Instruction and Operation Manual

Transcription

1 SUNDYNE LMG-4 GEARBOX (PHOENIX 2) Instruction and Operation Manual May 2006 Effective:May 2006 Visit our website at

2 COPYRIGHT All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior permission of Sundyne Corporation Sundyne Corporation WARRANTY Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the date of being placed in service (but not to exceed eighteen (18) months after the date of shipment) that the equipment at the time of shipment will be free from defects of design, material and workmanship. If any defects or malperformance occur during the warranty period, Sundyne s sole obligation shall be limited to alteration, repair or replacement at Sundyne s expense, F.O.B. Factory, of parts or equipment, which upon return to Sundyne and upon Sundyne s examination prove to be defective. Equipment and accessories not manufactured by Sundyne are warranted only to the extent of and by the original manufacturers warranty. Sundyne shall not be liable for damage or wear to equipment caused by abnormal conditions, vibration, failure to properly prime or to operate equipment without flow or caused by corrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no event shall Sundyne be liable for consequential or incidental damages. Effective:May 2006 Visit our website at

3 USING THIS MANUAL: This manual is part of the final data package for your Sundyne LMG gearbox. This manual provides useful information for the Sundyne gearbox, including how to: maintain it, service it, troubleshoot problems and order parts. In addition to this manual, the final data package includes drawings, Sundyne specification sheet, test data, inspection data, and material certificates if required. All dimensions are provided in English units followed by SI units in parenthesis. This manual contains the following sections: i. Introduction to the Sundyne Gearbox ii. Safety Precautions iii. Critical Startup Checklist 1. Lubricating Oil System Provides the following information: how to prepare the gearbox for start-up; how the lubricating oil system works; and specifications for gearbox lubricants. 2. Start-up Provides the procedure for starting the gearbox. 3. Servicing Provides procedures for servicing the gearbox. 4. Gearbox Disassembly Provides procedures for disassembling the gearbox and suggestions for inspection of disassembled hardware. 5. Inspection of Disassembled Hardware 6. High Speed Shaft End Play Provides a detailed description of how to set end play on the high speed shaft before re-assembly. 7. Gearbox and Process End Reassembly Provides a detailed re-assembly procedure for the gearbox and gearbox. 8. Spare Parts Contact and reference information. 9. Gearbox Trouble Shooting Provides a table for looking up gearbox problems; identifying possible causes; and finding the appropriate corrective action. Appendix A Drawings, including gearbox and gearbox cross section drawing and seal arrangement cross-section drawings, complete with component item numbers. Effective:May 2006 Visit our website at 1

4 i. Introduction to the Sundyne Gearbox Sundyne LMG Gearboxes are most commonly used in HPI, CPI, and Boiler Feed applications. They are also used in refineries, petrochemical plants, and power generation plants. Sundyne LMG Gearboxes offer industrial quality in a compact unit that is simple to maintain. For detailed specifications of Sundyne LMGV Gearboxes, see the specification sheet and bill of material or consult Sundyne Corp. For the primary components, reference the Gearbox section. ii. Safety Precautions Text Symbols The following symbols may be found in the text of this manual. They have the following meanings: WARNING: Text accompanied by this symbol indicates that failure to follow directions could result in bodily harm or death. ELECTRICAL HAZARD: Text accompanied by this symbol indicates that failure to follow directions could result in electrical damage to equipment or electrical shock. RECOMMENDED: Text accompanied by this symbol indicates recommended usage. REMINDER: Text accompanied by this symbol indicates a reminder to perform an action. EQUIPMENT USE ALERT: Text accompanied by this symbol indicates that failure to follow directions could result in damage to equipment. Equipment and Safety Precautions Sundyne Corporation manufactures centrifugal pumps to exacting International Quality Management System Standards (ISO 9001) as certified and audited by Lloyd s Register Quality Assurance Limited. Genuine parts and accessories are specifically designed and tested for use with these products to ensure continued product quality and performance. Sundyne cannot test all parts and accessories sourced from other vendors; incorrect design and/or fabrication of such parts and accessories may adversely affect the performance and safety features of these products. Failure to properly select, install or use authorized Sundyne pump parts and accessories is considered misuse and damage or failure caused by misuse is not covered by Sundyne s warranty. Additionally, modification of Sundyne products or removal of original components may impair the safety of these products and their effective operation. CAUTION Sundyne pumps may handle hazardous, flammable, and/or toxic fluids. Proper personal protective equipment should be worn. Precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in accordance with applicable environmental regulations. Note: Safety procedures must be applied prior to any installation, maintenance, or repair of a Sundyne pump. Failure to follow safety precautions may lead to injury! Effective: May 2006 visit our website at 2

5 Wearing Personal Protective Equipment To ensure safety, protective equipment must be worn at all times when installing, performing maintenance, or repairing equipment. The following safety recommendations must be adhered to for optimum safety: Safety glasses, with the minimum requirement of side shields, must be worn at all times. Steel-toed shoes must be worn when lifting equipment greater than 15 pounds (7 kg) or if pallet jacks or forklifts are operated. Hearing protection is strongly recommended at all times when noise levels exceed 85 db during an eight (8.0) hour period. Note: Chemical resistant gloves must be used if chemicals are utilized (refer to Using Chemicals for additional information). Note: A dust mask respirator must be worn if chemicals have warning labels regarding fumes, dust, or mists. When using more than one piece of protective equipment, consider their compatibility. For example, safety glasses will not interfere with hearing protection equipment. Be sure to clean all pieces of personal protective equipment immediately after each use. Using Forklifts Any persons operating a forklift must have an active recognized operator license. Note: Before initializing forklift operation, verify that the lift is in a safe operating position. Ensuring Electrical Safety All electrical sources must be powered-off before installation, service, or repair of equipment occurs. Note: Sundyne recommends that a Lock-out/Tag-out program be followed prior to altering the equipment. Locks or tags must be provided to warn employees that equipment is temporarily unavailable. Once all work has been completed, the person installing the lock or tag must remove it according to company procedure. Testing Equipment Prior to performing a test on newly installed, maintained, or repaired equipment; all personnel in the immediate area must be warned. Note: Follow company procedures prior to equipment testing at all times. Using Chemicals Any chemicals to be used must be accompanied by a relevant material safety data sheet (MSDS), in accordance with government legislation. If applicable, use chemical proof gloves. Note: An eye wash station (or equivalent) should be available in the event of injury. If any hazardous or flammable chemicals pass through the equipment, a complete decontamination of the equipment is required. Effective: May 2006 visit our website at 3

