2. Please note, use Indicator A as the station reference. For example, if you have a gear with 18 stations, when Indicator A is at Station 1, Indicator B will be at Station 10 (180 apart). Therefore, when Indicator A is at Station 1, stop the gear and record both the Indicator A and the Indicator B readings on the same line (for Station 1) of the worksheet.
4.2.1.4 Proceed to Step 4.3. 4.2.2 THREE-INDICATOR METHOD

This method may be employed if there is clear access to two positions at 180 apart on the thrust face of the trunnion bearing.

Place one indicator against the 000 rim face, shown at Position A in Figure 17. The other two indicators can be positioned against the thrust face internal to the trunnion bearing, shown at Positions C & D in Figure 17. The thrust face indicators must be placed 180 apart with both stems pointing in the same direction.

To begin, subtract the corresponding Indicator B reading from the Indicator A reading for each station and enter these values in Column 3. Then divide the values in Column 3 by 2 to obtain the runout for each station and enter in Column 4.

Rotate the shell one full revolution and record the indicator values for each station on Worksheet 4. The values for the mounting flange indicator (at Position A) can be recorded in Column 5 of the worksheet. The values for the trunnion bearing thrust face indicators (at Positions C & D) can be recorded in Columns 1 & 2 of the worksheet.
4.2.4.4 Proceed to Step 4.3.
4.3 ADJUST GEAR FOR OPTIMAL RUNOUT

4.3.1 ENTER AS-MANUFACTURED VALUES
For an ideal installation, the measured ring gear radial runout values should duplicate the values of the gear at the time of manufacture. These as-manufactured values are included in the inspection documents provided for each gear. Enter the as-manufactured values in the appropriate worksheet column. NOTE: If this procedure is being used to install an existing gear, the as-manufactured runout values may not be available. Contact the Factory to obtain the as-manufactured values if they are not available on site. In the event that the Factory no longer has the records for your installation, enter zeros in the as-manufactured values column of the worksheet.
4.2.2.3 Compute Runout

Complete the runout computation as described in Step 1.2.2.3.
4.2.2.4 Proceed to Step 4.3. 4.2.3 ONE-INDICATOR METHOD

This method may be employed if the shell is pressed firmly against the thrust face on which it will bear during normal operation. NOTE: This method assumes that there is zero axial runout on the thrust face.
4.3.2 CALCULATE THE INSTALLED RIM FACE RUNOUT

Next, calculate the installed rim face runout by subtracting the as-manufactured values from the measured axial runout values and entering the difference in the appropriate worksheet column.
4.2.3.1 Position Indicator

Place the indicator against the 000 rim face, shown at Position A in Figure 17.

Rotate the shell one full revolution and record the indicator values at each station in Column 6 of Worksheet 4. NOTE: Columns 1 through 5 of the worksheet will not be used with this method.
4.3.3 DETERMINE THE TOTAL INSTALLED RIM FACE RUNOUT

The total installed rim face runout can now be determined by subtracting the lowest installed rim face runout value from the highest installed rim face runout value. Verify that this value is below the allowable limit established in Step 4.1.
4.2.3.3 Proceed to Step 4.3.
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4.3.4 DETERMINE STATION-TO-STATION RUNOUT
The station-to-station runout can be calculated and entered into the appropriate column of the worksheet. Starting at Station No. 2, subtract the installed runout of Station No. 1 from the installed runout of Station No. 2 and enter this value as the station-to-station runout for Station No. 2. Repeat this for the remaining stations.
6.2.1 RECOMMENDED BACKLASH

If the shell is roller mounted and the shell temperature during operation will exceed 400F (200C), proceed to Step 6.2.1.2, otherwise, proceed to Step 6.2.1.1.
6.2.1.1 Backlash For Trunnion Mounted Shells and Low Temperature Roller Mounted Shells
The required backlash varies with the diametral pitch, the center distance and the temperature difference between the highest operating temperature of the ring gear and the ambient temperature at time of installation. The diametral pitch, center distance and ambient temperature are known factors. The actual operating temperature of the gear varies with the type of enclosure, type of equipment, lubrication and the product being processed. This value must be established by the shell manufacturer or estimated from similar installations. The backlash requirement is determined by adding two factors: (1) Thermal Backlash Factor allows for the thermal expansion of the gear and pinion during normal operation, and (2) Diametral Pitch Backlash Factor includes the recommended operating backlash for a given tooth size. The backlash requirement can be calculated as: Backlash Requirement = Thermal Backlash Factor + Diametral Pitch Backlash Factor The backlash requirement has a tolerance of +.010 in., -.000 in. (+0,25 mm, -0,00 mm). The Thermal Backlash Factor can be determined from the graph shown in Figure 18. Alternatively, the Thermal Backlash Factor can be calculated with the following equation: Thermal Backlash Factor (Inches) = Center Distance (Inches) X (Temperature Rise (F)/150,000) The Diametral Pitch Backlash Factor can be obtained from Table 6. Note, the diametral pitch is shown on the gear drawing.
4.3.5 PERFORM FINAL RIM FACE ALIGNMENT

Review the total installed runout values and the station-to-station runout values and verify that they are all within the allowable limits. If either the total installed runout or station-to-station runouts exceed the allowable, it will be necessary to shim between the gear and mounting flange. Adjust the gear to minimize the installed runout values (see Column 8 of Worksheet 4 or Column 6 of Worksheet 5) and repeat the above rim face runout inspection procedure.
STEP 5 FINAL FLANGE BOLT INSTALLATION

When the rim face and radial runout values are within the allowable limits, torque all flange bolts to the shell manufacturers specifications.
STEP 6 SET PINION 6.1

Before proceeding, it is necessary to select the proper alignment procedure to match your application. Follow the instructions below to determine the correct pinion setting procedure: If you are installing a new pinion with a new gear, proceed to Step 6.2, otherwise, If you are installing a new pinion with a used gear, proceed to Step 6.3.
6.2 PROCEDURE FOR INSTALLING A NEW PINION WITH A NEW GEAR

0.300 150F (83C) RISE
TABLE 6 Diametral Pitch Backlash Factor

Diametral Pitch (See Gear Drawing) /8 /4 /8 1 1-1/4 1-1/2 1-3/4 2 2-1/2
5
3 7
Diametral Pitch Backlash Factor (in) .055 .050 .045 .045 .040 .040 .035 .030 .030 (mm) 1,40 1,27 1,14 1,14 1,02 1,02 0,90 0,76 0,76
0.250
120F (67C) RISE
0.200
90F (50C) RISE
0.150 60F (33C) RISE 0.100 30F (17C) RISE 0.050
See Appendix III for a completed backlash calculation example.

