Helical Cooling B ABM Install Maint PDF
Helical Cooling B ABM Install Maint PDF
Helical Cooling B ABM Install Maint PDF
Routine Maintenance
INTRODUCTION
T he Premium Bevel
2. All gear units also have a code description on the nameplate for the identification purpose in the
following form:
B or ABM 222
By using this reference in conjunction with the sales brochure the cooling tower unit can be identified.
Note: When ordering replacement parts quote the following positively from the nameplate:
1. Order Number 2. Serial Number 3.Gearbox type 4.Reduction ratio
These are essential. Replacement parts cannot be identified without this information.
General Construction:
Spiral Bevel gears : Gears and pinions are manufactured from high quality case-hardening alloy steel,
precisely generated in Klingelnberg zyclo-palloid system and lap finished in matching sets.
Helical gears : These trains are generated from high quality allow case-hardening steel, which are
individually flank ground to precision grade accuracy. Case hardening surface with softer core provides
improved wear and fatigue resistance.
Case : The gearbox housing, constituting of single piece grey cast iron is of rigid construction with
stylish reinforcements. Provided with easily accessible service ports, they are suitably designed on
CAD workstations to absorb fan loads and simultaneously dampen loads and vibrations.
Bearings : Taper roller bearings from renowned manufacturers are used throughout. These bearings
are of ample capacity to support combined thrust and radial loads.
Shafting : Input shaft integral with bevel pinion is machined from case-hardening, high grade alloy
steel. Direct hardening steel is used for output shaft. The cylindrical seats for bearings, wheel, seal,
coupling, fan are finished by precision grinding. These are also designed to accommodate external
overhung loads and fan stresses, as appropriate.
Shaft seals : Shaft extensions are fitted with spring-loaded rubber seals to prevent outflow of oil. The
ingress of foreign contaminants is particularly arrested on fan end by employing double-seals with
grease accumulation between them. In addition, metallic labyrinth seals on output extensions takes
care of the moist atmosphere containing micro bubbles of water particles.
STORAGE
Protection of Unit:
All units prior to despatch are test run with a rust preventive oil giving adequate protection to internal
parts for a period of six months covering normal transport inland and overseas and coverage storage.
When the unit is installed, the rust preventative dissolves in the first fill of lubricant without harmful
effect. Shaft extensions are protected with a rust inhibitor which is proof against sea water and suitable
for under-cover storage upto 12 months.
Notes :
1. Where gear units are to operate in abnormal conditions or where they are to stand for long periods
without running, e.g. in plant installations, Premium must be notified so that suitable protective
arrangements can be made.
2. Gear units which are commissioned and then left standing for an extended period should be
operated, loaded, or unloaded for a short time every two weeks to circulate the lubricants to protect
surfaces. If this is not possible, the unit should be protected from corrosions.
INSTALLATION
Installation :
1. Clean ventilator and rust preventive from shaft extension.
2. Secure unit to a rigid foundation using HD bolts to GR8.8 Specification minimum.
3. Align unit with the floating shaft.
3. Install drive fan and coupling halves. Couplings should be machined for a clearance fit. Hammering
or mechanically forcing the coupling on the shaft can damage the bearings or disturb the setting of the
gears and is not permissible. Interference fits are permissible if the coupling half can be heated for
installation and fitted without hammering or mechanically forcing on the gear drive shaft. Check runout
of aligning surfaces on both coupling halves before installing connecting members.
4. Level gear drive. If shimming is required, take precautions to prevent distortion of the housing. Align
driver with gear drive to obtain parallel and angular alignment (See notes on shaft alignments).
Note : It is important to ensure when aligning unit that all machined mounting points are supported over
their full area.
4. Fit guard in accordance with factory acts.
5. Check motor wiring for correct direction of rotation (Clockwise when viewed from the respective shaft
ends)
All units are dispatched without oil. On installing the unit fill with recommended lubricant to correct level
on oil level indicator.
To prevent burning and fast wearing out of the lips of the oilseal due to dry running, a few drops of oil
must be squirted on the lips of oilseal to wet them prior to starting up of the gearbox initially as well as
at every re-start after rest period in excess of 24 hours, till oil circulation due to splash lubrication is
established.