6 Protection from Falling Fall protection and associated preventative measures are required when working on equipment located six feet or higher from the ground. Note: Follow company fall prevention procedures prior to working on equipment. Preventative Machine Guards Preventative guards must remain in place on all equipment. Note: Only remove the guards while performing maintenance or repair. Replace the guards immediately after working on the equipment and prior to start up. EXPLOSION/FIRE HAZARD Note: Never use an acetylene torch, open flame, or heat to attempt to remove parts that have seized together in Sundyne equipment. Any residual process gas or liquid that is flammable can result in an explosion or fire with potential for serious injury or death Effective: May 2006 visit our website at 4

7 iii. Critical Startup Checklist Gearbox Servicing: Fill gearbox within 1/4 inch (6.4 mm) from top of oil level sight glass with lube oil which conforms to the specification in Table 6.1. Where applicable, operate auxiliary lube gearbox to fill heat exchanger and filter. Add oil as necessary through fill fitting until oil level stabilizes in sight glass. The gearbox alone requires approximately six U.S. quarts (5.7 liters). Heat Exchanger If a heat exchanger for the gearbox is installed, adjust the cooling flow to keep the temperature of the oil to the bearings at F (49-60 C). Auxiliary Lube Pump If you have an auxiliary lubrication pump, unlock the electrical circuit and start it in the hand position. Check for oil leaks and recheck the oil level. Piping Connections Are the following bolted/threaded connections tight: a. Cooling water connections to heat exchanger? (if applicable) b. Gearbox oil drain plug? Effective: May 2006 visit our website at 5

8 1. Lubricating Oil System Remote skid mounted systems The oil used in Sundyne gearboxes must meet the specifications presented in Gearbox Lubricant Recommendations (see following page). In general, an ISO viscosity grade 46 oil will meet these specifications. Before using any oil, you should verify its properties by consulting its manufacturer. Failure to use the proper gearbox lubricant will void the warranty. No other additives are recommended. Effective: May 2006 visit our website at 6

9 Field Engineering Bulletin Bulletin No Sundyne & Sunflo Gearbox Lubricant Recommendations EFFECTIVE : JUNE 2004 Rev: D For years the preferred gearbox lubricant for Sundyne pumps and compressors has been automotive automatic transmission fluid (ATF). However, over time the additives in automatic transmission fluid have changed to coincide with the technical improvements in automobile transmissions. The additives in the new formulations of ATF, such as Dexron III, have been found to have negative effects on Sundyne gearboxes and could compromise mechanical integrity and reliability of the equipment. ISO Viscosity Grade 32 or 46 general purpose or synthetic oils are the recommended lubricants for Sundyne gearboxes as shown in Table 1 below. ISO VG 46 lubricants are now recommended for high horsepower gearbox models 33X and 34X with spherical roller bearings and high ambient temperature installations. Gearbox lube oil should be changed twice yearly or more frequently in severe environments which may be detrimental to the lubricant. Oxidized oil is frequently characterized by a darkening and/or thickening of the oil. Operating of gearboxes with oxidized lubricant should be avoided. Synthetic oils possess different characteristics than conventional mineral oils which make them desirable for various extreme conditions such as high and low temperature operation. Synthetic oils offer very low pour points, high temperature oxidation stability and a higher viscosity index. The operation of Sundyne equipment in high or low ambient conditions may require special consideration of gearbox lubricant and/or supplemental protective equipment such as heat exchangers or gearbox heaters. The lubricant chosen must be compatible with gearbox elastomers, Viton and Buna N. Any oil that contains an inert additive such as PTFE, molybdenum disulfide or silicon should not be used in Sundyne gearboxes. Use of lubricants containing inert additives will void the product warranty. Table 1: Use ISO Viscosity Grade 32 Lubricant ** Use ISO Viscosity Grade 46 Lubricant Models: LMV/BMP-311 LMC/BMC-311F LMC-BMC-311 LMV/BMP-313 LMC/BMC-313 LMV-322 All Sunflo Gearboxes Models: LMV/BMP-331 LMC/BMC-331F LMC/BMC-331P LMV/BMP-333 LMC/BMC-333 LMC/BMC-337 BMP-338 BMP-348 LMG-4 LMV/BMP-341 LMC/BMC-341F LMC/BMC-341P LMV/BMP-343 LMC/BMC-343 LMV-346 LMC/BMC-347 ** Use ISO VG 46 lubricant for high ambient temperatures above 40 C (100 F). Effective: May 2006 visit our website at 7

10 Recommended ISO VG 32 gearbox lube oil specifications: Gravity, API Pour Point, C ( F) -7 (20) max. Flash Point, C ( F) 204 (400) min. Viscosity, cst at 40 C cst at 100 C SUS at 100 F SUS at 210 F 28.8 to min. 150 to min. Viscosity Index 95 min. ISO Viscosity Grade 32 Color, ASTM D Neutralization Number, Maximum 0.20 Rust Protection, ASTM D 665, A & B Demulsibility, ASTM D 1401 Time to 0 ml emulsion at 54 C (130 F) after 30 min. at 82 C (180 F) after 60 min. Foam Limits, ASTM D 892 Sequence 1 Sequence 2 Sequence 3 Note: No other additives are recommended. Pass Pass Pass 25/0 max. 50/0 max. 25/0 max. Recommended ISO VG 46 gearbox lube oil specifications: Gravity, API Pour Point, C ( F) -7 (20) max. Flash Point, C ( F) 204 (400) min. Viscosity, cst at 40 C cst at 100 C SUS at 100 F SUS at 210 F 41.4 to min. 217 to min. Viscosity Index 95 min. ISO Viscosity Grade 46 Color, ASTM D Neutralization Number, Maximum 0.25 Rust Protection, ASTM D 665, A & B Demulsibility, ASTM D 1401 Time to 0 ml emulsion at 54 C (130 F) after 30 min. at 82 C (180 F) after 60 min. Foam Limits, ASTM D 892 Sequence 1 Sequence 2 Sequence 3 Note: No other additives are recommended. Pass Pass Pass 25/0 max. 50/0 max. 25/0 max. Effective: May 2006 visit our website at 8

