Bevel gears – assembling instructions
Bevel gears may be shipped with the stem nuts loosely fastened in place. This means that they may fall out of their seats while units are begin handled and causer accidents. Before handling a unit remove the stem nut and replace it when the handling operations have been carried out. Ensure that bevel gears are lifted with the stem nut uppermost.
Safety:
- Never use levers to increase the torque when opening or closing the bevel gear hand wheel.
- Never remove the valve bevel gear when the lined is under pressure.
- Never attach en electric actuator to motor driven bevel gear without adjusting the limit switches and the torque limit switch, and without making sure that the bevel gear is suitably matched to the actuators stalling torque.
- Never install the bevel gear before reading the following instructions carefully.
- Failure to follow all these instructions may place operating personnel in serious danger.
- N.B. Any application limits which differ from, or are additional to the technical information given in the catalog (such as information concerning a specific order) will be given in the order confirmation.
Storage:
The bevel gears are shipped with a primer coating only. This is only adequate to prevent corrosion under protected storage conditions. Before using there units outdoors, they must be given an adequate paint protection. The standard version of CML bevel gears must be stored outdoors, unless they are adequately protected from moisture.
Lubrication:
CML bevel gears are shipped with a fully capacity of grease. However, it is advisable – before installation – to check the level and to make any required addition through the greasing inlets above the pinion, the bevel gear wheel and any spur gears. For “R” type bevel gears it is necessary to grease the thrust bearing before finally assembling the stem nut.
Bevel and spur gears are lubricated with AGIP GR MU/EP1 grease, suitable for use within the -40 to +80°C range (lithium based grease with specific extreme pressure additive).
For non – standard applications (e.g. low temperature, underwater installations, etc.) which the customer has specified at the time of ordering, the bevel gears will be filled with special lubrications and their characteristic will be given in our order confirmation.
If bevel gears are stored for three months or more, we recommend that they should placed on their bases; and turned by hand without load until the lubricants is dispersed normally.
CML bevel gears can be used in any position, provided that the position are specified at the time of ordering. This will enabie us to change the type and quantity of lubricant, as necessary.
Installation procedures:
- Before installing the bevel gear, carry out a visual inspection to ensure that there are no craks or breakages due to handling and transport.
- To mount CMKL bevel gears on valves or sluice gates, use the flange sizes specified in our catalogue.
- To move and/or install our bevel gears we can provide the attachments shown in Fig. 1., provided that these are ordered by the customer. In any event, the valve or any other accessory connected to the bevel gear, cannot be lifted using the bevel gear lifting device, or through the bevel gear itself.
- The diameter d2 and the depth c2 are sized as prescribed by our technical catalogue and that they have the required tolerances.
- it allows the stem to pass freely, without being sol large that it prevents the thrust ring from making a seal. For bevel gears type R with a thrust bearing, d1 must be as follows: d1 = </=d(Shift) + 15mm.
- Type S bevel gears:To work on the bushing, remove it from the bevel gear , remove the OR seal, carry out the work. Then replace the bushing, taking care that the OR seal is replaced and is not damaged during refitting the bushing. A light application of grease can be made to make it easier to slide the bush into position.
- Type R bevel gears: To work on the stem nut, dismantle the thrust ring, the two thrust bearings with their four disks and the OR seal on the stem nut. When machining of the stem nut is completed re-assemble it taking care not to damage the OR seal. Clean the discs and the thrust bearings and grease them, re-assemble the thrust ring to facilitate the seating of the OR seal. When reassembling the bevel gear thrust group, and when re-assembling the bevel gear onto the valve, take great care not to damage the thrust bearing discs.
- When the position is completed. Check that the stem nut turns freely and has an axial play of 0,2 to 0,3 mm.
- For bevel gears which can be motorized, checked that the stem nut fins must be inserted in the narrow slots of the bevel gear wheel.
- For manual bevel gears, they can also be positioned within the wide slots, provided that at ordering the “ hammer blow” type are specified.
When the electrical actuators are assembled on to motorisable bevel gears, check the depth of the actuator seat and the length of the bevel gear shaft to ensure that the pinion will not forced inwards, damaging the radial support bearing.
- To install and use motorized bevel gears with electric actuators. In addition to the instructions given in this manual, those in the electric actuator “instruction book” must be followed. CML bevel gears can be applied to valves, sluice gates, and air lock, in the following versions: manual, motorized with actuators, or those fitted with an emergency manual control. If the bevel gear is fitted to any other item, unless approved in writing in our order confirmation. CML will not take any responsibility whatsoever, for any consequent in juries to persons or damage to things. It is the customer’s or user’s responsibility to provide to ensure that all the current safety regulations are observed; and it is his responsibility to provide the necessary training and equipment, for the personnel required to use and maintain the bevel gears.
Routine maintenance:
- When the bevel gears have been installed, we suggest that they should be checked visually at least twice a year and the following operations are carried out:
- Carry out a complete opening and closing operation.
- Make sure grease amount is adequate.
- Tighten the bolts holding it to the valve.
- Tighten the external bevel gear bolts, those attacking any electric actuator, and those of the hand wheel.
- Check the stem nut for any for any signs on wear.
- Check the tightness of the shaft cover and lubrication points.
CML bevel gears have several different specifications. The standard bevel gears only have sealed protection if the shaft cover is correctly assembling using Teflon tape ion the threaded part.
The bevel gears ordered with a CSI shaft cover (with a position indicator), must have an M10 hole 25mm deep, on the upper part of the valve stem. This is to be made by the customer.
Spare parts:If the bevel gear is damaged and needs components to be replaced the customer needs to give up the order number, so that the part required can be correctly identified (from time to time components may be modified to improve the product), The components list will be supplied on request.
