i) 6801 SERVICE MANUAL JULY 1961 For installing and aligning GRE oe THE FALK CORPORATION MILWAUKEE 1, WISCONSINFor Lang Life and Optimum Per! This manval shows in simple steps hew to check single helical, herringbone, or spur Cleoning — All teeth, mounting, and mating surfaces, must be thoroughly Geared before imtallation, Bumps and tures that may have oceurred in transit must be removed fo insure prope’ o& Sembly and tooth contact Geor and Pinion Match Marks. Folk plt gear halves must be assembled with the mating surfaces in the some Postion os when the teeth were cut. To ESure this rorul, motes the identical rombers ond letiers stamped on one Split of each gear half, in line with on Gignment bolt; ex ssown in Figure 3. These match marks are elso stamped on one shaft end of the mating pinion When assembled in the correc! operch ing position, the match merks on both gach and pnson Wil be viable on the Jackserews — On ring gears vsing jeckscrows in the bore of counterbore of the mounting lenge, place the screws inte pesiion before mounting the geor = ‘Wrenche: firall bolls 12" Tone, template of stalling kil a @) = leaves ran 200" thich black or hommer for final tightening. Machinist Level — At leost Thickness Gauges — With Contact Paint — Use tube of Prussian blue pigment, lamp formance, all gears must be installed properly and aligned accurately. ‘clignment and tooth contact during the process of installing Ting gears with generated teeth. The steps outlined herein should be Sudied thoroughly by ereetors and mechanics before, and curing, the instellation of gearing IACRSCREWS Figure 1 this , or me 2 iz igure 2. HERRINGBONE GEARS 15 Select wrenches 10 ‘ond nuts, Use sledge 18" preferred, Make f slope For level if in- in or dryer. 1ging from .0015” to is Shims — Usa shims starting ot "005" thick ard upward for ted lead and oil Apply with a brush. po ‘Two Dial Indicators — With 1001” greduations and at least “050” range. Be sure to use o ibutton shoe on indicater. Tool Post Holders — Check positions for mounting indicators nd provide tocl post holders, Upright spindles, ond several Clomps te suit, (Magnetic bose indicetor holders are usually easier to use.) to the driven equipment, as illustreted in Figure 1. On split geors, determine the correct mating position of the gear halves by observing the stamped match marks previausly referred to, so thet all jockscrews are on the same side of the gear when tt Is assembles. Falk Steelflex Couplings — Before pressing the coupling hub on the. inion Shafi, make certain that the hub cover ieiplaced on the shaft in the correct po- sition, Instructions fer inetallation and maintenance of Felk Stealfiéx Couplings ore published in Falk Service Manuals 4800 (up 10 Size 190F) or 4801 (Size 200F ond larger) Herringbone Pinions and Gears — Before mounting the coupling hub on herringbone pinions with symmetrical shaft evtensione, rafer to gear arrenge: nen! or assembly drawing to assure that the hub is pressed on the correct extension with ralation to hand of helix See Figure 2. arin Beateg podestls Pe PRELIMINARY INSTALLATION INSTRUCTIONS FOR SOLID RING GEARS Recheck the mounting flanges on geor ond driven equip: ment to moke certain thot any bumps or handling, cre removed. Secure the goat PAGE TWO. ‘burrs, incurred in ito the mounting flange with every fourth bok Frocoed with the same align ment ingtructione as indicated for split ring gears, Steps | thru 5, Pages 4 thr B. conn 161 THE ALK COMORATON ihe MUSA sits ceaPRELIMINARY INSTALLATION INSTRUCTIONS FOR SPLIT RING GEARS Mount One Gear Half —Recheck mouating flanges and remove ony burrs incurred in handling. Secure the gear half to the mounting flange with evary fourth bolt. Rotate the mill or kiln so that this gear half is positioned on the bottom with the splits in a horizontal postion, Check Clearance Bolt Assembly — Insert a clearance bolt from the top of the split inta ona of the clearance holes, lo cated noarsst the aulside diameter of the gear half, Ifthe bolt will pass completely through the hole, proceed with mounting the other gear halt, I the bolt will not pass com: pletely through the hole, because of intetference al the in side rim diameter of the gecr. all clecrance bolts will have to be inserted into this half (as far as they vill go) before the other gear half con be assembled. REFERENCE MARKS IDENTIFYING SURFACE FOR CHECKING RUNCUT res ALL ALIGNMENT BOLTS MUST BE INSTALLED BEFORE ANY OF THE CLEARANCE BOLTS ARE INSTALLED. ‘An alignment bolt assembly consists of; Tapered alignment bolt Split sleeve Two washers Two standard nuts Two lock nuts Four af those assemblies ore furnished with each gear, CAUTION: DO NOT DAMAGE THREADS DURING ASSEMBLY, Mount Second Gear Half — Make a final check for bumps ‘endl burrs on the mounting flanges and mating surtaces of both gear halves, Bring the escond half of the gaor into position. Assemble so thet the stamped match marke all ap- pear af the same split. Secure the gear half against the mounting flange with three botts, one near cach aplit and one 90” from split. These kolts should be snug enough te insure metcl-to-metal contac’, but not so fight that this gear half cannot be shifted slightly. Align the Pie Pa yp pt READING | = RECOMMENDED BACKLASH (CLEARANCE) at BL and BR Tele 28, Centied Refer to Table 2A or 2B ble 2A— Soler Sipperted Aaplicotions Temperature | 5, -e4eai |___ Geer Cantor Distance Inches to determine the tecem- [ianawal | Gear CouerD Bitrontal || Dipper spoce provided in the * 135-18 ae ririo 90) JM—hyp | 50-088 | ves— mys) 19 le 2B — Trurvon Supported Applications | oe age | Am AO] TET Pesan lah ove oe | ale 675 | ‘095 105) 120-190 Temperate Tp ss tonior | oe SS] gots) IS) @® ~ a 70080 te a0" | Aah ene ap’ or use | Mie | 24-058 es —073 a 135145 renee ame | renee) oe Sew 0 | ae | bao 080. “cso 090 a ba ef) 3 4” | 935-005 _ Dianetral [Terpereture|Recomnendea| Sint Pinion toraueel Fry 0980 [Poa Cio [teeta Te Comins | Baevach | row 0 feeler gauge between the | Postion Pacts ition ¢ 7 near zero measurement at CL and CR a oR o ie a am cs a BR, os determined in Step 2, Service Postion Short | FINAL CHECK FOR UNIFORM CONTACT PATTERN Apply a thin, smesth coat of colored pigment to five or six pinion teath, as described on Page 8 of Service Manual 801. Rell pinion back and forth to trace o contact pattern con the gear teeth. The contact may be scattered but should show across at laast 80% of the gaar face. Indicate below the station number and sketch the contact pattern traced on the gear teoth. Repeat this contact check ot throe more points, spaced 90° aparl. Also sketch below the pattern that has been polished on the colored surfaces of thé pinion testh. A minor pinion adjustment might be required 10 pro= duca the best average contact fer ail four stations STATON NO. STMLON NO. ‘STATON NO. STAMON No. lon TES S| se ) ) jE U zy PAGE B THE FALK CORPORATION, BOX 492, MILWAUKEE 1 WISCONSINThi: mest favorable positions on the gear for checking tooth contac! with the mating pinion are these where the maxi- mum plus (+) or mazimum minus {—) rim face runout is ob- tained. See example shown on Page 5, Rim face runou's generally follow a sine curve, the patern of which will vary depending upon the starting staton on the gear, A few 'ypical runout readings plotted on a graph are ilustrated in the chert an Page 11. Tha number of euch runout pat for a gear is equal te the number of stations For gears used on rod or boll mill applications, Iners should be in the mill before the pinion is eligned to the gear. Bring Favorable Checking Station to Mesh Point — Roll the gear to bring @ favorable checking station (which Is the one wth sither maximum plus (+) of maximum minus '—) rim face runaut reading} te the mash position. The mill should be pulled in the direction of its thrust, up against the trumnion bearing thrust face to enable the gear end pinion Faces to be aligned, Place the jon — Bring the pinion shait inte epproximate parellelism with the gear axis by leveling and preliminary shimming of the beorna pe estols. Next place the pinion into mesh with the gear for tefting of contact and backlash, If the gearing & sngle helical, the bearing caps should be romaved fo make ture ‘hat the thrusting is in the correct pedestal and that the frea bearing isin the center of ils axial Host, Where lockuts ara used te secure the bearing, check for tightness and make sure the lack fob on the washer is secure Torque Pinion to Gear — Fix gear to prevent ratation and torque pinion fo gecr in the actual direction in which + is fe operate, as ilustrated above and to the right. Ifa her- fingbone gear, make sure pinion apex centers on gear apex. This is done by barring pinion back and forth endo 'o make sure it is frae to float within the bearings. Ant: fricton becrings should te free to float and centered in their pedestals when pinion is centered against apex of geor. a ce a cout, “fi 8 tecsuting H 7 Clearer on Becklath Side, BL ond 3R contact and backlash must be done simultanecusly. Select the recommended becklash requirements from Table 24 or 28, Page 6, and proceed a: fallows, With pinion torqued firmly ta the gar, cheek the contact tand bocklash side of the ‘eeth at the mesh point, This is done by drawing a fecler gauge between teeth as shown in the sketch below. Adjust pedestals until a near zero feoler measurement is ebtcined of Cl ard CR, anda neer ‘equal backlash within the recommended range ot BL and BR as shown in the example below, Measurements should be made at four paints an the geer 90° apeirt Example: The exemple below short the contodt and backlosh meat romans taken for a trunnion supporied mill goer set with 106” enter dstarce, 1¥4 DP, 30” Fonrerhel! or ls tempercture dienes Fal, From Table 28, Page 6, the recommarcled baeklosh i, 055" - 734 tobe provided on Page 10 ofthe Handy Wk Set for recerding acival measurements EXAMPLE OF CONTACT AND BACKLASH FEELER GAUGE MEASUREMENTS Contact Beste rite ce car. | iusto [art [Tue | Oom Relative to Mesh a @ a 8 Starting Position | oso” | ace” ow | oar ‘90° from Storteg Station ow | oo ox 180° ‘rom Starting Serion ff cor” | ooo ora | over 270° rom Starting Station oo | cco Yom | oarAlter establihing pinion alignment with pedestals firmly se TYPICAL CONTACT PATTERNS fored, make a final check for tooth antec fo assure accu: * fate gear alignment. Apply a very thin, smooth coat of Prussian blue pigment, lamp black, of red lead, to five or six pinion teeth, previously cleaned, cz chown below, raking