50 100 150 200 250 300
0.000 0
Proceed to Step 6.2.2
CENTER DISTANCE (INCHES)
Figure 18 THERMAL BACKLASH FACTOR
6.2.1.2 Backlash For High Temperature Roller Mounted Shell

The backlash requirement is determined by adding two factors:
NOTE: See equation Step 6.2.1.1.
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(1) Diametral Pitch Backlash Factor includes the recommended operating backlash for a given tooth size, and (2) Wear Allowance Factor includes an allowance for wear of the shell riding ring and rollers. As the riding ring and rollers wear, the axis of the shell will drop vertically. As this occurs, the gear and pinion teeth will be forced into a tighter mesh. It is imperative that proper monitoring of the riding ring and rollers is performed to ensure that the gear teeth are not forced into tight mesh which could result in severe damage to the gearset. Therefore, this value should be selected to meet the requirements of each installation and ensure that a proper safety margin is maintained. An initial value of 0.030 in. (0,76 mm) may be used if prior operating data is not available. The backlash requirement can be calculated as: Backlash Requirement = Diametral Pitch Backlash Factor + Wear Allowance Factor The backlash requirement has a tolerance of +0.010 in., -0,000 in. (+0,25 mm, -0,00 mm). The Diametral Pitch Backlash Factor can be obtained from Table 6. Note, the diametral pitch is shown on the gear drawing. Proceed to Step 6.2.2
6.2.3 TORQUE PINION TO GEAR

Fix the gear to prevent rotation and torque the pinion to the gear in the actual direction in which it is to operate. For double helical gears, make sure the pinion apex centers on the gear apex. This is done by barring the pinion axially to make sure it is free to float within the bearings. Anti-friction bearings should be free to float and centered in their pedestals when the pinion is centered against apex of gear.
6.2.4 CONTACT AND BACKLASH MEASUREMENTS 6.2.4.1

Determine the allowable difference between Contact Left and Contact Right. This is determined with the following formula: A= (F x R)/D Where A = Allowable Difference between Contact Left and Contact Right - in/mm F = Face Width of Gear - in/mm R = Allowable Gear Rim Face Runout -in/mm (Table 5) D = Gear Outside Diameter - in/mm
6.2.2 PRELIMINARY SETTING OF PINION FOR BACKLASH AND TOOTH CONTACT

Place the pinion assembly approximately parallel with the gear axis by leveling and preliminary shimming of the bearing pedestals. It is recommended that a minimum of 0.030 in. (0,76 mm) of shims be used underneath each pillow block. This will allow for future adjustments if they become necessary. Shims should be steel and should support the entire pillow block. If the gear set is single helical, the bearing caps should be removed to make sure that the stabilizing rings are in the fixed pedestal and that the free bearing is in the center of its axial float. In the case of a double helical (or herringbone) gear set, the double helical pinion should have 0.092 in. (2,34 mm) minimum axial float and the bearings should be centrally located. Where locknuts are used to secure the bearing, check for tightness and make sure the lock tab on the washer is secure. Position the pinion to provide the proper backlash while maintaining the proper tooth contact. The setting of contact and backlash must be done simultaneously. Select the proper backlash requirement as described previously. The backlash must be set where the radial runout of the gear causes the minimum backlash. This would be at the station with the highest positive (+) radial runout. Refer to the Radial Runout readings recorded previously on Worksheet 3 in order to identify the Station where this will occur. NOTE: An easy method for preliminary alignment of the pinion is to push the pinion into tight mesh with the gear and look at the tooth contact patterns. Adjust the tight mesh of the pinion and gear until you obtain a balanced contact pattern. Then, using dial indicators, each of the pinion bearings can be backed off by the same amount to obtain the initial backlash setting for the set.
6.2.4.2
With the pinion torqued firmly to the gear, check the contact and backlash side of the teeth at the mesh point at each station. This is done by drawing a feeler gauge between the teeth as shown in Figure 19. Always check contact and backlash close to the pitch diameter line that has been scribed on the side of the gears as illustrated in Figure 20. The scribe lines can also be used to help control running backlash (clearance) by visual inspection. As shown in Figure 20, proper running backlash (clearance) is assured only when scribe lines are tangent or
RIGHT LEFT MEASURING CONTACT SIDE MEASURING BACKLASH SIDE MEASURING CONTACT SIDE
MEASURING BACKLASH SIDE
NO CLEARANCE ON CONTACT SIDE
CLEARANCE ON BACKLASH SIDE
Figure 19 CHECK BACKLASH
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operating apart. If scribe lines overlap, as in case 3, it is necessary to separate the gear and pinion to provide necessary backlash. Adjust the bearing pedestals until the difference between the Contact Left and Contact Right readings are as close to zero as possible without exceeding the allowable difference (A) calculated above, and you achieve a near equal backlash within the recommended range at Backlash Left and Backlash Right. Measurements should be made at each station of the gear and recorded on Worksheet 6: Contact and Backlash/Root Clearance. See Appendix IV for a contact and backlash feeler gauge measurement example.
1 . . . THIS 2 . . . OR THIS 3 . . . NOT TH
NOTE: In some cases (e.g. when the drive components are aligned), it may be easier to move the shell as opposed to the pinion pillow blocks. Consult the shell manufacturer before performing any such move.
6.2.7 CHECK FOR UNIFORM CONTACT PATTERN

