Turbo Gear MAAG Gear Co. Ltd.fights [Link], reserves a Jn connection with this document. MAAG Ge 5 >| r fp iL PIP} a UW ee pce 2 Gear daca 112 Lubrication system 113 Aecessories Vibration monitoring ‘Pemperature monitoring 1.4 Bearings LIS Alignmenc GENERAL INFORMATION Description of gear Shop test run Preparation for shipment Storage and Handling Eong eern storage uBRICATION INSTALLATION Preparation of gearbox Foundation Alignment of gear train Giger Setting of gearbox 4/312 Checking of gear cooth contact 4.4 Final preparations a 4 4 OPERATION Preparation for start-up Start-up Gear vooth contact under load Monitoring st lube oil pressure Monitoring of cemperatures Monitoring of vapracions Trouble shooting MAINTENANCE 6.1 Inspections Grit Gear tooth contact S112 Bearings 6.1/3 Backlash 6.1.4 Gear mesh lubrication Disaneling of gearbox Assembly of Gearbox Replacement of beariees Replacement of rotacang parts Lubricating 0:2 Spare pares Prolonged saut-downs all or Tae 5.03.86 (ane | “tures sear KS aaa 700.3202 4in connection with this document MAAG Gear Co. Lad. reserves SPECIEICATIONS GEAR DATA order No. 53798 type cB-s0 center distance 500 Power 29160 Speeds as70/10932 Drawings: Outline No.722.6904.06.0 + Assembly Wo.722.6906.01.0 Diagrams; Wiring diagram for kip's No.722.6904.11.2 + Vibration monitoring system No.722.6904.16.2 z pm | 1.2 tabrlonting system habe oft grade + nacho ott Viscosity 180 ve as “morc 042 circulation for gear 134 amin 41 premmure at gear inlet Morro! 1.75 bar Mest Lg a PREP aoe 1:38 BE it intet temmarature a oe mean iMnm La acoemsoriee Coupting input stage Sovpling otbpue"thate Attaché units Vibration monitoring: Bently novade nye | SUBS SSS sae Temoorature moniefeing | isto’ Scuase ‘ye | S30 == Paws nuns cra 700.1205 AABRG | ist | 63-50 S3798MAAG Gear Co. Lid. reserves all igs In connection with this docament. LELLELLLL S| | reese erases La 1s Bearings (Bearing No. see assembly drawing) Nq- nominal. @ianecers Clearance 180 am 180 mm 190 om 290 om ‘Thrust bearing pinion ‘Thrust bearing wheel Alignnont Shaft axis displacenent caused by housing thermal expansion and Load. Shaft position at ambient cemperature ( 26°C assumed) at standstill Pos. Shaft position at operating temperature ( 85°C assumed) under load Ve 7". a ore Tea aT 30.08.1993), ‘TuRRO cEAR "700.32005, fone | Rin isan NaI [Pe [PSiee|"an-so pis379899 al sights ‘document MAAG Gear Co,Ltd reser in connection with tis L >| L | bl GENER: muropyarron ‘The srincipal features of this MAAC curbo gear are: Gear case: Gray cast izon, split horizontally at the height Gf the shaft cencers. Bearing caps joined te the lower gear case by means of stud bolts. Drilled integral lube oi! passages to all bearings; goar mech-lubricstion by internal piping Inspection cover in upper gear case. Gears Single nelical, case-hardened and ground gears of forged alloy steel Bearings: Pinion shaft ‘Tilting pad journal bearings of design WAAC (rRTPAD) "Seepage 700,32002.27/28 Tilting ped thruse bearings ‘eed chase Gylindrica? journal bearings, split, the two halves fitted with stepped joints. Titting pad thrust beatings All bearing surfaces are white metal cast on free! seals. Batfle plates, split horizontally, fitted ia lower and upper gear case. Shop cost run Every gear unis is given a full speed work test at specified lube oil tenperacure and pressure. All relevant opersting data are recorded throughout the test and the Customer is provided with a full test recerd to Be forwarded to the responsible plant personel After che rest rin the nearhay in complaraly ess: end 11 parte visually inspected eR para esse Fes | “turbo dear Ksu 70032002 Tan — fe Como nA g inconnestion with | >bbe>bpbbb 4 otherase the clean gearbox is treated test run Zora storage up to 18 . Walvotsne Oil produczs used exclusively: S11 M for ali bright internal surfaces except bearings TECTYL 873 for all bearing journal surfaces. (A hon-drving conservant, i¢ allows