SHAFT ALIGNMENT
W hilst no general rule can be laid down for permissible error in lining up it is recommended that,
for flexible couplings, faces are true to within 0.05mm + 0.0002D (where D = shaft diameter) and the
peripheries within 0.1mm. With rigid type couplings this figure should be halved.
Errors of alignment are either angularity (Fig. 1) or eccentricity (Fig. 2) or a combination of both. B /
ABM series units are fitted with taper roller bearings on all input which are assembled with a
predetermined amount of axial float.
When the shafts moves axially it does so with a rocking motion, therefore, to facilitate accurate
alignment of the coupling halves, it is necessary that this end float is temporarily eliminated by the
adjustment of the end cover farthest away from the coupling. The end cover should be removed and
shims inserted between its spigot and bearing outer race, care being taken not to tip the outer track or
over tighten the bolts.
Errors of angularity : Correct before any attempt is made to eliminate errors of eccentricity. The
procedure is shown in Fig. 3 using a thickness gauge in conjunction with filler gauges. Readings should
be taken in positions 1,2,3 and 4 with any axial float taken up. Adjust units by shimming under feet.
Errors of eccentricity : These occur when the centre lines of shafts do not intersect (Fig. 2). When the
misalignment is in the vertical plane, it can be corrected by altering the height of the either units by
means of packing shims placed under feet.
When the error is in the horizontal plane, correction may be made by moving unit transversily until set
in the required position.
If both coupling halves are of the same diameter, their concentricity can be checked with the use of a
straight edge as shown in Fig. 4. If the coupling diameters are not equal, a straight edge should be
used in conjunction with a feeler gauge equal to half the difference in diameter.
Effect of Temperature :
Complete cooling tower drive packages are located in vicinity of induced draft caused by the cooling
fans and are not likely to encounter any condition of substantial temperature difference between the
unit and adjacent machinery. The relative change in temperature between the driver and driven is
generally negligible under these drive conditions.
GEARS
Gears :
Premium cooling tower units are fitted with either single bevel gear throughout or a combination of
single helical and spiral bevel gears. The helical gears are case hardened and profile ground, the spiral
bevel gears are lap-finished in pairs, all to give the highest standard of accuracy and finish while giving it
its quiet running characteristics.
1. Assemble unit including the top bearing housing cover but without input shaft.
3. Fit bearing housing assembly to case without shims, ensuring that the back faces of the mating gears
are flush with each other.
4. There should at this point, be a gap between bearing housing and case. This gap should be
measured and shims added equal to it.
Note: Operations 3 and 4 may be ignored if same gears are being refitted, In this case the old shims or
new one equivalent to them may be fitted.
6. Using side inspection cover, apply engineers blue to both flanks of pinion teeth.
7. Rotate gears slowly until a well defined contact marking has been produced on the wheel.
9. If tooth marking are not in the first diagram, remove bearing housing and
a) Add more shims if marking are as in second diagram
b) Reduce shimming if marking are as in third diagram
Note:After attaining the correct tooth marking, the backlash should be checked (see table on the
adjacent page).
If backlash is excessive, both bevel gears should be adjusted towards their apexes by adjusting the
shims accordingly. Adjustment in the opposite direction will increase backlash in the bevel gears.
Note: Gears may be observed through inspection cover.
CONTACT MARKING
B-Series :
VALUE B114 B116 B118 B120 B122 B125 B128 B132 B135
mm 0.08-0.13 0.08-0.13 0.10-0.15 0.10-0.15 0.13-0.18 0.13-0.18 0.15-0.20 0.15-0.20 0.20-0.28
Inc h 0.003-0.005 0.003-0.005 0.004-0.006 0.004-0.006 0.005-0.007 0.005-0.007 0.006-0.008 0.006-0.008 0.008-0.011
VALUE B214 B216 B218 B220 B222 B225 B228 B232 B235
mm 0.08-0.13 0.08-0.13 0.10-0.15 0.10-0.15 0.13-0.18 0.13-0.18 0.15-0.20 0.15-0.20 0.20-0.28
Inc h 0.003-0.005 0.003-0.005 0.004-0.006 0.004-0.006 0.005-0.007 0.005-0.007 0.006-0.008 0.006-0.008 0.008-0.011
ABM-Series :
VALUE ABM118 ABM128 ABM132 ABM222 ABM225 ABM228 ABM232
mm 0.10-0.15 0.15-0.20 0.20-0.28 0.15-0.20 0.15-0.20 0.15-0.20 0.20-0.28
Inc h 0.004-0.006 0.006-0.008 0.008-0.011 0.006-0.008 0.006-0.008 0.006-0.008 0.008-0.011
BEARINGS
Bearings :The bearings for B / ABM-Series are selected very carefully to best suit the requirements of each
unit and to more than adequately deal with the designed maximum loads acting on them.