sure entire. profiles of teeth are covered across face. Roll pinion Bock ond forth though the mesh several tines to Trace contact pattern on geor teeth, If motor power is not noilable use a torque arm, and “bump” teeth on both sides {pinion fs ralled back and forth. The contact potter may be Scattered but should thow across at least 80% of the gear face, 02 sketcnas fo the right show Single Hat Double Helical Aitor @ salsfastory contact pattern is established for the initial position of the gecr, the same contact check should be made at three more ponts on the gear, spaced 90° oper A minor adjustment te the pinion may he necessary te produce the best average contact on the geor. Inspection — Dowel all bearing pedestals and recheck all bolls fo secure gear setting. Inspect gear leety and remove il metal upsets and burrs which may have occurred in hend- Ting or assembly. Clean gear teeth and enclosures thor ‘oughly before enclosing gears Ifit i not posible fo use @ feeler gouge dus te space linita tions, proper contact pattern must be cbtcined by the trace method described in Step 4, Sotistectory contact patterns Fe shown in sketches above ‘After a cortect contact pattern has been established, check the backlash with an indicator, o& shoven in the illustrations. Determine proper backlash from Step 2, Care should be exercised in adjusting pedestals to establish correct backe lash, Use indicators et each pedestal for equal in or out movement to as rot to offect a change in contact setting, Afler proper backlash has keen obtained, recheck contact cos deseribed in Step 4. we Operation of Gears — Alter full lood is applied, it cim. Lubrication and Maintenance — Periodic inspections roriant fo recheck tooth contact periodically during the first should be made to assure: {ew hours of the tunningsn period fo determine the effect of (1) that proper tooth contact and adequate lubricotion eny serling of foundations, intial weer on bearings end to ero maintained) ctrute proper lbrcaton. iFminor adjustments are required, (2) that for split ring gears, the two halves are held procedures oullind in this bulletin for checking tooth con- tightly tegether af both splits. fact duting instalation should be followed for final inspec. See Falk Lubrication and Mintenance Service Manual £801 fion and readjvstments. (1961) for information and recommendations.This Work She ‘been tenected so all readings cun be pol for each sot of gears, Add Two indicators aro usad to check rim face runout when equiament has enc fleat in its bearings. Place indicators “A” ond "B™ squarely against the rim face stamped (000) 180° apart as illustrated, Set Uoth indicators of zero. Revolee gear ond record both readings simultaneously for each stamped station for one complete revaluton and record below. After one revolution both indicators should tegister within .004”. If net, repeat the check as indicators may have moved! Procedure for Runout Determination — The rim foce runout ie calculated from readings "A" and ""B". Record the readings from indicator "A" on line 2 and the readings from indicator °B'" on Ine 4 (uve she First four lines for a gear marked with 8 stations, ute the second four lines for geor marked with 12 stations). Retabulate the “"B" ‘readings (line 4) on line 5 with plus end minus signs reversed (+ to, — to ++). Next repeat the “A” readings (line 2) con line 6 with signs as originally recorded. Add the valves from lines Sand 6 and record on line 7 as follows: 1. Whee the (1) value is larger than the [~) valve, sublract the {} velve end the results|}. 2. Whore the (=) volo i larger than the (4 value, subtrect the [end he rosul is 3, Whoie both voluos are (+) edd the fo ond the result i (+ 4, Wheie both values ae (~) edd the wo ond the result Is (—). 5. Where the (4) ard (=) valuee ie equal, the result is zero 2 [Recta 6 A [valng NDIGATOR | St2T10N Ne 8 [iain UNE @ SIGNS verse | 02 NUS REARING minus ranenaines senreR 00 Pee FLUS(HIREADINGS 4.029} If gear cun be rotated without end float, place indicator squarely agains! the tim face stamped (000) et station stamped | and set fo zara, Revolve gear slowly, record readings at each station on bt a summary of Service Menvel 6801, The charts ané tables have sanontly tecordad, using one Work Shes? ional Handy Werk Sheets rood within scribed in Stap 1 6801.01 eT WA ed ETE TULY 1961 en Or Pore Fe ew fai | ee oh a oe [yh em ve | oo Ay ia yl ae | ae | 8 eh a |e a} 8 ae Divide the values from lina 7 by 2 and record the rasuts on line 8. These values ore thé rue rim foce runaut af the gear for each of the station numbers recorded at indicator position "A. They may be plotted on the graph below. Allowable Rim Face Runout is shown in Table 1, For gears operating ai 5 rpm and less the allow- cable rim face runout can be increased by 25 per- Cent. If rim face runout exceeds the allowable shown in Teble 1, correct hy shimming at flange bolts. eset | 002”, H not, recheck, o ute, method de. the allowable rim face runout is shown in Table 1. The totel rim face runeut is the algebraic difference between the chart below. After ove complete revolution, indicator should maximum plus (+) and maximum minus {~} reccings. waren none [1 | 2] 22 >«)?7 )))* Le pu fe [a READING [ [ I IHANDY