11 2. Startup Refer also to the Critical Startup Checklist in this manual. Step 1 Prime the lubricating system, as follows: All LMG-4 units require an auxiliary lubrication pump for start-up Fill the oil reservoir with lubricating oil in accordance with Gearbox Lubricant Recommendations, Field Engineering Bulletin Add oil as necessary through the fill opening (see tagging information on the LMG-4 gearbox) until the oil level stabilizes at the top of the bull s eye in the sight glass Start the auxiliary lubricating pump, and run it until the oil reaches the correct pressure and temperature. Add oil as necessary until the oil level stabilizes 3/4 of the way from the bottom of the gearbox oil level sight glass. Step 2 Step 3 Turn on the cooling water to the lubrication system heat exchanger. Adjust cooling water supply to heat exchanger so that oil temperature to the bearings stabilizes at 120ºF (49ºC) with ISO-32 oil or ºF (49-60ºC) with ISO-46 oil. 3. Servicing Regular Maintenance Gearbox Oil: Check the level of the oil in the gearbox immediately before and after initial start-up, and regularly while the pump is running. Be sure to keep the level of the oil at the top of the bulls eye in the sight glass. You can add oil while the pump is running (see-tagging information on the LMG-4 gearbox for where to add oil during operation). Failure to add oil through the correct port on the LMG-4 gearbox will cause blow back of the lubricant, possibly causing injury to the operator. DO NOT OVER FILL THE GEARBOX. This can cause damage to the internal components. Oil Pressure: The correct oil pressure from the main pump of the gearbox depends on the configuration of the bearings and the characteristics of the lubricating oil used. In the normal operation, the oil pressure supplied to the gearbox should be between psig ( kpa). Recommended limits are 20 psig (138 kpa) decreasing alarm and 15 psig (103 kpa) decreasing shutdown. Changing the Gearbox Oil and Filter: Change the oil in the reservoir and the oil filter elements every 6 months. SFHC recommended synthetics may go for a longer period of time before an oil change is required. Anti-Friction Bearings: Roller bearings on the low speed shaft should be replaced at any of the following times: after ten years, or if there appears to be unusual wear, or the bearings are assessed as damaged. Effective: May 2006 visit our website at 9

12 4. Gearbox Disassembly Note: In order to disassemble gearbox it is necessary to complete steps 1 through 18 of the Process End Disassembly. Step 1 If you have not drained the oil from the gearbox you should do so now. Remove hex head cap screws (905E) and lock washers (916A) from the gearbox seal (60C) flange. Step 2 Remove gearbox seal (60C). It is helpful to use a small flat blade screw driver to lift the seal flange up from the aluminum gearbox face, being careful not to hit the I.D. of the seal face against the high speed shaft (A130 ASSY). Effective: May 2006 visit our website at 10

13 Step 3 Carefully inspect the seal for abrasive particles or excessive seal face wear and any binding of the carbon seal nose. Replace or rebuild any faulty mechanical seal. Seals may be rebuilt by replacing the carbon seal nose, o-ring, and spring providing the retainer is not damaged or heavily worn. Replace the seal flange o-ring (936P). A seal repair kit may be available; contact your customer representative or the factory. Step 4 Remove o-ring (936K). Step 5 Remove rotating face (51D). Use two small flat blade screw drivers to help lift rotating face out of pocket in the gearbox taking care not to damage the gearbox seal o-ring chamfer at the I.D. of the rotating face (51D). Inspect the rotating face for any cracks, chips, or grooves. If any cracks or chips are present replace the rotating face. Replace or lap the seal rotating face if the wear track is rough or worn to a depth greater than.0002 inch (.0051 mm). Effective: May 2006 visit our website at 11

14 Step 6 Rotate gearbox in holding device so that the input shaft (A120 ASSY) is now pointing up. Make certain that the gearbox is steady and held in place by clamps. Remove nuts (914F) and (914E), remove flat washers (916J) and (916H). Next remove the 2 alignment bolts (909C) and 7 holding bolts (909B), and flat washers (916H) and (916J) making sure that the alignment bolts are removed first. Step 7 Remove the four round hex head socket screws (included with item 115) located on the top of the input seal (115). Failure to remove these screws and input seal drive lock collar will result in damage to either the input seal (115) and/or the input shaft (A120 ASSY). Effective: May 2006 visit our website at 12

15 Step 8 Gently pry input seal drive lock collar (included with item 115) located on the top of the input seal (115) to remove. Step 9 Remove Inlet Housing Install two 5/8 eye bolts into the top of the upper gearbox housing (101B). Use a hoist to lift the upper gearbox housing (101B) away from the other gearbox housings. At the start of lifting of the upper gearbox housing, gently tap the input shaft if necessary to free it from the upper housing. Effective: May 2006 visit our website at 13

16 Step 9 Continued It is a good idea to look into the upper gearbox housing (101B) and verify that the idler shaft assembly (A140 ASSY) is free of upper gearbox housing. If it is not free, loosen the shaft by hand before lifting the upper gearbox further. Step 10 After the mechanic rests the upper gearbox housing (101B) on a bench or table remove the input seal (115) from the upper gearbox housing (101B). Inspect seal. If it was leaking or is damaged replace input seal (115) with a new item. Effective: May 2006 visit our website at 14