After completing the secondary pinion alignment, and with the pedestals firmly secured, check the tooth contact to assure accurate gear alignment. Apply a very thin, smooth coat of contact marking medium to five or six pinion teeth (previously cleaned) as shown in Figure 21. Make sure the entire tooth profiles are covered across the face width. Roll the pinion back and forth through the mesh several times to trace the contact pattern on the gear teeth. If motor power is not available, use a torque arm and bump the teeth on both sides as the pinion is rolled back and forth. Photographs or tape transfers of the as-manufactured contact patterns are provided with the inspection documentation included with every ring gear. The installed pattern should match the as-manufactured pattern as closely as possible. For pinions with un-modified tooth attributes (typically with as-cut teeth) the contact pattern may be scattered but should be present across at least 80% of the gear face width and 50% of the tooth profile height. For pinions with modified tooth attributes (typically with finish ground teeth) the contact pattern should cover about 50% of the face width and 50% of the profile height.
Figure 20 SCRIBE LINES
6.2.5 INTERPRETATION OF FEELER GAUGE READINGS

The total of (Contact Left + Backlash Left) should equal the total of (Contact Right + Backlash Right). If these are not equal, the side with the lowest total is in a position that is closer in center distance than the side with the higher total. See Figure 23A, Misalignment in the Plane of Centers. If Contact Left and Contact Right are not equal, one end of the pinion is at a different elevation than the other. See Figure 23B, Misalignment at Right Angle to the Plane of Centers. The difference between the Contact Left and Contact Right readings should be as close to zero as possible without exceeding the allowable difference (A) calculated above. Because of radial runout in the gear, the total of (Contact Left + Backlash Left) or (Contact Right + Backlash Right) may vary at each position. This is not detrimental providing the amount of variation falls within the allowable radial runout.
6.2.6 SECONDARY ADJUSTMENT OF PINION

It is necessary to evaluate all values at each position before making any adjustments. Otherwise, one could create more misalignment at one position by correcting that of another. The best possible pinion move to correct the contact and backlash for all positions must be established. It is also necessary to take into account the change in shape and deflection of the shell when under full load. The shell deflection will affect alignment of the gear set and must be anticipated to obtain proper contact under running conditions. After establishing the pinion move which is to be made, place indicators on the pillow block which is to be moved, so that its change in position can be measured. The indicators should be placed before loosening the pillow block bolts. It is then possible to add or subtract shims or to shift the pillow block a known amount. The indicators should be checked again after retightening the bolts.
Figure 21 COAT PINION TEETH
After a satisfactory contact pattern is established for the initial position of the gear, the same contact check should be made at a minimum of three more equally spaced locations on the gear. A minor adjustment to the pinion may be necessary to produce the best average contact on the gear. Permanent records of the installed tooth contact patterns should be taken for future reference. Suggested methods are tape impressions, photographs or sketches.
6.2.8 PROCEED TO STEP 7.0
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6.3 PROCEDURE FOR INSTALLING A NEW PINION WITH A USED GEAR

6.3.1 RECOMMENDED BACKLASH
When setting a new pinion with an existing gear, it is important to ensure that the new pinion will mate with undamaged gear teeth. Inspect the contact flanks of the gear to verify that there are no signs of destructive wear such as pitting, spalling, or wear patterns on the tooth profile. Any defects in the gear teeth profiles will be quickly transferred to the pinion and could result in premature pinion failure. If defects are present in the gear teeth, it is recommended that the gear be removed and rotated so that the opposite flanks of the gear teeth will be in contact with the pinion. If the gear has already been rotated and there are no clean tooth flanks available, the gear should be replaced. Since the new pinion will be mating with a gear whose teeth are worn on at least one flank, the backlash tolerances described in Step 6.2 would not be valid. Therefore, when setting the new pinion, it will be necessary to use the root clearance to verify proper installation. The root clearance is defined as the distance between the tips of the pinion teeth and the roots of the gear teeth when they are in mesh. The distance should be measured at the center of the gear tooth root fillet radius. See Figure 22.
6.3.1.1 Root Clearance For A New Pinion Mating With Worn Gear Tooth Flanks
Before removing the existing pinion, measure the root clearance of the existing gear and pinion. This value is the required root clearance for the new installation to ensure that the new pinion will not operate on any steps along the used gear tooth flanks. Figure 22 shows a new pinion mating with the worn face of an existing gear. As the gear has been in service, a slight step has developed at the base of the gear tooth. It is important to ensure that the new pinion tooth flanks do not come into contact with this step or else premature failure could result. Proceed to Step 6.3.2.
6.3.1.2 Root Clearance For Pinions Mating With Unused Gear Tooth Flanks On Trunnion Mounted Shells and Low Temperature Roller Mounted Shells
The root clearance requirement is determined by adding two factors: (1) Thermal Backlash Factor allows for the thermal expansion of the gear and pinion during normal operation, and (2) Tooth Form Root Clearance Factor includes the recommended root clearance for a given tooth form. The root clearance requirement can be calculated as: Root Clearance Requirement = Thermal Backlash Factor + Tooth Form Root Clearance Factor
NEW PINION
The root clearance requirement has a tolerance of +0.010 in., -0.000 in. (+0,25 mm, -0,00 mm). The Thermal Backlash Factor can be determined from the graph shown in Figure 18.
UNUSED GEAR TOOTH FLANK
ROOT CLEARANCE EXISTING GEAR
WORN GEAR TOOT FLANK W/STEP
The Tooth Form Root Clearance Factor can be obtained from Table 7. Note, the diametral pitch is shown on the gear drawing.
TABLE 7 Tooth Form Root Clearance Factor

Tooth Form 1 DP , Mill 1-1/4 DP Mill 1 1- /2 DP, Mill 3/4 DP, FHD 7/ DP, FHD 8 7/ DP, FHD-LA 8 1 DP, FHD 1-1/4 DP, FHD 1-1/2 DP, FHD 1-1/4 DP, UFD 1-1/2 DP, UFD 1-3/4 DP, UFD 2 DP, UFD Approximate Tooth Height (in) 1.925 1.675 1.395 3.025 2.585 2.710 2.270 1.820 1.520 1.590 1.330 1.140 1.000 (mm) 48,9 42,5 35,4 76,8 65,7 68,8 54,7 42,2 38,6 40,4 33,8 29,0 25,4 Tooth Form Root Clearance Factor (Excluding Thermal Allowance) (in) .222 .204 .173 .356 .311 .196 .272 .220 .186 .204 .172 .150 .129 (mm) 5,64 5,18 4,39 9,04 7,90 4,98 6,91 5,59 4,72 5,18 4,37 3,81 3,28
Figure 22 NEW PINION MATING W/EXISTING GEAR
FIGURE 22: NEW PINION MATING WITH EXISTING GEAR
CAUTION: It is imperative to use the proper reference for root clearance measurements. The values in this manual are based on the clearance between the tips of the pinion teeth and the roots of the gear teeth. Do not measure the root clearance between the tips of the gear teeth and the roots of the pinion teeth as this could give erroneous results. If the teeth of the new pinion will mate with the worn flanks of the existing gear, proceed to Step 6.3.1.1, otherwise If the teeth of the new pinion will mate with the unused flanks of the existing gear and the shell is roller mounted and the shell temperature during operation will exceed 400F (200C), proceed to Step 6.3.1.3, otherwise, proceed to Step 6.3.1.2.
For example, if we have a gear with a 1 DP , FHD tooth form, 150 in. center distance, and an anticipated 90F temperature rise above ambient, the required root clearance would be: Tooth Form Root Clearance Thermal Backlash Root Clearance Requirement: Proceed to Step 6.3.2. .272 in. + .090 in. = .362 in.
638-110