free turning ofthe shatts during alignment) TECTYL 506 for unpainted outside surfaces and for spare In addition che free shaft ends are wrapped in a special protective paper. All opening in the gear case are plugged oF covered by’ flanges. Storage end handling On arrival at its destination the gear, under supervision 9f a responsible representative of the customer, should De inspected for damages incurred during transit. The tectyl coatings should be intact. If a gear is found te be damaged on arrival, MAG cust smnediacely be notified. If gear is to be stored it should be placed on a level base in @ clean dry room at as uniform a tenperature as, possible, ‘Tha gear ic to be Lifted using the Lifting luge at the Tower gearcase. (See figure below). Do not use Lifting lugs on upper gear case to lift entire gearbox ‘gearbox Proper lifting lugs are colour marked (vELL0K) am Daa Turk, su 700. 32002 MARE 1 5.Por storage Eeyond 10 renths oF conditions, euch az seaz"de storage oF open aiy storage (to be specified ty client), che storage under exerene hods are employed: following conservation 48) TE gear is co be stored fully assembled g or equivalent for all internal surfaces rant suztaces ‘Tecty1 506 for all pare z 3 é 3 with rotors and bearings removed From casing and packesed in special wooden ‘crates: IUERICAION £276 iants 3.1 bube ott ‘The Tube oi} supply for che gearbox is integrated in the lubrication syscem of the installation with common monitoring of pressures and temperatures ‘The Iube o{1 used must alweys be a high quality turko- machinery lubricating oil of the following specifications DIN S181 Group TD-L Viscosity: as shown on data sheet 1,2 (DIN 51562) Load carrying capacity: Gear test F2G 4/8 3/90 without. failure until load stage 5 ho EP. - fitives (DIN 1354) MAAG Gear Ca. Ltd. reserves al ‘in connection with this document. ‘The lubricating oil must be free from mineral acids, alkalies and asphalt os well as “free waver" No oils containing EP-additives may be used ‘The lube oft should be filtered to 25 microns or better hewaion with centrifugal purifiers recommended for extreme 7 cireuastances? 4 Ge, gerrbones ogre eyoten oll pressure, and seauired gear cs the header pipe or gear case’ flange, emis ori fiee ae 4 Slfendy mounted during the shep Cesk run and Giiaata fecsrdea 4 ‘The of1 pressure given on our daca sheet 1.2 is always the Bressure’ before the orifice. (avaten pressuse). The Stickies =A Eige is always’ Listed on coca dnser P'S The orifice plete is permanently and not to be removed during inspections or avernauls. 3.3 OU return piping ‘The geer outline Grawing listed on data sheot 1.1 shove the number, location ana size of o11 return pipes to the sump which are required to assure an adequate ie. immediate Greinage of the lube oil from the gearcase. AE least one pipe must lead directly to the sump. The elope Of the piping’ should be at least 1,10) A full pipe diameter (equal to gearcaee outlet diameter) must be retained over the full length of the return ‘The consequences of an inadequate drain are oil founing power loss, temperature rise and eventuel damage to the Soarbox. [recs ] a —_ rae ——] — Turks Gear si. 700,320; —— Hae Oi ROTOR Pane MBA 27‘The oi1 pipes and passages are created with the samy corro- sion protection as the gear parte. ‘he lube oil syscen should therefore not be started-up or cleaned before pre-commission ‘lushing. MAAG Gear Co, Lt. reserves bb ob Lb | L [nan | Resoex neice by SS | 26.03.86 ene [turbo vear xsi ‘rau. 32002 MAA 1 8in connection with this document. Telcos Preparation of gearbox Before installing the gearbox on its foundation base the bateide ia to be cleaned and the corrosion protective coat Sag removed from the unpainted outside surfaces (shat ends} by solvent. Gears treated for regular 18 nonths protection need x0 Geside cleaning as the thin film coating will easily be Tonoved during the pre-stare-up flushing of geartrain without