17 Step 11 Remove Input Shaft Assembly To accomplish this the mechanic must first lift up the idler shaft assembly (A140 ASSY) and tilt it away from the input shaft assembly (A120 ASSY). Step 11 Continued The mechanic should install a lifting eye to the input shaft assembly (A120 ASSY) and lift straight up and away from the bearing plate (102). Note: The top of the input shaft includes 3/8-16 UNC threads to install a lifting eye. Effective: May 2006 visit our website at 15

18 Step 12 Lube Pump Removal If it is necessary to remove the lube pump follow steps Otherwise skip ahead to step 15. It is necessary to remove the sump tube assembly before removing the lube pump. Loosen the tube-fitting nut and remove sump tube TU03AW03 or TU03AW04. Step 12 Continued Remove the tube fitting and nipple from the bearing plate. Effective: May 2006 visit our website at 16

19 Step 13 Remove the 2 socket head cap screws (905BU), x 2.5 long screws, from the lube pump assembly (A160 ASSY). There are two screws that hold the lube pump in place and two screws that hold the lube pump together. If by chance when removing (905BU) you loosen the shorter screws, replace immediately and move to the next screw on the lube pump assembly (A160 ASSY). Step 14 Install two 1/4-20 screws into the top of the lube pump assembly (A160 ASSY). These screws are used to pull the lube pump assembly (A160 ASSY) out of the bearing plate (102). Effective: May 2006 visit our website at 17

20 Step 14 Continued Remove the lube pump assembly (A160 ASSY) from the bearing plate (102). Step 15 Remove the pressure relief valve (175) from the top of the bearing plate (102). (Pictured in the lower right corner of the photograph). Inspect the pressure relief valve (175) for any foreign matter. If any particles or sludge is found replace with a new pressure relief valve (175). Remove 1/2 NPT pipe plug (924M) from the top of the Bearing plate (102). Remove o-rings (936T) and (936Y), from the lower bearing plate (102) and replace with new items (936T) and (936Y) during reassembly. Step 16 Remove the bearing plate (102) from the lower gearbox housing (101A). Make certain you use the 5/8 eyebolts to lift evenly and slowly. It is a good idea to use a hoist with equal length chains and hooks to facilitate an even lift of the bearing plate (102). If the bearing plate (102) is not lifted evenly it will catch the upper high speed journal bearing (151B) on the high speed shaft (A130 ASSY) and possibly damage the shaft or the bearing. Effective: May 2006 visit our website at 18

21 Step 17 Move the bearing plate to a workbench or table. Remove and inspect the upper high speed journal bearing (151B) and the upper thrust washer (155B) from the bearing plate (102). First remove the 3 hex head cap screws (905N) and lock washers (154E). Next pull the high speed journal bearing (151B) from the bearing plate (102). Save shim (158). Inspect the bearing for rub marks or uneven wear marks. If the bearing has scratches or dings or any unusual wear replace the upper high speed journal bearing with a new item (151B). If the upper high speed journal bearing checks good, tag the bearing as upper high speed journal bearing (151B). This will help insure it does not become mixed up with the lower high speed journal bearing (151A). Inspect the thrust washer (155B). If there are any burns or rubs replace the thrust washer (155B). Effective: May 2006 visit our website at 19

22 Step 18 Remove idler shaft (A140 ASSY). To do this the mechanic must lift the high speed shaft (A130 ASSY) slightly while pulling the idler shaft (A140 ASSY) up and away from the high speed shaft (A130 ASSY). Step 19 Remove the high speed shaft (A130 ASSY). Effective: May 2006 visit our website at 20

23 Step 20 Remove Lower Idler Bearing Remove the 2 socket head cap screws (905AB) from lower idler journal bearing (151D). Remove the lower idler journal bearing (151D). Use bearing puller tool TK01AW02 available from Sundyne. Thread two 1/4-20 screws through the tool into the top of the lower idler journal bearing (151D). Thread the bearing puller into the lower idler journal-bearing cavity and pull (jack) the lower idler journal bearing (151D) out of its location. Inspect the lower idler journal bearing (151D) for any unusual wear, rubs, scratches, or burns. If any abnormalities are found replace the lower idler journal bearing (151D) with a new item. Step 21 Remove Upper Idler Bearing Remove socket head cap screws (905AA) from the upper idler journal bearing (151C) located in the upper gearbox housing (101B). Remove the upper idler journal bearing (151D) following the same procedure as step 20 above. Use bearing puller tool TK01AW02 available from Sundyne. Thread two 1/4-20 screws through the tool into the top of the upper idler journal bearing (151D). Thread the bearing puller into the upper idler journal-bearing cavity and pull (jack) the upper idler journal bearing (151D) out of its location. Inspect the upper idler journal bearing (151D) for any unusual wear, rubs, scratches, or burns. If any abnormalities are found replace the lower upper journal bearing (151D) with a new item. Effective: May 2006 visit our website at 21

24 Step 22 Remove Lower High Speed Bearing Remove socket head cap screws (905M) and lock washers (154D) from lower high speed journal bearing (151A). The standard lower high speed bearing (151A) is an integral plain journal / deflection pad thrust bearing. Step 23 Remove the lower high speed journal bearing (151A) by pulling it straight up and out of the lower housing. Inspect the journal bearing and thrust pads for any rubs, unusual wear marks or scratches. If anything appears abnormal replace the bearing (151A) with a new item. If the bearing checks out good then tag bearing as lower high speed journal bearing (151A), so it does not become mixed up with the upper high speed journal bearing (151B). Step 24 Remove the oil filter (185). Step 25 Remove o-rings (936T), (936T), and (936Y), from the lower gearbox housing (101A) and replace with new items (936T), (936T), and (936Y) during reassembly. Effective: May 2006 visit our website at 22