6.3.1.3 Root Clearance For Pinions Mating With Unused Gear Tooth Flanks on High Temperature Roller Mounted Shells
The root clearance requirement is determined by adding two factors: (1) Tooth Form Root Clearance Factor includes the recommended root clearance for a given tooth form. (2) Wear Allowance Factor includes an allowance for wear of the shell riding ring and rollers. As the riding ring and rollers wear, the axis of the shell will drop vertically. As this happens, the gear and pinion teeth will be forced into a tighter mesh. It is imperative that proper monitoring of the riding ring and rollers is performed to ensure that the gear teeth are not forced into tight mesh which could result in severe damage to the gearset. Therefore, this value should be selected to meet the requirements of each installation and ensure that a proper safety margin is maintained. An initial value of 0.030 in. (0,76 mm) may be used if prior operating data is lacking. The root clearance requirement can be calculated as: Root Clearance Requirement = Tooth Form Root Clearance Factor + Wear Allowance Factor This root clearance requirement has a tolerance of +0.010 in., -0.000 in. (+0,25 mm, -0,00 mm). The Tooth Form Root Clearance Factor can be obtained from Table 7. Note, the diametral pitch is shown on the gear drawing. Proceed to Step 6.3.2.
6.3.4 CONTACT AND CLEARANCE MEASUREMENTS 6.3.4.1

Determine the allowable difference between Contact Left and Contact Right. This is determined with the following formula: A= (F x R)/D Where A = allowable difference between Contact Left and Contact Right - in/mm F = Face Width of Gear - in/mm R = Allowable Gear Rim Face Runout -in/mm (Table 5) D = Gear Outside Diameter - in/mm
6.3.4.2
With the pinion torqued firmly to the gear, check the contact side of the teeth at the mesh point at each station. This is done by drawing a feeler gauge between teeth as shown in Figure 19. Always check contact close to the pitch diameter line that has been scribed on the side of the gears as illustrated in Figure 20. The scribe lines can also be used to help control running clearance by visual inspection. As shown in Figure 20, proper running clearance is assured only when scribe lines are tangent or operating apart. If scribe lines overlap, as in case 3, it is necessary to separate the gear and pinion to provide necessary root clearance. Adjust pedestals until the difference between the Contact Left and Contact Right readings is as close to zero as possible without exceeding the allowable difference (A) calculated above, and you achieve a near equal root clearance within the recommended range at Root Clearance Left and Root Clearance Right. Measurements should be made at each station of the gear and recorded on Worksheet 6: Contact and Backlash/Root Clearance.
6.3.2 PRELIMINARY SETTING OF PINION

Place the pinion assembly approximately parallel with the gear axis by leveling and preliminary shimming of the bearing pedestals. It is recommended that a minimum of 0.030 in. (0,76 mm) of shims be used underneath each pillow block. This will allow for future adjustments if they become necessary. Shims should be steel and should support the entire pillow block. If the gear set is single helical, the bearing caps should be removed to make sure that the stabilizing rings are in the fixed pedestal and that the free bearing is in the center of its axial float. In the case of a double helical (or herringbone) gear set, the double helical pinion should have 0.092 in. (2,34 mm) minimum axial float and the bearings should be centrally located. Where locknuts are used to secure the bearing, check for tightness and make sure the lock tab on the washer is secure. Position the pinion to provide the proper root clearance while maintaining the proper tooth contact. The setting of contact and root clearance must be done simultaneously. Select the proper root clearance requirement as previously described. The root clearance must be set where the radial runout of the gear causes the minimum root clearance. This would be at the station with the highest positive (+) radial runout. Refer to the Radial Runout readings recorded previously on Worksheet 3 in order to identify the Station where this will occur.
6.3.5 INTERPRETATION OF CONTACT AND ROOT CLEARANCE MEASUREMENTS

If the Root Clearance Left measurements are consistently above or below the Root Clearance Right measurements, the side with the lowest total is in a position that is closer in center distance than the side with the higher total. See Figure 23A, Misalignment in the Plane of Centers. If Contact Left and Contact Right are not equal, one end of the pinion is at a different elevation than the other. See Figure 23B, Misalignment at Right Angle to the Plane of Centers. Because of radial runout in the gear, the Contact Left and Contact Right measurements may vary at each position. This is not detrimental providing the amount of variation falls within the allowable radial runout.
6.3.6 SECONDARY ADJUSTMENT AND FINAL CHECK OF PINION

Complete the final adjustment and contact check for the pinion as described in Steps 6.2.6 & 6.2.7.
6.3.3 TORQUE PINION TO GEAR

Fix the gear to prevent rotation and torque the pinion to the gear in the actual direction in which it is to operate. For double helical gears, make sure the pinion apex centers on the gear apex. This is done by barring the pinion axially to make sure it is free to float within the bearings. Anti-friction bearings should be free to float and centered in their pedestals when pinion is centered against apex of gear.
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SINGLE HELICAL
DOUBLE HELICAL
SINGLE HELICAL
DOUBLE HELICAL
Figure 23A MISALIGNMENT IN THE PLANE OF CENTERS
Figure 23B MISALIGNMENT AT RIGHT ANGLE TO THE PLANE OF CENTERS
STEP 7 INSPECT FINAL GEAR ASSEMBLY