WORK Place the indicetor square with the outside diometer of the gear SHEET CONTINUED ‘a station | and set to Zero, Use button type shoe on the stem Ouside [lowatle fend use minimum mitial tension 0 thos the stem will glide over inne] the teeth. Where machined surfaces are available en the gear / |-1Geor|. toe rim such a8 a se0l ring clameter, counter bore, or the gap die Loo) | test fe meter on heremgbone gears (see shetches), indicator con be set ¢ |] ae fegainet theve turfaces for radial runout check. i Revolve geor slowly and record readings at ecch station in char! 3 | 33 below, After one complete revolution, indicator should read w | a4 Mita G08" et maken 1 Record the algebuate difference yf ag etwoon the maximum plus (1) and maximum minus (~) read- va fae ings in the space to the right. on counter bore te | ae | Allowable Radial Runout — The allowable radial einout is SM fin e shown in Toble 2. For gears operating at 5 tpm or less, alow Sy ees B| os 50% mere. Total radial runout is the algabenic difference be. — RSSY 1224 fa | ae tween maxinum plus (+) and maximum minus () readings. IF see papi RuNOUY radial runout exceeds alloweble, recenter the gear, using jack cD) . i screws, hycraulie jacks, or astew jacks, [Fervor cannot Be cor on gen recor you a rected, check mounting flange fer concenuiciy. coer wmowwnes [| > [= [a [>= |e [7 fe |» [ow fuye fo | READING, [ | Refer te Teble 2A or 26 TH A—PMlurSvppened Anteaters [Tpevatne Signeral cr _| fo. dotermino tho recom: [Sixavat [Gear Genta Daiace] | Diferernel | OR Tao | ai vo 100 mended becklash. fitch arte 80 ° ° Record this velue in the |e | Te | sam | oe) oe space provided in the $0 ag | 1231 39 | riete 90° | Wa) | Oe ie ete | io20 chart to the right, below. |_tya__ [13838 | 135—145| Hl p— 255 | c80 090 |" athe Alison 1 igg.10| 1755 to 1i0" a9s-cias | 1138138 Dinneyal |__ Geer Centr Datvco Ins areie 5565 | 100 | “12000 tech” [pied | tread | Aw WH 19 va] Tt | 5 ' 6780 | os—ais | “T35—s Tt ea 670 | O70 — co 111 te 190 03370 | lama | fas > Wars | 045 055 | 085 008 | 065 —o75 cae sor ortess | O28 | Sabie | oon | toes 085 O48 | 100 L J 4" [3 hde | eso | 135165 Teh Dom ta|BeBS |] ar wise Geis | so—1a3| ve aso | We fes—07s | oso m 18 a 950° | ae e070 | OR0 #0 —— co 070 2 : gs fe0— 079 Gear | Diamerat frenpootweltegonmended Got tad—om | T00—110 ecomumundlsaf, Centers | Phe” | Sierentiol | Eucosh sitoro | Mle 75-085 | 095103 a sie wo70" | 2" ME | SB 355 | cro om | 95105 3 =a" | ct—tse | oop Wh et i cg [Te [Ba a Gear [Ten [aon [teh | Riot | cf Gor [teh [rg | tei [Rabe feet. Adjust pedestals to obtain o | % et See | neor zero meaturament at CLandcR |e | cl | ce | ot | ak rh ace [a |e | and near equal clecrarce at BL and | Sariag TE" ren BR, as determined in Step Z, Service | Pasion | sen 2 fw Manuel 6801. Resord readings at Four | 2 fre Do aw 1 different stations, 90° apart Set | | Sint i ee dl FO 1 Apply a thin, smaoth coat ef colored pigment to five or six pimon teeth, as described on Page 8 of Service Monual 7 Rall pinion back end forth to trace a coniact pattern tn the gear teeth, The contact may be scattered but should show acrots at least BO% of the gear face. Indicate below ‘he station number and sketch the contact potter traced on STaNON NO. STATON NO. STATION NO. THE FALK CORPORATION, lenient linalinetetbener weg ng oe he sts 2 erg ee ae the gear teeth. Repeat this contact check at three more poinis, spaced 90° apert. Also sketch below the pattern that has been polished on the colored surfaces of the pinion feeth, A minat pinion adjustment might be required to pro: duce the best average cantact for all four stations STATION NO. PINION BOX 492, MILWAUKEE 1 WISCONSINRIM FACE RUNQUT PATTERNS generally follow o typicel curve as indicated below. Whether curve. The total runou! is the distance from the highest Typical Runout Cure, Zoro Reading of” Gl gTTIOM To Zero Reading ab ond 7 ‘Mow Ps Reed at 10, ny sTaTION ar doen doting of 1 ond. Non tins Reading 3 2 {ay STMMON 1 ato Zar Reasg o 1. No Mins Readings ‘ow Fis Reina? Lessse78 9 0Nn BI (M1 STATION 1 ot : ero Reading ot] doe, nse Bong ot 7, No Ps Readings Teta 2+. OFTHIS 35 NOT THIS SCRIBE LINES Seribe lines are provided on large Falk ring gears and Pinions to help contral running eloaranca (backlath) by vieual p inspection on high temperature applications. As shown to hy the righ, proper backlash (clearance) is assured only when reribe lings arg tangent of operaling apart, If seribe linge 5 overlap, 05 in 3, if ® necessary to separate the gear and pinion to provide necessary running clearance. AVOID MISALIGNMENT Misalignment in Plane of Centers: Misalignment at Right Angle to Plone of Centers IF gears ate missligned in plane of IF gears ere misaligned at right angles centers, pattern as shown in sketches jo plane of centers, pattern shown in Below wil Wevelop, Pedestals should le kelches below wil develop. To coved, Single tial DDoubis Heicat Single Helical Dubie Hatz moved 19 correct this condition and 10 and to obtain full contact across entire obtain full contact aerate entire face face width of ger, move pedestals width of gear.Heat Bolt and Check Temperature |) —Heot the center unthreaded portion of the bolt with an ace! yiene torch until the surface is uniformly heated to