25 5. Inspection of Disassembled Hardware Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Clean and wash all gearbox housings (101B), (102), and (101A) with solvent and blow dry with clean high pressure air. Make certain to flush out all lube passages and blow-dry with clean high-pressure air. Check all lube passages with a flashlight to verify cleanliness. Inspect all bearing locations for critical size requirements (see Table 5.1). If any dimensions are found to be out of tolerance replace that housing. Inspect all bearings for damage. If any damage is found replace the bearings with new items. Inspect all shaft bearing surfaces for scratches, burns, dents, or dings. If bearing surfaces on shafts are burned and/or scored the shaft should be replaced. Scratches, nicks, or dings on shafting should be lightly stoned and polished to remove high spots. Check shaft runnouts for trueness. Replace shaft if it is bent. Inspect all shafts with gears. If gears are missing teeth, or are burned, replace gear or integral gear shaft as required. If gears show abnormal wear patterns, or have nicks and dings on the gear teeth, lightly stone or hone and polish nicks and dings from gear teeth. If abnormal wear pattern is evident this could indicate a bent shaft. Inspect the bearing thrust faces on the idler shaft (A140 ASSY). If thrust faces are burned or scored, replace the shaft. Check the thrust surface on the lower spur gear for abnormalities, replace as necessary. Step 9 Inspect the thrust face on the idler spur gear, which is pressed onto the idler shaft (A140 ASSY). If the thrust face on this gear is burned or scored replace this gear. If there are nicks or dings in the thrust face lightly stone or hone and polish these areas back to the original surface. Step 10 Inspect the internal lube pump (A160 ASSY) o-ring seal groove. If there are any nicks or dings in this area polish or hone them back to the original surface. If this cannot be accomplished replace the lube pump (A160 ASSY). If your gearbox had a catastrophic lube failure due to the lube pump (A160 ASSY) you should replace the lube pump as a complete assembly. Step 11 Inspect the gearbox seal (60C). If the carbon seal nose is nicked, scratched, or dinged, disassemble the seal and try to lap the seal nose back into tolerance. The flatness specification is two light bands or ( mm) flatness minimum. If this cannot be achieved replace the carbon seal nose. Check the constant force spring inside the seal retainer. If it is cracked, bent or deformed other than the cone shape, it should be replaced. Contact your customer service representative for part numbers on this seal. Effective: May 2006 visit our website at 23

26 Step 12 Inspect all rotating faces in your unit (process and gearbox). If rotating faces are nicked, cracked, or have wear rings from seal contact replace them with new hardware. Check the flatness of the rotating faces to factory specifications. Flatness is specified at two light bands or ( mm) flatness. (The flatness specification does not apply to wavy face type rotating faces.) The gearbox seal rotating face (51D) is to have a matte finish, specified as Ra micro finish, while still maintaining the flatness of ( mm) or two light bands. Step 13 Inspect the high speed shaft shoulder where the gearbox seal rotating face locates. Check for nicks or dings, and raised surfaces on this shoulder. If any abnormalities are found, the shoulder will need to be relapped to factory specification of two light bands flatness or ( mm). If this specification cannot be met replace the high speed shaft (A130 ASSY). Step 14 Inspect the high speed shaft (A130 ASSY) thrust surfaces. If these show abnormal wear, burns, gouges, deep circular scratches or wear patterns, replace the high speed shaft (A130 ASSY) with a new assembly. Step 15 Lubricate all other parts thoroughly with light turbine oil. Table 5.1 Item No. Description Characteristics Critical Size ±.0005 (.013 mm) 101A HO06AW03, Upper, G box Upper, Input Bearing Bore Ø ( mm) Housing Upper, Idler Bearing Bore Ø ( mm) 102 PL01AY04 Bearing Plate Lower Input Bearing Bore Ø ( mm) Upper High Speed Shaft Ø ( mm) Bearing Bore 101B HO05AW03 Lower, G box Lower, High Speed Shaft Ø ( mm) Housing Bearing Bore Lower, Idler Bearing Bore Ø ( mm) 6. High Speed Shaft End Play If a new high speed shaft assembly (A130 ASSY), lower gearbox housing (101A), upper or lower high speed journal bearing (151A or 151B), or thrust washers (155A or 155B) are installed, the high speed shaft end play must be measured and reset. NOTE:For accurate checking of shaft end play, all parts must be dry and free of oil. Step 1 Step 2 Install the lower high speed journal bearing (151A) into the lower gearbox housing (101A). Install the hex head cap screws (905M) and the lock washers (154D). Tighten screws (905M) to the specified torque per table 6.1. Install the upper high speed journal bearing (151B) into the bearing plate (102). Install the hex head cap screws (905N) and lock washers (154E) and tighten to the specified torque per table 6.1. Effective: May 2006 visit our website at 24

27 Step 3 Place both thrust washers (155A and 155B) into lower high speed journal bearing. Install the high speed shaft assembly (A130 ASSY) into the lower gearbox housing (101A) through the lower high speed shaft journal bearing (151A). Step 4 With the aid of two large diameter alignment bolts (909C), install the bearing plate (102) without the o-rings (936T), (936T) and (936Y). Clamp the bearing plate (102) and the lower gearbox housing (101A) together with two C clamps or bolts. Step 5 Step 6 With the shaft in a vertical position, move the shaft up and down while measuring the total end play with a dial indicator or depth micrometer. Shaft end play must be.015 +/-.002 inch (.38+/-.05 mm). If end play is not within this limit, calculate the shim thickness required to place the shaft within the proper end play. Select the required thickness shim using (158) series shim spacer sizes. Remove the alignment bolts (909C) and the C clamps from the bearing plate (102) and lower gearbox housing (101A). Now remove the bearing plate (102). Step 7 Remove the upper high speed journal bearing (151B) from the bearing plate (102). Step 8 Step 9 Place the required shim thickness (158) over the upper high speed journal bearing (151B) and reinstall per step 2. Repeat steps 3 through 5, and verify high speed shaft (A130 ASSY) end play. When end play is within factory specification, repeat step 6. Step 10 Remove the high speed shaft (A130 ASSY) and the thrust washers (155A and 155B). Step 11 Install thrust washer (155A) into lower high speed shaft journal bearing (151A) and install thrust washer (155B) into the upper high speed journal bearing (151B) with the flat side (no grooves) of each thrust washer towards the high speed journal bearing. Step 12 Lubricate the upper and lower thrust washers (155A and 155B) with light turbine oil and install the high speed shaft (A130 ASSY) into and through the lower high speed journal bearing. Step 13 Begin gearbox reassembly. Refer to the Gearbox and Process End Reassembly Procedure. Step 14 Lubricate all assembled parts with light turbine oil as your mechanic proceeds with the assembly. Table 6.1 GEARBOX TORQUE TABLE Item No. Location Torque Value 905E Gearbox Seal in-lbs. ( Kg-m) 905M,N High Speed Shaft Journal in-lbs. ( Kg-m) Brgs. 909B Gearbox Halves ft-lbs.( Kg-m) 909C Gearbox Halves, Alignment ft-lbs. ( Kg-m) 906B Sight Glass in-lbs. ( Kg-m) Effective: May 2006 visit our website at 25