Inspect the gear teeth and remove all metal upsets and burrs which may have occurred in handling or assembly. Recheck all gear bolts. If the gear is furnished with gear mounted seal accessories (e.g. angle dust guards) refer to the appropriate drawing for assembly. Clean gear teeth and enclosures thoroughly.
It will be necessary to repeat the above layout dye test after making any alignment adjustments.
8.2 CHECK THE CONTACT USING A PYROMETER OR INFRARED THERMOMETER

Misalignment in gear sets produces non-uniform load distribution across the face of the gearing and results in higher operating temperatures at the point of highest load. Equal temperatures at both ends of the pinion face indicate a uniform load distribution and optimum alignment. Non-equal temperatures indicate that the gear set is misaligned with heavier load distribution on the side with the higher operating temperature. The temperature distribution across the face may be determined by the contact pyrometer method or the infrared radiation thermometer method. The basic alignment theory for both methods is the same. The pyrometer method requires the gear set to be shut down and temperature readings to be taken immediately. The short duration of time required to stop the gear set and measure temperatures may be sufficient to allow temperatures to shift and thus give erroneous data. Therefore, when the pyrometer method is used, expedience is of utmost importance. When taking gear mesh temperature measurements, it is necessary to allow the equipment to operate at least 24 hours before taking readings to insure system temperature stabilization.
STEP 8 DYNAMIC ALIGNMENT CHECK

The only true measure of contact is under normal running conditions. This is necessary because of the effects of shell temperature, change in deflection of the shell or support structure, pinion shaft motion in the bearing clearance, motion of the foundation, shell shift in trunnion bearing clearance, etc. The initial alignment of the gear and pinion with feeler gauges and indicators is important and a good starting point, but the dynamic contact under normal load determines the load distribution across the face. The dynamic alignment is checked by using both the layout dye and the temperature measurement methods.
8.1 CHECK THE CONTACT USING LAYOUT DYE

After thoroughly cleaning the gear teeth, paint three teeth at six equally spaced positions around the gear with layout dye. Install the gear guard enclosure around the gearing and lubricate the teeth. See Lubrication and Maintenance Service Manual 638-050 for information and recommendations regarding lubrication. Run the equipment for six to eight hours at a minimum of 50% of full load. After the equipment is stopped, remove the lubricant from the marked teeth without removing the remaining layout dye. The layout dye should wear off of 95% of the face width of the gear teeth at each position which will indicate that the gear and pinion are in good alignment. If a gear has axial runout, the contact will vary from one side of the gear face to the other in a sinusoidal pattern with each rotation of the gear. The contact pattern on the pinion will migrate accordingly. However, inspection of the pinion teeth would show 100% contact, but in truth, it could be 50% contact on one side of the face during half of the gear rotation, and 50% contact on the other side during the rest of the rotation. A better indication of contact can be obtained by checking more gear locations. If anything other than 95% face contact at 50% of full load at all locations is found, realignment is required. When determining which direction to move the pinion or the shell, it is necessary to evaluate the contact patterns and relate them to the pinion rotation. Figures 23A and 23B offer some ideas for adjustments based on the contact patterns.
8.2.1 MEASUREMENT PROCEDURES 8.2.1.1 Surface Contact Pyrometer Equipment Stopped

A pyrometer capable of measuring 400F (200C) accurate to within 3F (2C) is recommended. Pyrometer measurements are taken at the pitchline on the loaded flank of the pinion tooth at the positions shown in Figure 24. The measurements must be taken immediately after shut down and directly through the lubricant film (i.e., the teeth should not be cleaned with solvent). Measurement Position 1 is always on the non-drive end of the pinion.
8.2.1.2 Infrared Thermometer Equipment Operating

Use an infrared radiation thermometer capable of measuring 400F (200C). The infrared thermometer must be calibrated prior to taking data. If the infrared thermometer used requires an emissivity setting, experience has shown that a value of 0.8 typically produces adequate readings. Position the detector approximately 3 feet (1 m) from the mesh of the gear set. Aim the instrument at five measurement positions across the face of the pinion as shown in Figure 24.
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Figure 25, dashed line, illustrates the distribution of a gear set having poor alignment. The temperature gradient of this set is +40F which indicates that misalignment is producing unequal load distribution that is higher on the non-drive end of the pinion. If the temperature gradient is less than 15F (8C), the gearset is adequately aligned. If the gradient exceeds this limit, the alignment of the gearset should be adjusted as described in Step 8.2.3.
NON DRIVE END
DRIVE END
8.2.3 ALIGNMENT CORRECTION

It is recommended that the pinion bearing pillow blocks be moved vertically and/or horizontally to improve alignment whenever the magnitude of the gradient exceeds 15F (8C). As stated previously, using the data collected on the Gearing Temperature Worksheet, it is possible to calculate the required pinion adjustments to minimize the operating temperature gradient. There are two ways to perform these calculations: (1) A computer program is available to Rexnord customers which will perform the calculations and indicate the required pinion adjustment(s). This program will operate on IBM PC compatible systems utilizing Windows 3.1 or higher. You may contact your local Rexnord Sales Office or the Factory to obtain a complimentary copy of this software. (2) The completed Gearing Temperature Worksheet(s) may be forwarded to Rexnord Engineering where the calculations will be performed for you. Rexnord Engineering will return the required pinion adjustment(s) to you along with any recommendations or concerns regarding the submitted data. This method has the distinct advantage of allowing Rexnord Engineering to review your application to ensure that the gearset is operating at peak efficiency. Please note that a separate worksheet should be used for each pinion. Also, a separate worksheet should be used for each direction of rotation. NOTE: For bi-directional rotation applications, it is imperative to provide operation data for both directions of rotation. The equipment should be operated for at least 24 hours in both directions to allow the system temperature to stabilize. After adjusting the pinion(s), operate the equipment for at least 24 hours, then recheck the temperature gradient and readjust the pinion(s) if necessary. CAUTION: Adjusting the pillow blocks could cause misalignment of the couplings and other associated equipment. Recheck and readjust these alignments after any pinion adjustments. The final load distribution check should be made in both directions of rotation for reversible equipment. It is recommended that periodic inspection be made to assure proper tooth contact. Periodic temperature monitoring should be performed for the first month of operation, under varying load conditions and in both directions of rotation (if applicable). If the temperature readings indicate that the alignment is satisfactory, dowel or permanently affix the location of the pinion shaft bearing support pedestals.
POSITION NO.
Figure 24 MEASUREMENT POSITIONS FOR PYROMETER AND INFRARED THERMOMETER
In addition, the infrared instrument should be aimed at the axis of the pinion shaft, not toward the pitch line of the tooth flank. Temperature readings, along with the other required application data, can be recorded on Worksheet 7: Mesh Operating Temperature. Please note, all of the data shown on the worksheet must be supplied in order to determine any required alignment adjustments later. When selecting the measurement positions, Position 1 is always on the non-drive end of the pinion face.
8.2.2 DATA INTERPRETATION TEMPERATURE DISTRIBUTIONS