Because of the load carrying capacity at higher speeds, taper roller bearings are used
throughout.
VALUE B114 B116 B118 B120 B122 B125 B128 B132 B135
Input Sha ft 0.025-0.075 0.025-0.075 0.025-0.075 0.025-0.075 0.025-0.075 0.050-0.100 0.050-0.100 0.050-0.100 0.075-0.150
Output Sha ft 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100 0.075-0.150 0.075-0.150
VALUE B214 B216 B218 B220 B222 B225 B228 B232 B235
Input Sha ft 0.025-0.075 0.025-0.075 0.025-0.075 0.025-0.075 0.025-0.075 0.050-0.100 0.050-0.100 0.050-0.100 0.075-0.150
Fina l pinion sha ft 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100 0.075-0.150 0.075-0.150
Output Sha ft 0.075-0.150 0.075-0.150 0.100-0.175 0.100-0.175 0.100-0.175 0.100-0.175 0.125-0.200 0.125-0.200 0.125-0.200
ABM-Series :
VALUE ABM118 ABM128 ABM132 ABM222 ABM225 ABM228 ABM232
Input Sha ft 0.025-0.075 0.050-0.100 0.075-0.150 0.050-0.100 0.050-0.100 0.050-0.100 0.050-0.100
Fina l pinion sha ft - - - 0.050-0.100 0.075-0.150 0.075-0.150 0.075-0.150
Output Sha ft 0.050-0.100 0.075-0.150 0.075-0.150 0.125-0.200 0.125-0.200 0.125-0.200 0.125-0.200
OIL SEALS
Replacement of oilseals :
Oil seals should be replaced whenever unit is dismantled or if in service it shows sign of leakage
or damage.
OPERATION
Operation :
No special break-in procedures are necessary except as noted under lubrication.
Each unit is subjected to a running test at the works to assure smooth and quiet operation. Excessive noise
or vibration at initial operation is an indication of one or a combination of the following :
(1) Misalignment,
(2) Imbalance of fan or other rotating parts,
(3) Improperly adjusted fan blades,
(4) Torsional vibrations,
(5) Unstable mounting
If noise or vibration persists, shut the unit down and correct the fault before further operation.
OPTIONAL FEATURES
Lubrication :
Check oil level weekly with each unit stopped. Add oil if level is below minimum level of oil level
dipstick.
Special precautions are necessary during periods of inactivity in excess of one week. When the
internal parts are not continually bathed by the lubricant as during operation, the gear drive is
particularly vulnerable to attacks by rust and corrosion. For best results, let the drive cool for
approximately four hours after shutdown, start the fan and let run for approximately five minutes. This
will coat the internal parts of the drive with cool oil. Thereafter, run the fan for five minutes once a week
throughout the shutdown period to maintain the oil film on the internal parts of the gear drive.
If the drive is to be inactive for a prolonged period, its is recommended that the unit be completely filled
with oil. This can be accomplished by filling through the air breather port. Cover the drive with a
tarpaulin or other protective covering. Drain the excess oil before returning the gear drive to service.
Oil Changes : As the oil is used, degradation takes place and since this process is more rapid
at high temperatures, the oil must be changed to ensure satisfactory lubrication. The type of oil and
time spent at highest temperatures determines the interval between oil changes.
Flushing procedure :
During change of oil the following outlined procedure should be maintained:
(1) Drain out the lubricating oil completely after initial running for a period of 200-350 Hours as per
convenience.
The procedure for changing the oil should be to drain the oil when hot and after circulation.
(2) Flush with flushing oil of viscosity grade 22 of any manufacturer. While flushing ensure that the
gearbox is in running condition.
(3) Ensure that the gearbox is filled in with the flushing oil to the highest level marked on the dipstick
through the plug provided at the top of the gearbox for oil filling and at the same time oil is being
drained out at the same rate through the drain plug provided at the bottom of the gear case.