harm eo the lube oi Gear treated for long term storage as per special agreement have to be also cleaned inside. ‘The cleaning should be done Shortly before flushing ¢o maintain corrosion protection as ong as possible, always taking conditions on site into consideration Foundation ‘The gearbox mist be installed on a solid rigid foundation Wihich is capable of absorbing reaction forces from torque Gnd chrust with minimal deformation in order to maintasn ESrrect dear shaft alignment resp- gear tooth contact. The fost suitable type of foundation to fulfill this require ment is a elded steel frame bolted down and enbeddes ‘The base frame support pade for the gearbox mist be na- thined accurately in one plane. Setween the pad surfece and fhe gearbox solid shin plates are recommended to allow for Jeter vertical corrections in alignenent. In order to factlitae later nachining (for realignement) the shom plates should be of at least 10 am thickness. Solid compact Bhim packs my be used as second choice. ‘The machined pads of the base frame sholld provide a level and undistorted support surface far the guarbox ‘To compute the correct alignment of the gearbox to driving and driven machine it hee to be considered that the centezs Of the gear shafts, when operating under load, are aot only Gispleced by thermal expansion of the goar case but also by Gynamic forces on the geartecth. ‘The values for shaft dieplacenenta fron rest at ambient Tanperature to full load operating condition are shova on the data sheet 1.5. These vertical and horizontal geur Hepiacemcnee have co be subtracted. tram rhe groweh figuresor the coupled machines to obtain the final Alsgnment Specification for the train pe TT [Daa 36.03.96 ane | Turbo Gear RSL 700.3200 i 2MAAG Gear Ca, Lt reserves al i in connection with ths docemen "esas Procedure of alignenent is usually as follows After setting the gearbox on the base trame it is roughly aligned to cold elignenent specifications and the follow ine Checks carried out for the frac eime Setting of gearbox The gearbox must rest evenly on all support pads, resp. ahim plates which of course are of exactly equal’ thickaess No gaps (feeler gauge) between gearbox and pads are acceptable. After having verified correct. setting of earbox the foundation bolts are tightened for check Checking of geastooth contact (MAAC personal recommended) Im order to ensure good surface contact of the gear ceeth over their full height and width under dynamie Sperecie gonditions of load end temperature, the load carrying recth Elanks have been ground with profile and longitedtscy The asseably drawing of every gear unit (1isted on data sheet par. 1.1) shows with @ sketch the proper no lose booth contact with the gearbox at ambient temperatuce, This | Eooth contact, is established during manufacturing of che gearbox with the gearcase in level and undistorted oss tion gad must, always be rechecked during installation on site to verify the correct mounting, a few consecutive teeth on the gearwhee! end ell pinion Eeeth are degreased and s thin even layer of engineers blue gpplied to the gear toochflanks. ‘the wheel is then sotaree #0 that the blue teeth pass through the mesh several eines with the pinion shatt being braked and pressed down in the bearings by hend. ‘At the pointe of tocth contact the engineers blue wiil be transferred to the flanks Of che Anson teeth. the contact patterns for the tooth flanks, so obtained, should conform approx. to the sketen on tne gesenbly drawing. Any deviations are caused by incorrect foundations. The appropriate carrection= should be made by changes in shinning betwoen gear case and support Pade ard the check repeated. Thereattar the atsanmmt af the gearhaw ie finalized and the blue-check repeated if gearbow has been moved. A permanent record of the pattern is to be mde by sticking Exansparent adhesive tape along the pinion coath. the pattern will be tranctarred ta the tape