Figure 25, solid black line, illustrates the temperature distribution of a gear set having optimum alignment. The temperature gradient, which is the temperature at Position 1 minus the temperature at Position 5, is zero and this indicates that the load distribution is equal.
215.0 210.0 205.0
TEMPERATURE (F)
GRADIENT = 210 - 170 = +40F
200.0
195.0 190.0
GRADIENT = 190 - 190 = 0F
185.0 180.0
175.0
170.0 165.0
1 2 3 MEASUREMENT POSITION 4 5
Figure 25 TEMPERATURE DISTRIBUTION
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APPENDIX I RIM FACE RUNOUT EXAMPLE

A typical gear had readings as listed in Table 8. This is a 288 in. outside diameter flange mounted gear with 18 stations, located on a trunnion mounted shell. The procedure given in Step 4 was used to fill in the worksheet columns. The installed rim face runout is shown in Column 8. The rim face runout from station-to-station is shown in Column 9. The total installed rim face runout is the difference between the maximum value and the minimum value of Column 8. In this case, the maximum values appear at stations 5 and 13. The total installed rim face runout is the difference between the two values or +.0054 in. - (-.0054 in.) = .0108 in. This value is below the allowable maximum value of .0140 in. given in Table 5.
Using an MF factor of .171 (from Table 4 for an 18 station gear), the maximum allowable runout between stations is determined to be .014 in. x .171 = .0024 in. Now, it is necessary to compare this allowable against each of the station-to-station runout values listed in Column 9. In this case we see that all of the Column 9 values are below the allowable station-to-station limit. Since the allowable is greater than the actual runout for both cases, the gear is acceptable as mounted. If the actual runout exceeds the allowable value, it will be necessary to correct the alignment by shimming at the mounting flange bolts.
TABLE 8 Rim Face Runout

Column 1 2 3 4 5 6 7 8 9 Station to Station Runout As Installed Axial (Difference Manufactured Runout (Column 6 Between Axial Runout Minus Column 7) Successive Stations Values in Column 8) .0000 .0022 .0034 .0044 .0046 .0044 .0034 .0022 .0000 -.0022 -.0034 -.0044 -.0046 -.0044 -.0034 -.0022 .0000 .0000 .0016 .0037 .0048 .0054 .0048 .0037 .0016 .0000 -.0016 -.0037 -.0048 -.0054 -.0048 -.0037 -.0016 .0000 .0016 .0021 .0011 .0006 -.0006 -.0011 -.0021 -.0016 -.0016 -.0021 -.0011 -.0006 -.0006 .0011 .0021 .0016
Station No
Indicator C
Indicator D
Indicator F or Column 1 Plus Column 3 Divided Column 2 by 2.0 .0000 .0012 .0026 .0038 .0050 .0062 .0076 .0088 .0100 .0086 .0070 .0056 .0040 .0056 .0070 .0086 .0100 .0000 .0006 .0013 .0019 .0025 .0031 .0038 .0044 .0050 .0043 .0035 .0028 .0020 .0028 .0035 .0043 .0050
Indicator A
Axial Runout
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
.0000 .0017 .0034 .0047 .0055 .0059 .0059 .0055 .0050 .0032 .0014 .0000 - .0010 .0000 .0014 .0032 .0050
.0000 - .0005 - .0008 - .0009 - .0005 .0003 .0017 .0033 .0050 .0054 .0056 .0056 .0050 .0056 .0056 .0054 .0050
.0000 .0044 .0084 .0111 .0125 .0123 .0109 .0082 .0050 .0005 -.0036 -.0064 -.0080 -.0064 -.0036 .0005 .0050
.0000 .0038 .0071 .0092 .0100 .0092 .0071 .0038 .0000 -.0038 -.0071 -.0092 -.0100 -.0092 -.0071 -.0038 .0000
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APPENDIX II RADIAL RUNOUT EXAMPLE

For a 288 in. outside diameter ring gear with 18 stations, the allowable radial runout is .021 in. (from Table 3). The allowable radial runout from station-to-station is determined by multiplying this value by the MF factor of .171 from Table 4 or .021 in. x .171 = .0036 in. The readings for the gear are listed in the Table 9. The total radial runout is obtained by combining the maximum reading with the minimum reading. In this case, the values are a maximum of +.0019 in. found at Station 17 and a minimum of -.0142 in. found at Station 8. The two combined yield a total radial runout of .0161 inches which is below the allowable limit of .021 in. Next, by comparing the allowable station-to-station runout of .0036 in. against all of the station-to-station runout values listed in Column 4, it can be seen that the station-to-station runout is acceptable. Since both values are within the allowable limits, this installation is acceptable.
APPENDIX III BACKLASH CALCULATION EXAMPLE

Using a gear set with a diametral pitch of 1 DP and center distance of 150 in. The ambient temperature at the time of installation is 70F and the expected operating temperature is 130F. To begin, determine the Thermal Backlash Factor for this application using Figure 18. It will first be necessary to calculate the temperature rise of this gearset during operation as 130F - 70F = 60F. From Figure 18 we see that the Thermal Backlash Factor is .060 in. Next, the Diametral Pitch Backlash factor can be obtained from Table 6 which equals .045 in. for this example. The recommended backlash at ambient temperature can now be calculated as .060 in. + .045 in. = .105 in.
TABLE 9 Radial Runout