(4) The activities mentioned above should be carried out for a considerable period which will depend
upon the amount of contamination of the lubricating oil due to generation of wear debris and formation
of sludge.
(5) Continue the operation till the original color of flushing oil is observed and signs of contamination
are not visible.
(6) Recycling of the flushing oil may be done after passing through filters of 200 mesh.
LUBRICATANTS & SHIPPING SPEC.:
Recommended lubricant :
RECOMMENDED
LUBRICANT ISO VG 460
Brand Grade
Balmer Lawrie Protomac SP 460
Bharat Petroleum Amocam 460
Castrol Alpha SP 460
Gulf Harmony 460
Hindustan Petroleum Parthan 460
Indian Oil Servomesh SP 460
Veedol Apreslube 460
UNIT SIZE B214 B216 B218 B220 B222 B225 B228 B232 B235
Ne t We ight(Kg) 285 300 320 360 480 588 788 1050 1596
Gross We ight (Kg) 310 328 351 391 524 644 863 1150 1748
Oil qua ntity(litre ) 7 10 15 20 25 35 50 85 90
ABM-Series :
UNIT SIZE ABM118 ABM128 ABM132 ABM222 ABM225 ABM228 ABM232
Ne t We ight(Kg) 95 205 386 715 890 896 896
Gross We ight (Kg) 115 231 435 782 1005 1012 1012
Oil qua ntity(litre ) 10 35 70 50 85 85 85
MAINTENANCE
Maintenance schedule:
SL. ACTIVITIES TO BE CARRIED OUT FREQUENCY TOOLS / GAUGES /
NO. INSTRUMENTS ETC. TO BE
USED
01. Inspect visualIy for oil leaks and/or unusual Weekly By observation/Feeling
noises, vibrations etc.
In case of any leakage through oilseal replace
the same.
In case of unusual noise and vibration, inspect
the internals and bearings for any damage
through inspection cover.
02. Check and top oil to maintain its level when the Weekly Dipstick provided with
gearbox is stationary (Higher oil may lead to gearbox
over-heating and leakage).
Change oil when its color is blackish and
viscosity is more than 460.
03. Check and ensure tightness of the following Fortnightly With torque wrench
mounting fasteners:
a) Bolts for bevel bearing housing and top
bearing housing
b) Bolts for catchers/covers
c) Bolts for inspection cover
d) Bolts for foundation
04. Check alignment of the drive machine and Fortnightly Dial gage, Feeler gage,
leveling of the gearbox installation Straight bar etc.
05. Clean the joint faces of catcher/cover and Half-Yearly Locktite 574
bearing housing and use Locktite on the face
before tightening. Threadlocker
Use thread lock for mounting all the bolts. Before 270READLOCKER 270.
applying thread lock ensure that the joint faces
and thread surfaces are cleaned properly.
Brand name of Locktite 574 and Thread locker
270 is Loctite and manufacturers name is Any sharp tool like
Locktite India ltd. knife/thinner etc.
Clean the joint faces and thread surfaces to
ensure that no foreign material like dried
Locktitie sealing compound used earlier or dirt
etc. exist.
06. Inspect visually all the internals and bearing to Half-Yearly as By observation.
find out if any damage or breakage is there or and when oil
not. leakage
Change Oil seal. through oil
seal is
obtained.
TROUBLE SHOOTING
Trouble shooting :
If the unit fails to deliver its scheduled functions, check the following points before intimating / calling the
same to service engineer / Greaves service cell.
WARNING : The customer shall be responsible for the proper use of articles supplied by the company, particularly the rotating
elements between their driven members, and their guarding for safety, and the company shall not be responsible for any
injury or damage sustained as a result of the improper use of the article supplied.
Attention is hereby drawn to the danger of using naked lights in proximity of openings in gear drives supplied by the company,
and the company shall not be liable for any claim for injury or damage arising from any contravention of this warning.
IDENTIFICATION OF PARTS
4 8
5
13
6 8 13
1
7
9 14
2
3 10
4 11
12
Important :
When ordering spares or replacement parts the following details from the name plate must be quoted :
1. Serial No.
2, Geared reducer Type /Size
3. Ratio
IDENTIFICATION OF PARTS
4 12
5 8
6 5
1 8
7
2 9
3 10
4 11
13
18
13 18
14 19
15
16
17
Roller Holdback with final pinion shaft
20