A TEMPERATURE OF 600" F., INCLUDING AMBIENT TEMPERATURE. Check temperature every 3 ar 4 min: uies with ¢ surfaces pyrometer. Use a heoting Hip on the torch, and hold the tip no closer than 112" from the bolt." Approximately 20 minutes is required for proper heating, Caution — When heating the bol, care must be taken to HEAT THE BOLT EVENLY. The torch must bbe moved constantly se that no area reaches a temperature above 400" F. Clearance bolts are heat treated and any reduction in. hardness caused by overheating wil reduce the tensile slrengih of the bolt Tighten Nuts Quickly ©) — After proper heating, sip the bolt into the hole and QUICKLY run a mvt on tha bottom threcde. Tighten nut with a wrench and sledge. Run on top ard bottom lock nuts and tighten with wrench and sledge. Install remaining clearance bolts in the some manner. After all bolts have been installed, the splits should be feeler tight {less than .0015"), After all split bolls are in place, instell every fourth flange bolt in she top hal! of the gear.F Koon Maintenance of Rotating Equipment: Maintenance of Kilns, Calciners, and Dryers Preventive maintenance of rotary kilns can be almost completely summed up by one word: alignment. RR. Pippit, Monsanto Co., Sods Springs, Idaho Rotary kilas are rugged, relatively simple machines, and as such are better suited to 4 preventive maintenance Program than to a remedial one, ‘The most important ob- Jeclive of sucl a maintenance effort is to assure that the eavipmant has not heen misaligned by setling er tipping of the foundation which, if zot corrected, will create prob- Joms with the kiln shell, the riding rings, the irurmion and thrust roller, and with the main gear and piston. ‘The kiln alignment. check should start with the top machined surfaces of the carrying mechanism frames, so shown ia Figure 1. The frames at each pier should be examined to determine that. the elevation in the same as when initially installa, tha: the slope is still correct, and. hat the frames level in the tranaverse direction It devia- tion in slope and transverse levelness are found, tipping of the pier is indicated. Depending upon the degree of de- Yiation, thought should be given to resetting the frame to the propor slope and iovel. ‘After the carrying mechanism frames elevations have bboea checked, the longitudinal centerline of the frames should be confirmed, Todo this, establish an offset center line along the side of the ila from the firs: to the last support as shown in Figure 1. The offiet of tae centerline should be at a distance so that visibibty is unobstructed, fanc at an equal distance from tho eentarline mark on the carrying mechanism frames on the two extreme supports of the kiln. Measurements should he taken end recorded from tho offuet ccnerline to the centerline marke on the fremesat all intermediate supports ‘Measuremeats for the intermediate supports should nor- imally equal the offset distance assumed at the extreme supports ofthe kin. If all measurements are not equal, one cor more piers have shifted, or on original error in center- line markings has been uncovered. A plot of the offset measurements ve. axial epecing of tho sapporta wil in dieate which centerline marks are out of line. The plot should confirm the shifted piers found during the elevation chook or should indicate the centerline marks that were in eror. Aller any pier eorrections or feamne reveling have been done, nev centerline marks should be plainly scribed to replace those which were out af line, CEP Februuty 1976 If the centerline markings for the two exteme mp- ports were true, anynew marks can be located by meastr- ing the assumed affeat.distance from the offeat line. If they ‘were not true, a new offiet lineshould be established, using tho two furthoct apert cupporta having true markings. Or proper distances can be calculated from the plot using Proportions determineé by the similar triangles crested between the converging offset Line and the true centerline. Shell alignment Next to be checked is the alignment of the shell, From th true centerline marks that have ben confizmod or os- tnblished, locate the axial reference lines on the slope machined surfaces of the carrying mechanism frames, These reference lines should be situated across beth ma- cchined surfaces on each side of the kiln at a distance ecual totheradiusof new riding ring. Lay a straightedge along the reference lines and bridging the frame on each side of the kilt, Using a pole exiending above the horizentel centerline of the riding ring, hold a plumb line against the outside diemeter of the riding ring. Cerefal reedings should be taken and recorded of the dis tances between the plumb Tine and the reference lines ex- teaded by the straight edge. If there distances are equal on-beth sides of the kiln the shell isin alignment at that support. The original di tance from the true centerline to the reference lines minus the distance from the plumb line to the reference lines is equal to the present radius of che riding ring at thet support. Ifthe distances from plumb line to the réference lines are not equal on both sides of the kiln, i indicates that the seis cut ef alignment at thet support. ILis out of alignment an amount equal t one-half of