Column Station No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 1 2 3 4 Station-to-Station Radial As-Manufactured Installed Radial Runout (Difference Runout Radial Runout Runout (Column 1 Between Successive Indicator Minus Column 2) Stations in Column Values Reading 3) .0000 .0017 .0017 .0000 -.0034 -.0079 -.0130 -.0181 -.0226 -.0260 -.0277 -.0277 -.0260 -.0226 -.0181 -.0130 -.0079 -.0034 .0000 .0000 .0023 .0038 .0044 .0043 .0031 .0000 -.0039 -.0098 -.0133 -.0155 -.0165 -.0168 -.0165 -.0155 -.0133 -.0098 -.0039 .0000 .0000 -.0006 -.0021 -.0044 -.0077 -.0110 -.0130 -.0142 -.0128 -.0127 -.0122 -.0112 -.0092 -.0061 -.0026 .0003 .0019 .0005 .0000 -.0006 -.0015 -.0023 -.0033 -.0033 -.0020 -.0012 .0014 .0001 .0005 .0010 .0020 .0031 .0035 .0029 .0016 -.0014 -.0005
638-110
APPENDIX IV CONTACT AND BACKLASH FEELER GAUGE MEASUREMENT EXAMPLE

A gear has an outside diameter of 288 in. and a 30 in. face. From Table 5, the allowable rim face runout is 0.014 in. The allowable difference between Clearance Left and Clearance Right (A) is found with the following formula: A = (F x R)/D Where: A = Allowable Difference between Clearance Left and Clearance Right - (in.) F = Face Width of Gear - (in.) R = Allowable Gear Rim Face Runout - (in.) D = Gear Outside Diameter - (in.) A = (30 in. x 0.014 in.)/288 in. = 0.0015 in.
The feeler gauge readings for the gear are shown in Table 10 First, verify that the total of Contact Left plus Backlash Left equals the total of Contact Right plus Backlash Right at each station. Looking at the right two columns of the completed table, it can be seen that this is essentially true for all stations. The minor variances in the middle station readings are not a significant concern. Next, determine the maximum difference between Clearance Left and Clearance Right at any given station, which is .0014 in. for this example. This value is less than the allowable value A calculated above, so this is an acceptable preliminary setting.
TABLE 10 Contact and Backlash/Root Clearance

Station No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Contact Flank Left .0014 .0014 .0011 .0006 .0000 .0000 .0000 .0000 .0000 .0000 .0000 .0000 .0000 .0006 .0011 .0014 Right .0000 .0000 .0000 .0000 .0000 .0000 .0006 .0011 .0014 .0014 .0014 .0011 .0006 .0000 .0000 .0000 Variance .0014 .0014 .0011 .0006 .0000 .0000 .0006 .0011 .0014 .0014 .0014 .0011 .0006 .0006 .0011 .0014 Backlash Flank or Root Clearance Left .0499 .0493 .0501 .0524 .0558 .0592 .0625 .0659 .0670 .0676 .0670 .0654 .0625 .0586 .0546 .0516 Right .0513 .0507 .0513 .0530 .0558 .0586 .0614 .0645 .0656 .0662 .0659 .0648 .0625 .0592 .0558 .0530 Total of Contact and Backlash Left .0513 .0507 .0513 .0530 .0558 .0592 .0625 .0659 .0670 .0676 .0670 .0654 .0625 .0592 .0558 .0530 Right .0513 .0507 .0513 .0530 .0558 .0586 .0620 .0656 .0670 .0676 .0673 .0659 .0631 .0592 .0558 .0530
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WORKSHEET 1: MOUNTING FLANGE RUNOUT (For One Indicator-, Shell Axial Runout Indicator Fixture-, and Three Indicator-Methods)
Project:__________________________________________ Equipment ID: _____________________________________ Column 1 2 Date: ___________________________________________ Recorded By: ______________________________________ 3 Column 1 Plus Column 2 4 Indicator F or Column 3 Divided by 2.0 5 6
Station No.
Indicator C
Indicator D
Indicator A
Axial Runout
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Total Flange Runout (difference between highest and lowest Column 6 value):
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WORKSHEET 2: MOUNTING FLANGE RUNOUT (For Two Indicator-, Method)

Project:__________________________________________ Equipment ID: _____________________________________ Column Station No. (Indicator A) 1 Indicator A 2 Indicator B Date____________________________________________ Recorded By ______________________________________ 3 Column 1 Minus Column 2 4 Axial Runout (Column 3 Divided by 2.0)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Total Flange Runout (difference between highest and lowest Column 4 values):
638-110
WORKSHEET 3: RADIAL RUNOUT

Project __________________________________________ Equipment ID: _____________________________________ Gear Drawing No.: __________________________________ Column 1 Radial Runout Indicator Reading 2 As-Manufactured Radial Runout Values Date____________________________________________ Recorded By: ______________________________________ Gear Serial No.:____________________________________ 3 Installed Radial Runout (Column 1 Minus Column 2 4 Station-to-Station Runout (Difference Between Successive Stations in Column 3)
Station No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28 30 31 32 33 34 35 36 1
Difference Between First and Last Station 1 Readings from Column 1 (must be <.002) Total Radial Runout (difference between highest and lowest Column 3 values): Allowable Radial Runout: Allowable Station-to-Station Runout:
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WORKSHEET 4: RIM FACE RUNOUT (For One Indicator-,Shell Axial Runout Indicator Fixture-, and Three Indicator-Methods)
Project:__________________________________________ Equipment ID: _____________________________________ Gear Drawing No.: __________________________________ Date: ___________________________________________ Recorded By: ______________________________________ Gear Serial No.:____________________________________
Column
4 Indicator F or Column 3 Divided by 2.0
Station No.
Indicator C
Indicator D
Column 1 Plus Column 2
Indicator A
Axial Runout
Station toInstalled Axial Station Runout (Difference Runout As-Manufacture Between (Column 6 dAxial Runout Successive Minus Values Stations in Column 7 Column 8)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Total Rim Face Runout (difference between highest and lowest Column 8 values): Allowable Rim Face Runout: Allowable Station-to-Station Runout:
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WORKSHEET 5: RIM FACE RUNOUT (For Two Indicator-Method)