28 7. Gearbox and Process End Reassembly Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Wash all gearbox housings and be certain the lubrication galleys are clear. Attach the sight glass (191) using socket head cap screws (906B), and tighten to specified torque per table 6.1. Put pipe plugs (924A, 924AJ, 924R, and 924RP) in lower gearbox housing (101A). (As applicable.) Freeze lower idler journal bearing (151D) in dry ice for 1/2 hour and install into lower gearbox housing (101A) with socket head cap screws (905AB). Install lower thrust washer (155A) into bearing (151A) with grooves facing away from bearing. No shims will be used at this position. Install the lower high speed journal bearing (151A) into the lower gearbox housing (101A). The lower high speed bearing can be distinguished from the upper high speed bearing by a hole in its flange that engages a pin in the lower gearbox housing. Apply blue Locktite 243 (or equivalent) to the hex head cap screw (905M) threads and install the screws and lock washers (154D). Tighten screws (905M) to the specified torque per table 6.1. If the unit has vibration probes in the lower position, the probe brackets will be attached to the high speed bearing. In this case two of the hex head cap screws (905M) will be replaced with #10-24 studs, washers and nuts for attachment of the bearing and probe bracket. Apply red Locktite 272 (or equivalent) to the stud threads before installing. Install the high speed shaft assembly (A130 ASSY) into the lower gearbox housing (101A) through the lower high speed shaft journal bearing (151A). Install lube oil pump (A160 ASSY) with o-ring (936Z) into bearing plate (102), using socket head cap screws (905BU) and lock washers (154Z). Lubricate o-ring (936Z) with a compatible lubricant before installing lube pump. Before tightening the cap screws, verify that the threaded port of the lube pump is visible through the hole in the wall of the bearing plate. Step 8 Install sump tube nipple (944B) and connector (944C) into the bearing plate (102). Step 9 Step 10 Install pipe plugs (924AT, RL, RR, RX, Q, and QA) as required and relief valve (175) into bearing plate (102). Install the upper high speed journal bearing (151B) into the bearing plate (102). Apply blue Locktite 243 (or equivalent) to the hex head cap screw (905N) threads and install screws and lock washers (154E) and tighten to the specified torque per table 6.1. Install upper thrust washer (155B) into bearing (151B) with grooves facing away from bearing. Use Vaseline to hold upper thrust washer in place. If the unit has vibration probes in the upper position, the probe brackets will be attached to the high speed bearing. In this case two of the hex head cap screws (905M) will be replaced with #10-24 studs, washers and nuts for attachment of the bearing and probe bracket. Apply red Locktite 272 (or equivalent) to the stud threads before installing. Effective: May 2006 visit our website at 26

29 Step 11 Set high-speed shaft (A130 ASSY) end play. NOTE: SHIM BEHIND THE UPPER HIGH SPEED JOURNAL BEARING ONLY TO ACHIEVE.015 +/-.002 inches (.38 +/-.05 mm). See previous section on setting High Speed Shaft End Play. Step 12 Install idler shaft (A140 ASSY). Pull high speed shaft (A130 ASSY) up approximately 1.0 to 1.5 (25.4 to 38.1 mm) and slide idler shaft (A140 ASSY) into the lower idler journal bearing (151D), meshing the gear teeth on the lower idler shaft spur gear and the high speed shaft gear. Step 13 Step 14 Install o-rings (936Y, 936T, and 936T) into the lower gearbox housing (101A). Install the bearing plate (102) onto the lower gearbox housing (101A). Be careful not to knock the upper thrust washer (155B) out of its location. Be careful not to scratch, ding, or dent the upper high speed journal bearing (151B). Step 15 Install o-rings (936Y and 936T), into the bearing plate (102). Step 16 Install lower input shaft roller bearing (125D) race into the top of the bearing plate (102) so it locates against the lube pump (A160 ASSY). Step 17 Install the sump tube (173) into the sump tube fitting (944C). Step 18 Pull up on the idler shaft (A140 ASSY) approximately 1.0 to 1.5. Install the input shaft assembly (A120 ASSY) into the bearing plate (102) and mesh the input shaft assembly (A120 ASSY) gear with the idler shaft (A140 ASSY) gear. Make certain that the slot in the lower end of the input shaft fits over the lube pump (A160 ASSY) drive pin. Step 19 Freeze upper idler journal bearing (151C) in dry ice for 1/2 hour. Install the upper idler journal bearing (151C) into the upper gearbox housing (101B). Use socket head cap screws (905AA) to secure the upper idler journal bearing (151C) to the upper gearbox housing (101B). Install flatfoot input seal anti-rotation device (918E) in upper gearbox housing. Effective: May 2006 visit our website at 27