the difference between the two dislances, If the amiount of misalignment is relatively small, back off the earzying rolier en the side having the long dimension until the evo disiances are equal. If the amount of misalignment is relatively large, move both carrying rollers to the side with the long di- mension until the distances are equal.vio 2 ou ‘ Ti ua Sen vp wns cats eueaiam of snk, EL aa plerfgnh ne ie cetiin oe \ \ B as, Loceee zen aatis Figure 1. Kiln alignment procedures. Record all moyements of bearings; however, donot ‘make any adjustments of besrings before determining that such movement will not adversely affect the mesh of the ‘main gear and pinion. Tn some eases, the phimb line will sway when held against the riding ring. This can be caused by an out-of- round carrying roller or a warped shell. When this occurs, tho meen of the readings on cack aide of the kiln should be used as the evaluation distances until the mechanical Problem can be corrected. Tn other instances, large diameter carrying rollers may interfere with the plumb line held against the riding ring. In these situations, it will be necessary to make a simple jib to hold the plumb line 6 to 8 in, away from the zidiag ng. The amount the jib holds the plumb line away from the riding ring must be compensated for when the riding ring radiusis determined. ‘Aftar the axis ofthe shell haa been lined up with the true kiln contarline, the next step is to align the axis of the shell asa straight line on the proper slope. The foundation or installation of the kiln will indicates dimension from the ‘machined surfaces on the carrying mechanism frames up- ward to the kiln axis. From this dimension subtract the riding ring radii that were recorded during the shell center- 2 line alignment procedure. The remainder vill be the di- mension from the machines surfaces of the carrying mechenism frame tothe loweot point of the riding ving, the outside diameter ofthe riding ringat the kiln centerline. ‘This dimonsion in cheeked by placing a straight edge on iegonelly opposite machined pads on the frame so that the straight edge intersects the kiln centerline under the rigingring Find the shortest measurement that can be ob- tained between the gutside diameter of the riding ring and the underside of the straight edge. This messurement should be equal to the remainder dimension above alter compensstion has heen made for deviation of the carrying mechanism frame from the trus slope plane. If the measurement and rersainder dimensions are not equal, adjust both carrying rollers in er out equal distances until the required elevation is obtained. Equal movement of the rollers is required so that cxnterline ligament vill no: be disturbed. ‘Again, do uot mate say movements ofollers until it as been determined that the movements will not adversely affeccthe mesh of the main gear and pinion. At the thrust riding sing, the clevation checking men- surement.can be taken ty setting ascale upright on each of two diagonally opposite machined pads and then pulling @ CEP February 1978fn coolers and Sigh ond on kites ond Figure 2. Alignment of carrying rollers. ‘wire under the thrust riding ring so that it contaets the ring while indicating identical cimensionson the owoscales, Carrying rollers With the kiln shell now in centerline and slope align: ‘ment, the carrying rollers should be checked and aligned itnecessery, as shown fa Figure 2. A porfeclly aligned carrying roller is one whose anis is perallel to the atis of rotation of the kiln shell. Auy mis. alignment, or “out,” of the carrying roller introduces wear between the carrying rollerand the riding ring. The degree ‘of wear, of course, depends on the degree of “et” of the carrying roller. In the past, the thrust rollers on a kiln were a safety feature. The downhill thrust of the kil wos absorbed by cutting the carryingrollersand “floating” the kiln between the thrust rollers. This wana built-in wear situation for the conying rollers. For same years now, thrust rollers have bean dasigned to take the full downhill thrust ofthe kiln, but the pructice of “floating” the kiln has persisted, This practice should be discontinued, beeanse even if dene properly it has the CEP February 1976 Duill-inwoar feature; and ifit ie not done properly, t cen, lead to excessive wear when one roller cut too much in one direction is compensoted for by another soller cut in the opposite direction. When a carrying roller is aligned parallel to the axis of rotation of the kiln, the carrying rolle: and shaft will be ‘downhill due to thelr own weight. The downbill end of the carrying roller shaft will bear against the bearing cap of the downhill bearing. If a carrying roller has any cut to i, the cut should be suck that it will relieve the thrust roller of lead, not add tw iteload. Since thia mewns that the carrying roller mustattempt to meve the kiln uphill, it follows that the carrying roller must be forced downhill From these two facts, we can see that carrying roller shafts shoold always bear agoinet the cap of the downhill bearing. Any of these shafts that are not beering against the cap of the downhill bearing are either over-loading the throst rollore or aro part of wear combination with other rollers cut too