Project:__________________________________________ Equipment ID: _____________________________________ Gear Drawing No.: __________________________________ Date: ___________________________________________ Recorded By: ______________________________________ Gear Serial No.:____________________________________
Column Station No. (Indicator A)
3 Column 1 Minus Column 2
4 Axial Runout (Column 3 Divided by 2.0)
5 As-Manufactured Axial Runout Values
6 Installed Axial Runout (Column 4 Minus Column 5)
7 Station-to-Station Runout (Difference Between Successive Stations in Column 6)
Indicator A
Indicator B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Total Rim Face Runout (difference between highest and lowest Column 6 values): Allowable Rim Face Runout: Allowable Station-to-Station Runout:
638-110
WORKSHEET 6: CONTACT AND BACKLASH/ROOT CLEARANCE

Project:__________________________________________ Equipment ID: _____________________________________ Gear Drawing No.: __________________________________ Date: ___________________________________________ Recorded By: ______________________________________ Gear Serial No.:____________________________________ Backlash Flank or Root Clearance Variance Left Right
Station No.
Contact Flank Left Right
Total of Contact and Backlash Left Right
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Allowable Difference Between Contact Left and Contact Right (A): Backlash/Root Clearance Requirement:
638-110
WORKSHEET 7: MESH OPERATING TEMPERATURE

Project __________________________________________ Equipment ID: _____________________________________ Pinion Location ID _________________________________ Pinion Rotation ___________________________________ Falk Pinion PN: ____________________________________ Recorded By: ______________________________________
SHELL ROTATION
2ND PINION, FOR DUAL PINION DRIVE RING GEAR
HORIZONTAL ANGLE OF PINION FROM HORIZONTAL
DISCHARGE
SHELL
SHELL ROTATION DIRECTIO (VIEWED FROM FEED END)
COUPLING
PINION ROTATION PINION ROTATION INTO MESH OUT-OF MESH
MOTOR OR DRIVE DRIVE END PINION BEARING
PINION NON-DRIVE END PINION BEARING
Angle of Pinion from Horizontal degrees [(-) if below horizontal, (+) if above}
Direction of Shell Rotation: CW/CCW [As viewed from feed end]
Temperature at Position Date Time H Actual Motor Power Non-Drive End 1 2 Middle 3 4 Drive End 5
H The equipment should be operating for at least 24 hours in any given direction before recording temperatures. In addition, it is not necessary to record temperatures
more often than every six to eight hours, after temperature has stabilized. Position 1 should always be on the non-drive side of the pinion face. Positions 2 through 5 should progress in even increments across the face towards the drive side. A separate worksheet should be used for each pinion. In addition, a separate worksheet should be used for each direction of rotation. That is, do not record data for more than one pinion or one direction of rotation on the same worksheet.
638-110

Installation - Ring Gear Installation Manual

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RING GEAR INSTALLATION

Installation Manual Falk Ring Gear (Page 2 of 31)

TABLE OF CONTENTS General

Installation and Alignment

Falk Ring Gear Installation Manual (Page 3 of 31)

TOOLS FOR INSTALLATION

ALIGNMENT BOLT CLEARANCE BOLT

Installation Manual Falk Ring Gear (Page 4 of 31)

LAST STATION NUMBER CASTING SERIAL NUMBER (FXXXX-A)

OUTSIDE DIAMETER (XXX.XXX)

STATION NUMBER 1 (LOCATED AT SPLIT)

STEP 1 CHECK THE AXIAL RUNOUT OF THE MOUNTING FLANGE

FALK M.O. NUMBER (X-XXXXXX-XXX-201) STATION NUMBER 2

Figure 3 EXPLANATION OF NUMBERS STAMPED ON RING GEARS

PARTS FURNISHED FOR ASSEMBLY OF GEARS

Figure 6 JACKSCREW ARRANGEMENTS

Falk Ring Gear Installation Manual (Page 5 of 31)

1.1 MARK FLANGE STATIONS

1.2 PERFORM AXIAL RUNOUT READINGS

1.2.1.4 Determine The Total Axial Runout

1.2.1 SHELL AXIAL RUNOUT INDICATOR FIXTURE METHOD

1.2.1.1 Position Indicators

1.2.1.5 Proceed to Step 2. 1.2.2 THREE-INDICATOR METHOD

1.2.2.1 Position Indicators

1.2.2.2 Collect Runout Data

Figure 7 SHELL INDICATOR POSITION

1.2.1.2 Collect Runout Data

1.2.2.3 Perform Runout Calculations

1.2.1.3 Perform Runout Calculations

Installation Manual Falk Ring Gear (Page 6 of 31)

STEP 2 ASSEMBLE GEAR TO THE SHELL 2.1 CLEAN GEAR

1.2.2.5 Proceed to Step 2. 1.2.3 ONE-INDICATOR METHOD

1.2.3.1 Position Indicator

1.2.3.2 Collect Runout Data

1.2.3.3 Determine The Total Axial Runout

1.2.3.4 Proceed to Step 2. 1.2.4 TWO-INDICATOR METHOD

1.2.4.1 Position Indicators

2.3 SOLID GEARS, FLANGE MOUNTDESIGNS

1.2.4.2 Collect Runout Data

2.4 2-PIECE SPLIT GEARS, FLANGE MOUNT DESIGN

1.2.4.3 Perform Runout Calculations

2.4.2 CHECK CLEARANCE BOLT ASSEMBLY

1.2.4.4 Determine The Total Axial Runout

1.2.4.5 Proceed to Step 2.

Falk Ring Gear Installation Manual (Page 7 of 31)

2.4.4.2 Install Alignment Bolts

2.4.4.3 Draw Alignment Bolts Securely Into Sleeves

CAUTION: Do not damage clearance bolt threads during assembly.

2.4.3 MOUNT SECOND GEAR HALF

TABLE 1 Alignment Bolt Torque Values

2.4.4.4 Check Split Alignment

2.4.4 INSTALL SLEEVES AND ALIGNMENT BOLTS

2.4.4.1 Coat and Insert Sleeve

2.4.4.5 Complete Alignment Bolt Hardware Installation

Installation Manual Falk Ring Gear (Page 8 of 31)

MAXIMUM RIM FACE STEP AT SPLIT .003 (0,076mm

Figure 10 SPLIT INSPECTION

Figure 11 HEAT CLEARANCE BOLT

TABLE 2 Clearance Bolt Tightening Torque

2.4.6 CLEARANCE BOLT TORQUING PROCEDURE