30 Step 20 Install the upper gearbox housing (101B) onto the bearing plate (102). Make sure that the upper input bearing race and the input shaft are leveled before installing the upper housing. Step 21 Step 22 Install alignment bolts (909C) and washers (916J) through gearbox housings. Install nuts (914F) and washers (916J) onto alignment bolts (909C) and tighten to specified torque per table 6.1. Install fasteners (909B) and washers (916H) through gearbox housings. Install nuts (914E) and washers (916H) onto fasteners (909B) and tighten to specified torque per table 6.1. Step 23 Install Input Seal Before installing the input seal, note the location of the flatfoot anti-rotation device in the upper gearbox housing. Effective: May 2006 visit our website at 28

31 Step 23 Continued Note the flat on the seal, which is to be aligned over the flat foot in upper gearbox housing. Step 23 Continued Remove the four round hex head socket screws (included with item 115) and the locking plate located on the top of the input seal (115). Retain these parts for reassembly. Install input seal (115) over input shaft assembly (A120 ASSY) and press into the upper gearbox housing (101B), seating the input seal (115) firmly against the locating shoulder in the upper gearbox housing (101B). To ease assembly, Tool T-HO06AY-47 is available from Sundyne. Gently tap insertion tool if necessary to fully seat the seal. Effective: May 2006 visit our website at 29

32 Step 23 Continued Re-install the locking plate and four hex head socket screws into the top of the input seal (115). Step 24 Turn the complete gearbox assembly over so the high speed shaft (A130 ASSY) is pointing vertically toward the ceiling and the lower gearbox housing (101A) is on top. If there are pins in the gearbox at the seal mating face, be sure that the slots on the seal face align with the pins Step 25 Install the rotating face (51D) over the high speed shaft (A130 ASSY) with the chamfer in the rotating face (51D) toward the high speed shaft shoulder (A130 ASSY). Effective: May 2006 visit our website at 30

33 Step 26 Install the roll pin (918D) into the lower gearbox housing (101A). Use a soft mallet to seat the roll pin (918D) into place. Step 27 Assemble seal o-ring (936P) to seal (60c). Step 28 Install the gearbox seal (60C) onto the lower gearbox housing (101A). Use socket head cap screws (905E) and lock washers (916A), and tighten to specified torque per table 6.1. Step 29 Step 30 Step 31 Step 32 Step 33 Install initial fill pipe (951D), (947L), and (924RF) into upper gearbox housing (101B). Install vent pipe (951C), (947D), and (186) into upper gearbox housing (101B). Install pressure gauge (942F), (177), and (193C), into upper gearbox housing (101B). Install O-rings (936B) and (936C) onto diffuser (13) and reinstall the assembly of the gearbox/process end into the pump housing (1). Reconnect all lubrication lines and electrical connections. GEARBOX OVERHAUL 1. GENERAL A. The main lube oil pump is driven directly from the input shaft The pump is non-reversible and rated at 15 gpm at 3600 rpm and 12.5 gpm at 2960 rpm. B. The high-speed bearings supporting the output shaft are supplied in various configurations Be sure the correct bearing part number is used in the correct location (refer to the parts list). C. Carefully inspect gearbox components for excessive wear, corrosion, or signs of overheating. Refer to Figure 28 for bearing fits and clearances If the gearbox has suffered major damage, it may be less expensive to exchange the gearbox rather than proceed with an overhaul. For details on the exchange gearbox program, please contact your local Sundstrand Fluid Handling representative. If there is a question regarding the deterioration of any of the components, please contact Sundyne field service. D. If particulate matter is found in the gearbox, it will be necessary to flush internal lube passages and the external lube system. To flush the internal lube passages, remove the lube orifices (174A, B) which supply oil to each roller bearing. The lube orifices have a inch diameter orifice hole. Be sure it is not clogged. Also, remove the internal pressure relief valve (175) from the bearing plate. Flush the oil passages and clean the housings Effective: May 2006 visit our website at 31

34 2. GEARBOX INTERNAL REPAIR A. In general, most gearbox repairs will be limited to replacing badly worn or failed components Refer to Figure 28 for bearing and shaft clearances. B. Gearbox housing roller bearing steel liners are not intended to be replaced in the field. They are bored on location in each housing and then staked. C. If further information is required to evaluate components, contact Sundyne field service. Training aids are available. 3. GEARBOX REASSEMBLY A. Before beginning the reassembly, check to be sure the gearbox housings have been cleaned and the internal oil passages flushed if needed. A. Check to be sure any replacement parts needed are of the correct part number for the position in which the part will be used. Refer to the parts list for the specific gearbox being worked on. C. Roller bearings on the input (A120) shaft assembly should be changed after five years in service. During a field overhaul, a judgement is required to determine if the roller bearings should be replaced. The nature of the overhaul and the length of time the gearbox has been in service are major factors. Should you elect to change bearings a hydraulic press and an oil bath type of bearing heater will be required. The roller bearings are held on the shaft with a light shrink fit. The gears have a moderate shrink fit and are driven by a key. If a bearing puller is lacking a gear may have to be removed along with a roller bearing in order to facilitate the bearing removal. Do not heat the gears or bearings above 350º F for more than two hours during reassembly. D. The output shaft assembly (Al30) is dynamically balanced and usually does not require disassembly. Inspect for damage to the bearing journals and thrust runners, discoloration from overheating, and even contact on the gear teeth. E. Reassembly will be the reverse of the disassembly procedures with the exception of setting the output shaft (A130) position and axial end float 4. OUTPUT SHAFT SHIM ADJUSTMENTS A If any major components (Output shaft assembly, high speed bearings. or gearbox housings) have been replaced, readjustment of the bearing shims (158) may be required. B. Refer to Figure Shims (158) are used under the upper high speed bearing assembly (151A& B). The shims are adjusted to achieve proper axial float (endplay). Both must be checked with the output shaft thrust toward the impeller. The adjustments are made with dry bearings. Oil under the thrust surfaces will produce inaccurate readings Effective: May 2006 visit our website at 32