severely downhill. Allrollers should always he downhill as I tible, However, to adjust the roller to achieve this con dition, the direction of thrust of each zeller should fiast be determined. This can be done by sounding the bearing caps ‘witha heavy hammer, or prefersbly by measuring the diGORREST OPRRATING PosiTioNs PIrcH Ling Use an CLOSE POINT WRONG--£0 NOT OPERATE WHEN PITCH LINES OVERLAP. CORRECT OPERATING POSITIONS WHEN SHELL Is 10r wne“ar cheanse POINT tance between the sides of the raller ard each beating housing. The shorter of the two dimensions will be found at the boaring housing toward which tho roller ia thrusting. ‘Adjust the appropriate bearing inward so as to make the roller move uphill. Furn the adjusting screw 1/12 of a turn (or approximately 0.020 in, of bearing movement) and wait for 2or 3 minutes to see if the roller is moving uphill. This would be indicated by an incrasse in the clearance between the roller and the pointer. Continue adjusting 1/12 turn oF 9.020 in, increments until the rollar moves uphill. “To verify that the bearing is sctually moving during ich adjustment, it may be necessary to oot a dial indicator against the beating housing. If the roller does not move uphill efter one-half turn of the screw (0.125 in, movement of the bearing), adjustment should be shifted to the other bearing which should he moved outward, using the same imeremant and procedure. This is done so thet this exces- sive movement dees not disturb dhe kiln centerline align: mant. ‘When the roller starts to move uphill, the final adjust- ‘ment shifts to the bearing whose inward movement is op- propriate to make tho roller move downhill. Tura the ed- justing screw 1/48 turn at a time (approximately 0.006 in. bearing movement) until the roller moves downbill. If the coarse adjustment hes been done carefully the roller will ‘move dowabill in 1/12 total turn or less “a ee ee ee Figure 3. Pinion and gear must mesh properly. With the carrying roller approaching exact parallel to the azis of Kiln rotation, the carrying rallar may respond quite slowly to the adjustment, which will eat it to thrust in the opposite direction. A dial indicator can be used sgainst the sides of the carrying roller to save time by detecting movement of the roller as soon as itocours. During any adjustment of a carrying roller, the final ‘movement of any bearing should be inward, oven if it be- comer necessary to more a bearing an extra amount out: ‘ward to achieve this, On rollers found to be thrusting in the uphill direction, clamp the pointer to the downhill bearing so that itis 0.78 fn, away from the side of the reller. Starting with the bear- ing whose inward adjustment will eause the roller to move downhill, use the same coarse adjustment procedure until the'rollor moves downhill. Make # 0.005 in, adjust- ‘ment until the roller moves uphill; then a final 0.005 in. adjusiment to move the roller dowabill, Attaining minimum possible wear After all rallers have been adjusted in this manner, the downhill threat of tho Liln will be absorbed by the down Lill thrust roller. The carrying sollers will be absorbing very little and consequently will experience the minimum. possible wear. Pointers can now he permanently attached ata known distance from the rollers as an expeditious CEP Februcey 1978heck of the ditection of thrust and of end hrust plate Afr all carrying rollers have been adjusted, the carry- ing rollers and riding ring might zot have full contact across their facoa. No chsnges in carrying roller adjust- ment should be made. Itis better to allow the rolling sur- faces to wear in to full contact than it is to cut the roller {nto full contact. A roller out to obtain full contact fo a roller adjusted so that wear will destroy full contact. Allmovement of all hearings should be recorded during the adjustment precessas should all future adjustments af any beatings. These records will be an aid to maintain proper kiln alignment. ‘The rules for determining which bearing to move for a required direction of earrying roller movement or thrust 1 with clockwise sotation, movethe beating on the lft inward to make the roller move and thrust dewn- bil 2. On kilns with counter-clockwise rotation, move the bearing on the right inward to make the reller move and ‘thrastdosenhill ‘Retation is determined by standing at the discharge end and looking up the kiln. Right aud left is determined by standing in front of the rllor and bearing assembly being ‘worked on. Teshould be noted that all alimment and adjustment work oan be carried out while the kiln is operating, f the main gear and pinion have been provided with scribed Ditch lines. The ptzh lines serve as a rough guide to msin- (Gaining proper engagement while theallgamentand adjust rent is being done. The pitch lines ean be 0.125 in. away from tangency but should never overiap, ‘Aker the alignment and adjustment of the kiln and carrying roller: is complete, the main gear and pinion setting shotld he checked. ‘The main gear should. be checked for radial runout and cerrested if necessary. The sear joint bolts should be checked for tightness. The gear ‘te-zear flange bolts should be checked for proper uniform tightness, With the gecr centered around the axis of