which con be Fomoved and stuck onto paper. ‘This record can chen be kept for comparison with futuve checks, Note: Blue-checks are alweys made with the gear unit descoup led aT be Gear KSL 700.32092, 206.1.2 Bearings sal journal bearings ‘wheelshate) A vioual indications of vear is of course the abserce of the Scraping narks on the whize-metal surface. however a few polished spots at the botcom of the bearings de not’ usually indicate wear. They are causee during seart-op and ore cormon on searings of heavy gears, serves al sights gn approximate check of the bearing clearance can be made by mounting dial gauges on the shaft journals adjacent o gach bearing and recording the movement when the shart 43 being Isfced. ‘this method ie not entirely accurate sr dee Pendable also oil tilm is not considered, bearing war is ot necessarily in the vertical plane, nor does it have to be across the full wath of the bearing’ ‘in connection with this document MAAG Geer Co. Lia Measuring Rearing Clearance a} Remove rotating pares (see par. 6.2) 'b) Replace and tighten bearing caps on bearings. | tae ©) Measure bearing bore diameter norma to bearing Separation with inside meroneter (Smooth white-metal surface before measuring as re- quired) @) Measure beering journals of shaft and subtract from bore Sianerer to obtain dlametral clearance |p| UL P| ed ilting cad journal bearings (pinionshatt). see also pages 700.32002.27 38 Ronove each Hearing pad assembly and measure overall thichness of bolted ped with shima and pivot place, the original dimension is masked on the side of each pad Te is generally recommended to exchange both bearings of a geven shat in order to avoid corrections of tosth keaing and gear traia alignnent an | fof ime 6.1.3 Beckles! Backlash is measured with the gear case upper part renoved. = One dial indicator each is mounted perpendicular towards a — Sonvenlent eootht lank of pinion and” gesemnaet ens mee, == is" then rotated manually Ehvoumn Teche eye tic eRe Gicteronce in cial readings represenes Sheree zak [>] SETEITON: Fe fuenion of Svein gaan fo13 ga vac | Eknot"fapetced by enlarged beetinan ee eeetge ‘ie teeth cory. due 26 Dearie wart ae Saat [ras] iseuaaa| SS [26.03.38 re t Turbe Gear KSL 700. 32032 WARE I 1Backlash on gvars with con-adjustable bearings is Sutonae:celly correct. Om gears with adjustable beaings it is necessary vo check the backlash between gearveath after avery change of bearing shine or after installation of Spare bearings ‘the min. allowable backlash is noted on the assenbly Growing of the gearbox. as a guide for ellowable max. backlash use twice the noved mn, figure 6.1.4 Gear mesh Iubsication ‘To inspect epray noles in gear mesh lubrication pip:ag for obstruction, the gear case upper part and preferebly also the piping itself have co be removed. MAAG Geer Co. Ltd. reserves all sigh in connection with this document | ry SS [[Link] Vee | “twrno cear kot 700. 32002 i [ee asa Na aor N Pane MARE 20MAAG Gear Co, Lid. reserves al in connestion with tis docu! Abnormal cooth ‘anage: Scoring Corrosion Overheating Insufficient visco- sity of 2ape oil Chemical:y agressiv Of lube Insufficient lube oll supply to. gear Backlash £o small. (adjustable bearing only) Impurities in lube off (metal particle: Grinding cust, moulding Send, ete.) Contact supplier change oil Have 041 ana- lysed. 26 neces- sary change of), oi) quality oF Supplier Check oi1 system clear spray holes Restore proper Backlash’ Clean system and gearbox 9 Tooth fractue Baproper tooth Toading? Shock loaé due to Foreign body passin tooth mesh Fatigue failure starting st local- ized fault in cooth aurtece Gintticees or metal Jurgical! Install replace: ment rotor end Fostore proper tooth concert Tae a A 6 Turbo Gear ssi 70032062 16 many 6.1 Inspections 6.1.2 Gaazeooth coneact ae the first opportunity after commissioning, then at least dace every year che contact sattern of the Joaded tooth Seb be checked visuliy, This can be done easily Sa the snspectson cover from che upper gear case (see par. 5.2). ‘the tooth flanks should show a full width even meshing pattern with no sign of corner-loading. For best evaluation Gf tooth bearing the teeth should be cleaned and side Lighted by torch. 