35 C. A suggested procedure for shimming follows: (1) Install bearings (151 A & B) without shims in the output housing and bearing plate. (2) Place the output housing on a raised surface (open side up) with room for the output shaft to project through. (3) Install the output shaft (A130) in the output housing bearing. (4) Install the bearing plate using caution not to damage the thrust washer (155B). Temporarily leave out the idler shaft assembly (A140), gearbox gasket (105) and o-ring (936T) from the gearbox split line. Install the two alignment bolts (909C). Do not install the gearbox input housing. Using short bolts or C clamps. Clamp the bearing plate to the lower housing to assure a metal-to-metal fit between the faces (5) Turn the assembly over with the output shaft extended up. Install a dial indicator in a position of your convenience (inside or outside gearbox) and measure shaft axial float. From the total float reading subtract inch (.38mm) which is the desired end float. The remaining amount should be the required thickness for the shim under bearing (151B). (6) Shims (158) are normally supplied in inch (.127mm) and.010 inch ( 25.4mm) thickness. Select the proper thickness shims that best obtain the shaft end float dimension. NOTE Axial float should be ±.002 inches (.38 mm). ± (.05 mm) It is preferred to have slightly excess end float as opposed to having too little. (7) Install the shims and recheck the endplay. Repeat the procedure if necessary. (8) After proper shimming. complete the reassembly of the gearbox as a reverse of the disassembly procedures Effective: May 2006 visit our website at 33

36 FIGURE 10.1 Effective: May 2006 visit our website at 34

37 8. Spare Parts 1. General Assemblies, subassemblies and components of the Sundyne LMG-4 gearbox are illustrated on the exploded and cross sectional views in Appendix A. The corresponding parts lists, keyed to each part by item number, identify detail parts by part name, quantity and location. 2. Recommended Spare Parts Refer to your final data package for recommended spare parts identified for your particular unit. These are provided as guidelines only. 3. Ordering Spare Parts When ordering spare parts, give the unit serial number and list each part by the part number as shown on the Bill of Material which is included with each gearbox shipment (preferred method), or list each part by item number (as listed in this manual), part name and gearbox model. Specify quantities desired. Order parts from your Fluid Handling representative or directly from Sundyne Corporation at one of the following locations. Sundyne Corporation Phone Number: West 64th Avenue Fax Number: Arvada, Colorado 80007, USA Sundyne Corporation Europe Phone Number: (13-15 Boulevard Eiffel Fax Number: Zone Industrielle De Dijon-Sud 21600) B.P Longvic Cedex France Or visit our Genuine Service and Parts site at Effective: May 2006 visit our website at 35

38 LMG-4 RECOMMENDED SPARE PARTS LIST GEARBOX ITEMS TYPICAL CLASS (2) LOC NO. OPTION (1) PART NUMBER DESCRIPTION CB GK01AW02TA GASKET, CHEM BARRIER ALL SEAL, ASSY, INPUT ALL FILTER, OIL, SUNDGARD C ALL BEARING, UPPER, INPUT D ALL BEARING, LOWER, INPUT A ALL BE09AW12xxxB BRG, JOURNAL, OUTPUT, LOWER B ALL BE09AW0xxxxx BRG, JOURNAL, OUTPUT, UPPER C ALL BE09AW010 BRG, JOURNAL, UPPER IDLER D ALL BE09AY040 BRG, JOURNAL, LOWER IDLER B ALL WA05AW0x WASHER, THRUST, UPPER D ALL RJ09AWxxxx RING, MATING C ALL SE04AW01B10 SEAL, ASSY, GEARBOX N ALL UC O-RING, MANIFOLD P ALL UC O-RING, OUTPUT SEAL T ALL UC O-RING, LUBE PORT Y ALL UC O-RING, PARTING FLANGE ZF ALL UC O-RING, LUBE PUMP A130 ALL SH01AW08xxxxx SHAFT, ASSY, HIGH SPEED A160 ALL PU04AW01x PUMP, LUBE, REVERSIBLE NOTES: (1) Options: CB = Chemical Barrier (2) Class 1 = Minimum recommended spare parts necessary to perform a startup and inspection of a new unit. Class 2 = Minimum recommended spare parts necessary to cover 1-2 years of normal service Class 3 = Minimum recommended spare parts necessary for critical service, or units that will be installed in remote locations. Revised 11/12/03 Effective: May 2006 visit our website at 36

39 12. Gearbox Trouble Shooting Table The Gearbox Troubleshooting Table provides useful information to assist in the analysis of gearbox performance problems. Gearbox Trouble Shooting Table Symptom Possible Cause Corrective Action Change of gearbox oil from normal color to milky pink or yellow. Shaft sleeve rubs on inside diameter of seal. Excessive gearbox light turbine oil fluid consumption. Excessive oil foaming High gearbox temperature. Gearbox oil contaminated with water or process fluid. Inspect gearbox heat exchanger for leakage. Check for excessive process seal leakage. Inspect shaft sleeve o-rings. Verify that seal housing port 1 and other seal drains are open for unrestricted seal leakage flow. Gearbox journal bearing failure. Install replacement exchange gearbox or repair gearbox as outlined under MAINTENANCE. Low speed shaft seal (115) leakage. High speed shaft mechanical seal (60C) leakage. Leakage through heat exchanger into cooling fluid. High oil level Low gearbox temperature. Incorrect lubricant. Heat exchanger fouled or coolant shut off. Oil level too high. Check drain port for leakage. Replace shaft seal if required. Check upper gearbox housing drain port for leakage. Replace shaft seal if required. Pressure test heat exchanger and replace if required. Shut down the unit and check oil level. Adjust coolant to heat exchanger, keeping oil temperature at 140 F., 60 C. Fill with light turbine oil. Check coolant flow and / or clean heat exchanger. Check oil level and adjust. Effective: May 2006 visit our website at 37

40 SUNDYNE W. 64 th Avenue Arvada, Colorado USA FAX: Sundyne Europe Dijon (Longvic) France +33 (0) FAX: +33 (0) ANSIMAG ANYSPEED CASTER GSP HMD/KONTRO MASO/SINE COMPRESSORS SUNDYNE SUNFLO Effective: May 2006 visit our website at 38 Sundyne Corporation 2006 All Rights Reserved