zote- tion, theengageanent of the pinion with the gear should be checked for proper depth and contact pattern. Te may be necessary to reposition the kiln by uniform adjustment of carrsing rollers to obiain proper engagement rather than obtain itby eopositioning the kiln drive. Gear and pinion alignment ‘The main gear is equipped with adjusting serews to facilitate centering the gear on the shell. This gear mnust nmin true, Several points eround the circumference of the gear should be checked with a feeler gauge for uniform fontact acrces the full face of the tacth, and ange bolts should be inspected periodically to make sure they are tight at all times. A tight fit ean be achieved by pulling ‘each bolt up tightly, then hesting the bolt io about 350°F and advancing the nutan additional 20° rotation Pinion and gear must mesh properly, as shown in Fig- ure 3. Pitch lines are serihed on both sides of the gear and inion at the factory. The pinion should be set so that the Titch lines on the gear and pinion are 0.125 in. apart when the shell is cold. When the shell is hot, the pitch lines, should he from 0 t00.0625 in apart. Inno care should the pitch lines overlap, as this would cause excessive wear and overloading of the pinion shaft and bearings. Mesh of the gear and pinion should be checked al regular intervals, beeause any wear or adjustment on the carrying rollers will change the mesh. If the pinion is meshing tco Geeply, the kiln should be raised to fts original position by moving the carryirg rallers in toward the centerline of the kiln, 5 Floating-iype riding rings should be lubricated between CEP February 1976 ea riding rings and filer bars with a thick paste of graphite and just enough ail to act as a good binder. The lubricant shold be applied intially to the inner surfaceof the riding ring at all spaces between filler bars. Subsequent apptica- tion of hibricant need to be made only at four evenly spaced points around the circumference of the ring. The lubricant can be most easily spplied with an extended nozzle hand gun. "The practice of using water baths to lubricate the faces of the carrying rollers and riding rings has been virtually discontinued because of the possible detrimental chemical action of the water To prevent spalling, a solid graphite carbon block, Dizon H-80-D or its equivalent, is now recommended. This block has erces sectional dimensions of 1 x 6 in. and lengths up to 20 in. The graphite block will effectively lu- bricate the faces when held against the roller face by its own weight. For use on older kilns # holder may be fabricated from steel plate and easily attached to the carrying roller guard. The holder and graphite blocks should be the sane length as the face ofthe roller. Questions and answers Q. How do you takea kink or a warp out of akiln shell? A. Thereareseveral waysto do this, The choise depends 4 greatdeal on how long youcan afford to havé the kiln cut of service, You ean remove the brick and heat the shell from the inside if you know the particala: area where the warp othe kink exie's. Simply let it rise to a temperature at which the yield point is lowered, and keep the kiln 10- tating. The kink should then straighten cut. If you doa't hhave enough kiln heat for that, you will have to apply heat from the exterior. It is atime consuming operation. Sovoral kilns have been corrected by cutting and welding, but re- moving kinkis pretly much a “cut-and-try” operation. Q. Kilns are geting longer arc longer, end the practice is te have them uncovered. Doesn't this present a problem to the life of the kitn and refractories, particularly when a sudden raizstormoccurs? ‘A_ Tewouldn't hava tno much effect on the shell beenuse this is made of mild steel and, in fact, some kilns ere water-sprayes. Of course, this is a continual situation. However, ifycu had « red spot on top and the powor hickod off when the storm started, you have a contracting shell and perhaps the brick will spall eff. But as long a3 the kiln keepsrotating ata uniform speed, the brick shoulda’t suffer. T know of two rotary lime kilns in New Orleans ‘which had to have a roof installed over them just because of tae heavy rains. They were losing too much brick @. Whatdo you recommend fora shutdown procedure of a rotary kiln, and what problems can arise such ae with bearings? A. The recommendation would be to run it continuously. ‘unl it has cooled off. If you want to limit the amount of spill-out of the kiln (say t's your cealer that’s giving you a problem) there is a procedure of timing of intervals for shutting dewn, This calle for putting the kiin on emergency drive and rotating it for five mimutos. After a five minute halt the kiln is rotated in exactly 180° incréments until ‘coal. For the first hour, the time between 180° rotation should be § min.; for the second hour, 10 min.; thereafter, 30 min, "There isno particular shutdown procedure for kiln bear- ings, but ifthe kiln is to be dowa for a long tlme, the bear ings should he filled with oil to cover tha shafts so they. don't rust. # RE. Pippi ie promnls working m2 rtaling equipment edit for the Signonta Ce Previwsly Ye Warkel ot Ieibtetance eapervs0% for the firm. Pgpitt attandeé the Uriversty of lino were he susied mecanical engine 45