1 one-sided tooth contact mey eventually lead to ofl £i2m E,Bakdow with scoring of toothflanks or excessive Tocalsted Stross with tooth =eakage. | A oinsacrefectory tooth contac: should therefore immediately | be corrected | Bearing wear, even within permissible limits, my already Cause a one-sided tooth pattern. So will unstable founda~ {fons welch may require gear cooth inspections at more fre- quent intervals. MAAG Gear Co. Ld, reserves ali in connection with this document, Ef the sheft bearings and foundation are found in Serviceable condition process as follows: fa) adjust tooth contact by shinning gearbox appropriately: Retignten foundation doles Re-apply red coating to sane teeth atter degreasing the foorh flanks wich tri-chior or equivalent tse: DYKEN LAYOUT RED Dx 296 (one can supplied with every gesrbox) » Depending on anount and lecation of correction it my be Recessery co realign all oF pare of the gear train, 4) After vunning the aenr for 9 few haves ar | pswbuon high part load re-check the tooth contact pattern. For additional information regarding gear tooth bearing | problems contact HANG Gear-Wheel Co. Zurich, Service Dept. Lt tears, Eelex’ 22704 mazch telefax 01/278 78 80 phone 01/278 78 78 al i [Resins | =p ri ose SS [25.02.26 "Purbo Gnas SSL 700.3202, == se re a NETO oe MARE | 18flow-through lubrication . ___ | fosseece case nae 2 | fe TE | | Rich bearing ngusticient 0:1 | check oft systen ZE | | tomerscare pressure 20 beorinod inerease oft BE Howto asarbox, | 38 eniarge orifice i tnocseec: bearing | correct to gE clenrance nominal 82 Insufficient 1ub- | check oil cooler 38 ricent cooling” | Clean waversise |, of Excessive nisenigne-| ne-align gear $5 enc of train fe | ao | Bcessive heat-up eo nigh 911 stow | check oi1 pres- of gearsen Sure check if orifice tanore Fetes) Ace baen x fistakenly re: “on miseal r Tnsufficient oil Enlarge or re Al feeuen Gerange Serta A Bipine A Foaming ef tubo oi! | change tube oi2 laser Seform os oie cA biter [ 4 rN Signs of wear on Insufficient ‘Check lubrication geek cowrlings wien | Huaeieaelst Systen,eapestaliy Spray nostiss. Dire accumlation | Clean coupling install ada:- tonal etter or centrifuge. Shatt~misalignnent | Re-align Fehler shafeiag Passage of electric | insulation of Receeaaty fnocana Blip’ ring SS [Besos “Exe [rust Gear ao 70032099 = Com aa WARE 15 |* | PS ‘108 | possIELE CAUSE ‘REMEDY 2. 5 — : § | | Sivcacions etere ex wom | Replace besrings 33 beletis He efece tooening | Insta spare aS rotors gs unbalance Re-balance shafts 33 oe Bent shaft Check runour in ee chee Teak H SHEET fotons gs waar of geercoupbing Refer to sestiont zs unsatisfactory gear | Make no-load ones geneeee” (habe Cobth contac Siturment SSeS Sade eee eat arian | Deformation of gear-| Check foundation I ‘Al case t Al) 6. Ai) [Noise Detect toothing | anstall spore 4] Peters ry ai improper tooth | Readjust tooth 4 contact Sontact; ence Tal ‘Sorter toacingy | Founsston i A Defect gear coupling Refer to se:tioné dl 4 defect ott puro | Check pump ana = (lrece driven’ puny aeive, af neces oniys Sary feplace, = Gearcase distorted | restore prover navn | Gerestfaciey in | focth contact, (tess than 908 of Stanieeion oF Eheck Foundation Coste Shatner fa | Shnnges an founda oeal ete Bearing worn or mis-| Replace beerings =a aiigned re ceerect sligmest roe laonaae| a aa a —— 36 Et | turbo Gear KSL moo 31002 MBRE ! 16MAAG Gear Co. Ltd. reserves ol sights in connection with this document, epoca] uo p)_Afcer severs! Nourse af ful: load operation or, if no Dar:-cad cuocks were powsiale, after max, one howe o full load, che tooth contact pattern is co be checked again. Te’ should extend over at leact 904 of the face width wsthous indicaezon of heavier loading to ene side. To correct an unsatisfactory tooth contact patern the Gear case is to be shinmed stepwise at the appropriate Guarser, ané the procedure sepeated Corrections of the geartooth pattern by internal modification (Lowering a bearing) nay only be carried out by trained personne Monitoring the lube ofl pressure Manostar settings for alarm and shut-down are given in data sheet pars1.2 ‘The oil prossures mentioned always refer to the system Pressure, ive, ahead of any throttling device (orifice) wnich may have been Fitted at gearbox inlet. (Ordésce Plates if used are mentioned in deta sheet par. 12), Operating oi2 pressures somewhat higher than the specified normal pressure are acceptable provided the oll resera Biping to the sump is dimensicned for unrestricted Sraining. Monitorino the temperatures ‘The bearing tenperatures measured at the shop test run 0 Rot allow a clese astimate of she temperatures measured at Full load ‘Therefore we recommend co set the thermostats after heving established actual full load indications, considering ales the excepead oil inlet temperature fluctuation Alarm secting ar 59°C (9°F) above actual normal ful Load Temperatures are not be exceedad: Shut-down setting at 10° (18°F) max. above alarm setting. In due consideration of hearing metal strength the Following limic tomeracures are not to be excceded: Alam shue~down Thermometers mounted sore "100°¢" vertically in wells Gary (212) ‘Thermo couples or at mounted 130°C ass'c into" loaded bre. zone (266"r) (75°F) The gear train s furthermore zo be shut-down in the event gf temperariire :luctuation at constant speed. load and cit inter tonperacuze. Dar Tame ean 6.03.86 or | “turbo Gear ssu '700.32002 faa rm aT‘The set=ings for alarm end shut-down are to be detemined Guring che comissioning of the gears. They should be set Tow as possible bor suficienely high so as not to shutdown the inseellacion during sransient instability. As @ guide co vibration Limics use a) shat vibrations: ALA RM 2 times the spec. KPI Limit’ tails/pp) SHUT-DOWN | ‘slavm setting + 1 ail b) Vibracions measured cx lower gear case MAAG Gear Co, Lt. reserves al rigits in connection with his document vor - 2056 (oct. 1984) © Ho fe = G0/WGS-NL9E (Febr. 1962) 5.7 Trouble shooting a oasERVARION POSSERLE CAUSE Ree ill [a ‘All | Hasueeiciene ox Worn of pump overhaul pu ifeeguiar Tube oi A) | pressure I oversiow valve | Check agiustea Lay froken or nal: | or repair 4 aajuarea |__l Restricting filter | Clean, if rece A sary repiace rN eartelage Air in punp suction | seal 1eax the axon tow oil level in | Pind cause, some peril | Leakage of lube oi1 | Repair oF seal = pipisg | Insufficient oi1 | increase orifice flow size where feted: raise | E supply pressure | a opacd | en urbe Sear 1st roo. 32002 — Te OGTR TEGR Pe MARE | ieMAAG Gear Co. Lit. reserves al rights in connection with his After the gear cooth contact, with gearbox firmly tolted to base, has been accepted by the responsible personel, the inspection cover is replaced and carefully Sealey ‘The gearbox is then secured against lateral dislocation by Snstalling the locating keys at the base flange taes outline drawing listed in par, 1.1 for mumberend iacation Of Keys), the keys are fitted to the indiviudal tees withour side clearance but sone head clearance ‘The holes in che foundation have to be drilled to the sane Giamete: as he holes in the gearcase flange using te latter as guide. Then the hole is reamed to the Tequired Sienecer with s caper of 280 After the gearbox is permanently located in place the shaft couplings and the lube oil piping are connected ep. Note: If the gearbox, is not to be started up within days after checking’ the tooth contact, the corrosion pro- fection of geerteeth is co be restored especially oe severe anbient conditions prevail at sice > ie 3.36 [ome ["husio cane seu = fag. aa0%2 im = sare =